Laminated Motor Core Separation for Dimensional Accuracy
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Solution Overview
Problem
Existing manufacturing methods for laminated cores of rotating electric machines face issues with dimensional accuracy due to excessive attraction of core elements by magnets, leading to oversized dimensions in the lamination direction.
Innovation Solution
A manufacturing method and apparatus that includes a laminating step, a core separating step, and a fixing step, utilizing a pressing device to maintain core elements in a lamination direction and a core separating device to move elements orthogonally, ensuring precise separation and fixation of core elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a magnet is provided at the distal end of the push-out blade to take out core elements, then the core elements can be attracted and moved, but the core elements are attracted more than required, causing the dimension of the laminated core in the lamination direction to become excessively large
Solution Approach 1:
The patent removes the magnet from the push-out blade, extracting the harmful magnetic attraction function while retaining the mechanical push-out capability. This eliminates the excessive attraction of core elements that caused dimensional inaccuracy, while the push-out blade still successfully separates and moves the laminate through mechanical force alone.
Solution Approach 2:
The patent converts the harmful effect of excessive magnetic attraction into a beneficial controlled process by eliminating the magnet and using only mechanical pushing force. This allows precise control over the separation distance, ensuring the laminate is moved exactly to the required position without being attracted beyond the set dimension.
2Manufacturing precision
If core elements are laminated tightly to reduce dimension, then the dimensional accuracy improves, but the space factor utilization decreases
Solution Approach 1:
The patent introduces a dynamic pressing mechanism that applies controlled pressing force during the lamination process. This dynamic pressing allows the core elements to be tightly bound with precise dimensional control, maximizing space factor utilization while maintaining manufacturing precision. The pressing force is optimized to achieve the best balance between tightness and accuracy.
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
Improves dimensional accuracy and productivity of laminated cores by minimizing interlayer gaps and enabling stable grasping and fixation, enhancing motor output through higher space factor and reduced defects.
Implementation Method 1
a pressing device configured to press an element laminate formed by laminating a plurality of core elements each punched out from an electromagnetic steel sheet in a lamination direction of the plurality of core elements
Implementation Method 2
A magnet is provided at a distal end of the push-out blade... there is a risk in that core elements are attracted more than required
Data Source
AI summary
A manufacturing method for a laminated core of a rotating electric machine includes a laminating step and a core separating step. In the laminating step, a plurality of core elements are laminated, thereby forming an element laminate. In the core separating step, under a state in which the element laminate is pressed in a lamination direction of the plurality of core elements, a part of the element laminate is moved from the element laminate in a direction orthogonal to the lamination direction by a set dimension in the lamination direction, thereby obtaining a separated laminate.