Laminated Core Bonding Pattern for Accuracy and Low Stray Current
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Solution Overview
Problem
The existing laminated cores face challenges in ensuring dimensional accuracy and improving magnetic properties, leading to potential issues with handling and magnetic performance.
Innovation Solution
The laminated core is designed with a combination of fastening and adhesion methods, where some sets of electrical steel sheets are fastened but not adhered, and others are adhered but not fastened, to enhance dimensional accuracy and prevent stray currents, while adhering every other or prime-numbered sets to increase resonance frequency and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If all sets of electrical steel sheets are fastened, then dimensional accuracy is improved, but stray current generation increases
Solution Approach 1:
The patent divides the electrical steel sheets into multiple sets and applies different bonding methods to different sets. Specifically, some adjacent sets are fastened while others are adhered, creating a segmented bonding strategy that resolves the contradiction between dimensional accuracy and stray current prevention
Solution Approach 2:
Different regions (sets of sheets) are given different bonding characteristics. Fastening is applied to some sets where dimensional accuracy is critical, while adhesion is applied to other sets where preventing stray current is more important, achieving local optimization of both requirements
2Object-generated harmful factors
If all sets of electrical steel sheets are adhered, then stray current is prevented, but dimensional accuracy deteriorates
Solution Approach 1:
The bonding strategy is segmented into multiple groups of adjacent sets, with each group receiving a different bonding method (fastening or adhesion). This segmentation allows the system to prevent stray current through adhesion while maintaining dimensional accuracy through selective fastening in other regions
Solution Approach 2:
The patent applies local quality by making different sets have different bonding properties. Sets requiring better dimensional stability receive fastening, while sets where stray current prevention is prioritized receive adhesion, optimizing both functions locally across the structure
3Reliability
If electrical steel sheets are adhered every N sets, then resonance frequency is improved, but handling properties may deteriorate
Solution Approach 1:
The patent segments the bonding pattern into regular intervals (every N sets) while combining it with selective fastening in other sets. This segmented approach allows the adhesion at regular intervals to improve resonance frequency while the fastening in intermediate sets maintains handling properties
Solution Approach 2:
The bonding system uses a composite approach combining both adhesion and fastening methods in a structured pattern. This composite bonding strategy leverages the vibration-damping properties of adhesion for resonance control while using fastening to maintain structural rigidity for handling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures improved dimensional accuracy, magnetic properties, and reduced noise due to increased resonance frequency, enhancing the handling and performance of the laminated core in electric motors.
Implementation Method 1
Some sets of electrical steel sheets among all sets of the electrical steel sheets are fastened but not adhered to each other, and the remaining sets of electrical steel sheets are adhered but not fastened to each other
Data Source
AI summary
A laminated core includes a plurality of electrical steel sheets that are stacked on one another. All sets of the electrical steel sheets adjacent to each other in a stacking direction are fixed to each other in the laminated core. Some sets of electrical steel sheets among all sets of the electrical steel sheets are fastened but not adhered to each other, and the remaining sets of electrical steel sheets are adhered but not fastened to each other.