Laminated Core Bonding with Separated Heating and Cooling Zones
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Solution Overview
Problem
Existing installations for producing laminated cores for electrical machines have low component utilization, high energy consumption, and increased wear due to simultaneous heating and cooling requirements, as well as limited flexibility in accommodating different lamination pack dimensions.
Innovation Solution
An installation with spatially separated heating and cooling stations, using a workpiece carrier to apply axial prestressing force to electrical steel laminations coated with Backlack, allowing for controlled temperature and force application, and enabling energy-assisted cooling, which reduces energy consumption and wear while allowing for modular design and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating and cooling are performed in the same device simultaneously, then the production process can be completed in one cycle, but energy consumption increases and component wear increases due to unnecessary heating or cooling
Solution Approach 1:
The device is divided into two spatially separate functional units: a heating unit and a cooling unit. The heating unit contains heating elements that heat the lamination stack, while the cooling unit contains cooling elements that cool the stack. This segmentation allows each unit to operate independently, eliminating the waste of heating or cooling components that are not currently needed, thus reducing energy consumption while maintaining continuous production capability.
2Productivity
If heating and cooling are performed in the same device simultaneously, then the production process can be completed in one cycle, but component wear increases due to unnecessary heating or cooling
Solution Approach 1:
The device is divided into two spatially separate functional units: a heating unit and a cooling unit. The heating unit contains heating elements that heat the lamination stack, while the cooling unit contains cooling elements that cool the stack. This segmentation allows each unit to operate independently, eliminating the waste of heating or cooling components that are not currently needed, thus reducing energy consumption while maintaining continuous production capability.
3Device complexity
If a single device performs both heating and cooling functions, then device complexity is reduced, but adaptability to different lamination pack dimensions is limited
Solution Approach 1:
Both the heating unit and cooling unit are designed with universal applicability to accommodate lamination packs of different dimensions. The heating elements and cooling elements can be adjusted or reconfigured to suit various sizes of lamination stacks, allowing the device to handle diverse electrical machine components (stators, rotors, transformers) without requiring specialized configurations for each dimension set.
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
The solution achieves optimal component utilization, reduces energy consumption and wear, and enhances flexibility in producing laminated cores for various electrical machine components by separating temperature zones and using energy-assisted cooling, allowing for efficient production of rotor or stator laminations with minimal unnecessary thermal loading.
Implementation Method 1
a heating station for heating the semi-finished product
Implementation Method 2
a cooling station for cooling the semi-finished product with energy assistance
Data Source
AI summary
A installation for producing laminated cores, bonded over their entire surface, for an electrical machine, comprising: a workpiece carrier for receiving a semi-finished product and for applying a defined axial prestressing force to the semi-finished product, the semi-finished product having a plurality of electrical sheet laminations coated with Backlack, and at least two stations, comprising a heating station for heating the semi-finished product and a cooling station for energy-assisted cooling of the semi-finished product, wherein the at least two stations are arranged spatially separated from one another and are passed through by the workpiece carrier.