Laminated Core Manufacturing with Index-Rotatable Dies
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Solution Overview
Problem
The existing methods for manufacturing laminated rotor and stator cores from the same strip material often result in surplus punch-out areas, leading to reduced material yield and waste, especially when the lamination heights differ between the two cores, as in hybrid-type stepping motors where the rotor core requires a shorter lamination height.
Innovation Solution
The method involves using a multi-functional apparatus with index-rotatable rotor and stator core lamination dies, allowing for the production of multiple types of laminated rotor cores with varying lamination heights and shapes from the same strip material, utilizing a single rotary drive source for efficient rotational lamination, thereby optimizing material usage and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If both laminated rotor core and laminated stator core are manufactured from the same strip material with sequential punching, then material yield is improved, but surplus punch-out area remains when lamination heights differ, reducing material yield
Solution Approach 1:
The mold apparatus is segmented into multiple independent punching sections, each capable of producing iron core pieces with different lamination heights. This allows the surplus punch-out area to be utilized for producing additional rotor core pieces with varying heights, thereby eliminating waste and improving material yield while maintaining flexibility for different motor requirements
Solution Approach 2:
The mold apparatus is designed with multi-functionality to produce multiple types of iron core pieces (both stator and rotor cores with different lamination heights) from the same strip material in a single operation. This universal capability allows the system to adapt to different product requirements without sacrificing material efficiency
2Loss of substance
If iron core pieces are punched out from surplus punch-out area and stored as stock, then material utilization increases, but stored pieces are disposed without use when no opportunity arises, lowering material yield
Solution Approach 1:
The manufacturing system maintains continuous useful action by producing multiple types of iron core pieces with different lamination heights simultaneously in the same punching operation. This eliminates the need to store surplus pieces for future use, as they are immediately produced according to actual demand, ensuring continuous production efficiency and eliminating material waste from unused stock
3Loss of substance
If multiple types of laminated rotor cores are manufactured from the same strip material, then material yield is improved, but device complexity increases
Solution Approach 1:
The mold apparatus is divided into multiple independent punching sections, each capable of producing iron core pieces with different lamination heights. This segmentation allows the complex task of producing multiple rotor core types to be broken down into manageable sections, improving material yield while keeping the complexity of each individual section manageable
Solution Approach 2:
Multiple punching operations for producing different types of rotor cores are merged into a single integrated mold apparatus. This combining of functions into one device achieves the goal of producing multiple rotor core types from the same strip material while avoiding the need for multiple separate devices, thus limiting the increase in overall system complexity
Data Source
AI summary
At the time of manufacturing both a laminated rotor core 13 and a laminated stator core 14 by punching out a plurality of iron core pieces 11 and 12 from a same strip material 10 and laminating the punched out iron core pieces 11 and 12, respectively, a plurality of kinds of laminated rotor cores 13 and 13a are manufactured by further punching out a plurality of iron core pieces 11a from the strip material 10 and laminating the punched out iron core pieces 11a. Here, the plurality of kinds of the laminated rotor cores 13 and 13a can be used for different electric motors.