Laminated Core Magnetic Pole Elongation via Preliminary Slotting
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Solution Overview
Problem
Existing methods for manufacturing laminated cores for stepping motors face issues with distortion and inaccurate dimensional control during the elongation of magnetic pole pieces, leading to poor caulking and dimensional accuracy, and variations in magnetic properties.
Innovation Solution
A method involving the initial formation of preparatory slots, partial or full coining of magnetic pole shaft pieces to elongate them radially, followed by blanking of finishing slots and shaping of magnetic pole tooth pieces, with deformations straightened and pilot holes used for precise alignment and lamination, ensuring elongation within a specific thickness range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the magnetic pole piece is deeply pressed to increase elongation, then the elongation of the magnetic pole piece is increased, but the magnetic pole piece becomes largely distorted, causing adverse effect on product quality
Solution Approach 1:
The patent applies preliminary action by forming preparatory slots before the coining process. These preparatory slots are positioned at specific locations where distortion is likely to occur during elongation. By pre-positioning these slots, the subsequent coining process can elongate the magnetic pole piece without creating excessive distortion, as the preparatory slots guide the deformation process.
Solution Approach 2:
The patent segments the slot formation process into two stages: preparatory slot formation and finishing slot formation. The preparatory slots are formed first to establish a baseline geometry, then finishing slots are formed after coining to achieve the final precise dimensions. This segmentation allows the elongation process to proceed without excessive distortion while maintaining manufacturing precision.
2Loss of substance
If one die device is used to produce both rotor core sheet and stator core sheet from one thin strip material, then material yield is improved, but metal clippings are formed in narrow gaps causing punching operation to fail and die device to be damaged
Solution Approach 1:
The patent applies preliminary action by forming preparatory slots before the coining and finishing slot operations. These preparatory slots are created at locations where metal clippings might form during the punching operation, allowing them to be removed in advance. This prevents clogging of the die device during subsequent operations while maintaining the ability to use a single die device for producing both rotor and stator core sheets.
3Reliability
If different die devices are used for rotor core sheet and stator core sheet blanking, then punching operation reliability is maintained, but material yield decreases and cost increases
Solution Approach 1:
The patent enables the use of a single die device for both rotor and stator core sheet production by applying preliminary action to form preparatory slots that prevent metal clipping formation. This preliminary slot formation eliminates the need for different die devices while maintaining punching operation reliability, thereby improving material yield and reducing costs.
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
This method stabilizes the elongation of magnetic pole pieces, improves dimensional accuracy, enhances caulking precision, and maintains magnetic properties, resulting in higher material yield and reduced production costs.
Implementation Method 1
a part or a whole of the magnetic pole shaft pieces each are coined to elongate the magnetic pole pieces in a radially inward direction
Data Source
AI summary
A method for manufacturing a laminated core includes (1) blanking a rotor core sheet 15 and a stator core sheet 14 from a thin strip material 27 and (2) laminating the stator core sheet 14 inside a die. The stator core sheet 14 includes a ring-shaped yoke piece 18 and plural magnetic pole pieces 19 integrally connecting to a radially inside of the yoke piece 18. Each of the magnetic pole pieces 19 includes a magnetic pole shaft piece 20 and a magnetic pole tooth piece 21. The magnetic pole pieces 19 are formed by blanking preparatory slots 29; coining a part or a whole of the magnetic pole shaft pieces 20 to elongate the same in a radially inward direction; and thereafter, blanking the finishing slots 30 and shaping the magnetic pole tooth pieces 21.