Laminated Core Manufacturing Edge Alignment and Uplift Prevention
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Solution Overview
Problem
Conventional laminated core manufacturing methods face issues with edge position shifts and uplift during the overlapping and punching process, leading to inefficiencies and increased costs due to the need for complex correction devices and maintenance.
Innovation Solution
A laminated core manufacturing device and method that includes an overlapping unit, edge aligning unit, uplift prevention unit, and edge position correction unit to stabilize and align edge positions, preventing uplift and ensuring accurate feeding into the punching die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple steel sheets are punched out simultaneously to enhance efficiency, then productivity increases, but edge position shifts and uplift occur during overlapping and punching
Solution Approach 1:
The patent applies preliminary action by performing edge alignment and uplift prevention on multiple steel sheets before the punching operation. The edge alignment device adjusts the positions of multiple sheets to ensure their edges are aligned, and the uplift prevention device secures the sheets against the lower die. This preliminary preparation eliminates edge position shifts and uplift during punching, maintaining manufacturing precision while enabling simultaneous punching of multiple sheets for high productivity.
2Device complexity
If conventional punching methods are used without edge alignment, then device complexity is low, but edge position shifts cause production inefficiencies
Solution Approach 1:
The patent introduces intermediary devices - the edge alignment device and uplift prevention device - that act as mediators between the steel sheets and the punching operation. These intermediaries prepare the sheets by aligning edges and preventing uplift, ensuring accurate feeding into the punching die. While these devices add some structural complexity, they eliminate production inefficiencies caused by edge position shifts, thereby maintaining high productivity.
3Loss of energy
If sheet thickness is reduced to reduce eddy current loss, then motor efficiency improves, but the number of laminated sheets increases prolonging punching time
Solution Approach 1:
The patent applies preliminary action by performing edge alignment and uplift prevention on multiple thin steel sheets before punching. This preparation enables the simultaneous punching of multiple sheets in one operation, significantly reducing the total punching time compared to processing sheets individually. The motor efficiency benefit from reduced eddy current loss is maintained while the time loss from increased sheet count is eliminated through parallel processing.
Data Source
AI summary
A Laminated core manufacturing device includes: an overlapping unit configured to overlap the plurality of laminated core materials conveyed along different conveyance routes; an edge aligning unit configured to align edge positions in a width direction of the plurality of laminated core materials between the plurality of laminated core materials; an uplift prevention unit configured to prevent uplift of the plurality of laminated core materials; an edge position correction unit configured to correct the edge positions in the width direction of the plurality of laminated core materials; and a punching unit configured to punch out the plurality of laminated core materials which are overlapped by the overlapping unit and have been subjected to an edge position alignment process performed by the edge aligning unit, an uplift prevention process performed by the uplift prevention unit, and an edge position correction process performed by the edge position correction unit.