Laminated Core with Round Corners for Wire Winding

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Solution Overview

Problem

Existing laminated cores face issues with efficient wire winding due to damaged wire insulation coatings and low winding efficiency, caused by rectangular magnetic pole shaft sections and sharp edges, which also lead to flux decay and inaccurate assembly of laminated core segments.

Innovation Solution

A laminated core design featuring triangularly shaped brimmed concavities and convexities at joining sections, with round corners on magnetic pole shaft and tooth sections, and a manufacturing method that includes specific punching and lamination steps to prevent wire damage and ensure accurate assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If rectangular magnetic pole shaft sections are used, then manufacturing is simplified, but wire insulation coatings are damaged and winding efficiency decreases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwire insulation integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The magnetic pole shaft section is designed with round corners instead of sharp rectangular edges. This curvature prevents wire insulation damage during winding while maintaining manufacturing feasibility through standard punching processes with rounded dies.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Ease of manufacture

If rectangular magnetic pole shaft sections are used, then manufacturing is simplified, but winding efficiency and space factor are reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidwinding efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Round corners on the magnetic pole shaft section enable wires to be wound completely perpendicularly without spaces at corners, maximizing winding density and space factor while maintaining manufacturing simplicity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If sharp edges are present on magnetic pole tooth sections, then manufacturing is easier, but wire insulation coatings are broken

Engineering Contradiction:

Improvemanufacturing easeVSAvoidwire damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The radially outward sides of the magnetic pole tooth section are designed with rounded corners instead of sharp edges, preventing wire insulation damage during high-speed winding while remaining compatible with standard punching manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Loss of energy

If magnetic pole tooth section is larger and positioned closer to winding machine, then magnetic efficiency is improved, but wire damage occurs during high-speed winding

Engineering Contradiction:

Improvemagnetic efficiencyVSAvoidwire insulation damage

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

Rounded corners on the magnetic pole tooth section eliminate sharp edges that cause wire damage during high-speed winding, allowing the magnetic pole to be positioned optimally for magnetic efficiency without compromising wire integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

5Device complexity

If conventional joining sections are used, then assembly is simpler, but assembly accuracy is insufficient

Engineering Contradiction:

Improvejoining section complexityVSAvoidassembly accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Positioning protrusions and recesses are provided on the yoke-segment pieces at the joining sections, enabling preliminary positioning and accurate alignment of laminated core segments before final assembly, thereby improving assembly accuracy without significantly increasing complexity.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7667367B2Laminated core and method for manufacturing the same

Publication Date: 2010.02.23 MITSUI HIGH TEC INC

AI summary

A laminated core formed by reliably and firmly connecting laminated core segments (10) in an annular form by first and second joining sections (19, 20) thereof, the first and second joining sections (19, 20) formed by alternately laminating sets of core segment sheets (21) and sets of core segment sheets (22), each set consisting of a predetermined number of sheets, the core segment sheets having brimmed concavities (24, 25) and brimmed convexities (23, 26) located at both ends of yoke-segment pieces (27, 36), wherein each laminated core segment (10) has round corners formed at both sides of a magnetic pole shaft section (12) and radially outward sides of a magnetic pole tooth section (13) at lower and upper laminated portions of the laminated core segment (10), thereby preventing damage to wires wound around the magnetic pole shaft section (12).