Laminated Core Hybrid Connection for Electric Machine Efficiency
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Solution Overview
Problem
The manufacture of laminated cores for electric machines faces challenges such as short-circuit links, minimal tensile strength, and inefficiencies in adhesive application processes, which affect the magnetic flux and efficiency of electric motors/generators.
Innovation Solution
A hybrid connection method is introduced, where laminations are connected using a force-locked connection and a material fusion connection, with adhesive applied on the laminations before or after punching, forming a hybrid connection that compensates for the disadvantages of individual connection methods, enhancing temperature resistance, chemical resistance, and handling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical connection with projections and depressions is used to connect laminations, then quick connection during punching operation is achieved, but short-circuit links are generated within the core
Solution Approach 1:
The connection system is segmented into two independent parts: mechanical projections/depressions for quick positioning and connection, and separate adhesive application zones for electrical insulation. This segmentation allows each connection method to perform its specific function without interfering with the other, eliminating short-circuit links while maintaining quick connection speed.
Solution Approach 2:
The connection system uses a composite approach combining mechanical connection (projections and depressions) with adhesive connection. The adhesive layer acts as an electrical insulator while the mechanical features provide structural connection, creating a hybrid system that eliminates short-circuits while maintaining productivity.
2Object-generated harmful factors
If adhesive connection is used to connect laminations, then short-circuit links are avoided, but processing speed must be reduced for proper adhesive curing
Solution Approach 1:
Adhesive is applied partially only in specific zones rather than across the entire lamination surface. This partial application reduces the total curing required while maintaining electrical insulation where critical, allowing faster processing speeds without compromising the elimination of short-circuit links.
Solution Approach 2:
Adhesive application is localized to specific areas where electrical insulation is most critical, rather than applying adhesive uniformly across all laminations. This local quality approach maintains the benefit of preventing short-circuits while minimizing the total adhesive curing time required, preserving processing speed.
3Productivity
If initiator/activator is used with adhesive systems, then high processing speeds are achieved, but ideal mixing ratio and positioning must be maintained with very high technical expenditure
Solution Approach 1:
The adhesive and initiator/activator are applied in separate, segmented zones rather than requiring precise mixing. This segmentation eliminates the need for complex mixing mechanisms and positioning systems, reducing device complexity while still enabling fast-curing adhesive systems to achieve high processing speeds.
Solution Approach 2:
The mechanical projection structure serves as an intermediary that physically separates adhesive and initiator/activator application zones, preventing the need for complex mixing mechanisms. The projections provide structural definition for where each chemical component is applied, simplifying the overall system while maintaining high processing speeds.
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 hybrid connection method allows for quick and reliable assembly of laminated cores with improved resistance and efficiency, reducing the number and size of connecting locations while maintaining high specifications, thus enhancing the performance and durability of electric machine components.
Implementation Method 1
an adhesive or two adhesive systems are applied onto the bottom side and/or the top side of the laminations
Data Source
AI summary
The laminated core (12) comprises laminations (10), which are arranged one over the other and which are each connected to each other by means of a first connection (9, 15). In addition, at least some of the laminations (10) are connected to each other by means of a second connection (11). By using two connections, the advantages thereof can be bundled, whereby the number and/or size of the connection points can be reduced while the requirement for the laminated core (12) remains the same or very high requirements for the laminated core (12) can be met or even increased. Advantageously, an adhesive is used as one of the connections (11), while the other connection (9, 15) can be a form-fitting connection. The adhesive (11) is applied to the lower side (13) and/or upper side (14) of the laminations (10) before or after the punching of the laminations (10). However, the two connections can also be formed by two adhesive systems. Finally, the connections (9, 10; 11) can also be formed by at least one weld seam and additionally by an adhesive.