Laminated Core Manufacturing Apparatus Edge Position Correction
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Solution Overview
Problem
Conventional laminated core manufacturing techniques face issues with shift and uplift of laminated core materials during the punching process, leading to collisions with the die or falling off, which decreases production efficiency and increases costs due to the need for additional devices for meandering correction and detection.
Innovation Solution
A laminated core manufacturing device and method that includes an overlapping unit, an edge position correction unit to align and correct edge positions, and an uplift prevention unit to prevent uplift, ensuring stable feeding of materials into the punching die, thereby reducing shift and uplift of laminated core materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the sheet thickness of electrical steel sheets is reduced to decrease eddy current loss, then the efficiency of electric motor is improved, but the number of laminated electrical steel sheets increases which prolongs punching out time and decreases production efficiency
Solution Approach 1:
The patent combines multiple thin electrical steel sheets (e.g., 5 sheets of 0.20mm thickness) into a single laminated core material package before punching. This merging approach allows the punching machine to process the combined package as one unit, significantly reducing the total punching time compared to processing each sheet individually, while still achieving the desired thin effective thickness for low eddy current loss.
Solution Approach 2:
The patent performs preliminary lamination of multiple electrical steel sheets using adhesive bonding before the punching operation. By pre-assembling the sheets into a bonded package, the system eliminates the need for repeated positioning and handling of individual sheets during punching, thereby reducing processing time and improving production efficiency while maintaining the thin-sheet configuration for energy efficiency.
2Productivity
If multiple laminated core materials are overlapped for simultaneous punching to enhance efficiency, then production efficiency is improved, but shift and uplift of materials during punching occurs leading to collisions with die or falling off
Solution Approach 1:
The patent applies adhesive bonding to preliminarily fix multiple laminated core materials to each other before the punching operation. This preliminary fixation ensures that when the materials are overlapped for simultaneous punching, they remain stable and do not shift or uplift during the process, preventing collisions with the die or falling off while allowing efficient multi-sheet processing.
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary substance between the laminated core materials. This adhesive mediator bonds the multiple sheets together, creating a unified structure that maintains positional stability during the punching process, thereby enabling simultaneous punching of multiple sheets without the shift and uplift problems that would occur with loose stacking.
3Manufacturing precision
If additional devices for meandering correction and detection are installed to prevent shift and uplift, then positioning accuracy is improved, but device complexity and installation costs increase
Solution Approach 1:
The patent uses an adhesive layer as a simple intermediary to bond laminated core materials, which inherently prevents shift and uplift during punching without requiring complex meandering correction or detection devices. This approach achieves the necessary positioning accuracy through the bonding action alone, avoiding the need for additional mechanical correction systems.
Solution Approach 2:
The patent extracts the function of preventing shift and uplift from complex mechanical correction devices and achieves it through the simpler adhesive bonding method. By removing the need for additional correction and detection devices, the system maintains manufacturing precision while significantly reducing device complexity and installation costs.
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 position correction unit configured to align edge positions in a width direction of the plurality of laminated core materials between the plurality of laminated core materials and to correct shift of each edge position of the plurality of laminated core materials with respect to a standard edge position; an uplift prevention unit configured to prevent uplift 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 a process to align the edge positions and to correct shift of the edge positions performed by the edge position correction unit, and a process to prevent the uplift performed by the uplift prevention unit.