Laminated Core Manufacturing via Strip Segmentation and Elastic Push-Back
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of variant-shaped laminated cores for reluctance type resolvers is hindered by low productivity due to the time-consuming process of disengaging caulking projections and recesses, and the resulting waste of core sheets with through-holes that cannot engage previously laminated sheets.
Innovation Solution
A method involving punching out core sheets of different types from a strip, forming cutouts and caulking portions in both core sheets and outer plates, and laminating them to form the variant-shaped laminated core, allowing for progressive press die equipment use without needing to change die devices frequently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If core sheets of different types are punched out using multiple press die devices, then the variety of core sheet types is improved, but the productivity is reduced due to frequent die device changes
Solution Approach 1:
A single press die device is designed to punch out multiple types of core sheets by utilizing different regions of a continuous strip material. The die device includes multiple punching portions that can simultaneously or sequentially punch out core sheets of different types from different positions on the strip, eliminating the need to change dies for different core sheet types.
Solution Approach 2:
The strip material is divided into multiple regions, each designated for punching out a specific type of core sheet. By segmenting the strip into different zones with predetermined patterns, the press die device can efficiently produce various core sheet types from a single continuous material feed without requiring die changes.
2Manufacturing precision
If excess core sheets are laminated to form successive lamination, then the required thickness is achieved, but the productivity is reduced due to time-consuming disengagement of caulking projections
Solution Approach 1:
Instead of punching out complete core sheets and then laminating them, the invention extracts only the necessary portions from the strip material. The press die device punches out the exact shape and size needed for the final core, eliminating the need to create successive lamination and subsequently remove excess portions through disengagement of caulking projections.
Solution Approach 2:
The press die device performs preliminary punching to create the exact core shape and size before lamination occurs. By pre-forming the correct geometry in the strip material, the lamination process directly produces the final core structure without requiring subsequent removal of excess material or disengagement of caulking elements.
3Ease of operation
If through-holes are created in core sheets to prevent engagement, then the removal of lamination units is facilitated, but material yield is reduced due to waste core sheets
Solution Approach 1:
Instead of creating through-holes in entire core sheets, the invention applies local modifications only where necessary. The press die device punches out the precise core shape without creating unnecessary through-holes, maintaining material integrity and yield while still allowing for easy separation of lamination units through localized features only at the boundaries of the required core geometry.
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 significantly improves productivity by eliminating the need to punch and laminate excess core sheets and reduces material waste, enhancing geometric accuracy and quality of the variant-shaped laminated cores.
Implementation Method 1
punching out a required number of core sheets for each of the plural types from the strip being transferred, to form the outlines of the core sheets, and push back the punched out core sheets into the strip
Implementation Method 2
the core sheets are laminated and interlocked by caulking portions
Data Source
Figure 1(A)~1(B)
Figure 2(A)~2(B)
Figure 3
AI summary
A method of producing a laminated variant-shaped core 10, comprising: Step A of punching out a required number of core sheets 12-14 for each of plural types, from a strip 11 to be processed, to form the outlines of the core sheets 12-14, and push back the punched out core sheets 12-14 into the strip 11; Step B of forming cutouts 28, 30 and 32 reaching outer peripheries of outer plates 27, 29 and 31, the outer plates 27, 29 and 31 being the same in outer shape and respectively containing thereinside the core sheets 12-14, the cutouts 28, 30 and 32 having inner edges respectively in contact with the core sheets 12-14; Step C of forming caulking portions 21 in each of the core sheets 12-14 and caulking portions 33 in each of the outer plates 27, 29 and 31; Step D of punching out the outer plates 27, 29 and 31 from the strip 11 to form the outlines of the outer plates 27, 29 and 31, and laminating and interlocking the core sheets 12-14 to form the variant-shaped laminated core 10 and laminating and interlocking the outer plates 27, 29 and 31; and Step E of removing the outer plates 27, 29 and 31 located outside the laminated and interlocked variant-shaped core 10. The method permits dramatic productivity improvement when compared with conventional methods.