Laminated Block Orientation Verification for Iron Core Assembly
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Solution Overview
Problem
The existing methods for manufacturing laminated iron cores in rotating electric machines often result in erroneous coupling due to incorrect orientation or lamination order of laminated blocks, leading to defective products.
Innovation Solution
A method is introduced that involves using orientation identification portions on the laminated blocks to determine their correct orientation and order through imaging and comparison with registered images, ensuring accurate lamination during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If laminated blocks with different shapes are laminated to form a laminated iron core, then the laminated iron core can be manufactured with complex geometries, but erroneous coupling occurs due to incorrect orientation or lamination order
Solution Approach 1:
Orientation identification portions are disposed on the laminated blocks in advance during manufacturing, and a registered image of the correct orientation is stored beforehand. This preliminary preparation enables automatic orientation verification before lamination, preventing erroneous coupling while maintaining the ability to manufacture complex geometries.
Solution Approach 2:
The manual or visual inspection method for verifying laminated block orientation is replaced with an automated imaging system. The imaging device captures images of the orientation identification portions, and the control unit automatically compares these images with the registered correct orientation image, substituting mechanical verification with optical detection and automated image processing.
2Device complexity
If manual inspection methods are used to verify laminated block orientation, then device complexity is low, but manufacturing precision and reliability deteriorate due to human error
Solution Approach 1:
Manual inspection is replaced with an automated imaging system that captures images of orientation identification portions on laminated blocks. The control unit automatically processes these images and compares them with registered correct orientation images, eliminating human error and significantly improving orientation accuracy while maintaining reasonable device complexity.
Solution Approach 2:
A registered image representing the correct orientation of the laminated block is created and stored in advance. This copy of the correct orientation serves as a reference standard that is repeatedly compared against actual laminated blocks during manufacturing, ensuring consistent and accurate orientation verification without requiring manual expertise.
Data Source
AI summary
A laminated block correctness determining method determines whether a laminated block to be laminated is a correct laminated block when manufacturing a laminated iron core by laminating laminated blocks. Orientation identification portions are respectively disposed on opposite end surfaces of each of the laminated blocks in an axial direction. The laminated block correctness determining method includes acquiring, with an imaging device, a captured image of the laminated block by capturing one end surface of the laminated block in the axial direction. The laminated block correctness determining method further includes determining whether the orientation of the laminated block is correct by comparing the orientation identification portion in a registered image with the orientation identification portion in the captured image.