Laminated Core Segment Manufacturing Virtual Line Segmentation
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Solution Overview
Problem
Existing methods for manufacturing laminated core segments from wide thin strip material result in low material yield and thickness deviations across different lines, leading to inefficient production and inconsistent core thickness.
Innovation Solution
A method involving the formation of virtual lines on the strip material, where core sheets are blanked and laminated with alternating directions, and distinguished by unique marks for sorting and thickness adjustment, allowing for precise control of core thickness through re-pressing and visual inspection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple core sheets are manufactured in parallel lines from wide thin strip material, then production efficiency is enhanced, but thickness deviation occurs across different lines
Solution Approach 1:
The patent divides the wide thin strip material into multiple virtual lines (first virtual line, second virtual line, etc.) in the width direction, allowing simultaneous manufacturing of multiple core sheets in parallel. This segmentation enables increased production efficiency while maintaining thickness consistency through separate control of each virtual line's blanking positions.
Solution Approach 2:
The patent applies local quality by allowing arbitrary positioning of segment core sheets along the feed direction within each virtual line and alternating directions of segment core sheets in adjacent virtual lines. This enables localized adjustment of blanking positions for each virtual line to compensate for thickness variations in the thin strip material, ensuring consistent core sheet thickness across multiple production lines.
2Loss of substance
If segment core sheets are blanked at arbitrary positions along feed direction, then material yield is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs dynamic positioning of segment core sheets along the feed direction within each virtual line, allowing flexible arrangement to maximize material utilization. The die device can blank segment core sheets at arbitrary positions while maintaining control through the virtual line framework, improving material yield without excessive complexity.
Solution Approach 2:
The die device is designed with multi-functionality to handle arbitrary blanking positions along the feed direction while maintaining consistent manufacturing processes. The same die device can blank segment core sheets at different positions and in different directions within each virtual line, reducing the need for multiple specialized devices and controlling overall system complexity.
3Measurement precision
If distinguishing marks are added to identify virtual lines, then thickness measurement and adjustment capability is enabled, but manufacturing process complexity increases
Solution Approach 1:
The patent uses distinguishing marks (such as different colors, patterns, or visual identifiers) on segment core sheets from different virtual lines to enable identification and tracking. This allows for thickness measurement and adjustment specific to each virtual line while maintaining a relatively simple marking system that can be integrated into the existing manufacturing process.
Solution Approach 2:
The distinguishing marks enable a feedback mechanism where thickness measurements from different virtual lines can be tracked and adjusted independently. The system can identify which virtual line a core sheet belongs to through its distinguishing mark, measure its thickness, and provide feedback for adjustment, enabling precise control without excessive system complexity.
Data Source
AI summary
A method of manufacturing laminated core segments including: a process to blank and laminate, wherein the segment core sheets formed in the adjacent virtual lines are aligned so that directions of the segment core sheets alternate, each of the segment core sheets are blanked and formed by a die device, and the laminated core segments are formed by laminating the blanked segment core sheets in the die device; a process to eject, wherein each of the laminated core segments formed by blanking and laminating in each virtual line is ejected from the die device; and a process to identify a blanking position, wherein the distinguishing marks are provided for the laminated core segments to identify the virtual lines therefor.