Laminated Core Manufacturing with Temporary Interlocking and Resin Binding
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Solution Overview
Problem
Existing methods for manufacturing laminated cores, such as those described in WO2010/082465, face challenges in efficiently removing temporarily-interlocking portions without causing the laminated core to fall apart, particularly when the fixtures are slid in a limited direction or when metal sheets are flipped, which can lead to inefficiencies and potential damage.
Innovation Solution
A manufacturing method involving a progressive die to stamp metal sheets into workpieces with temporarily-interlocking portions, allowing for easy removal of these portions radially outward or inward, and subsequent integration with resin filling to form a laminated core without swaged areas, enhancing the ease of handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixtures are used to temporarily bind core sheets with swaged areas, then the laminated core can be manufactured and permanently bound with resin material, but the fixtures must be removed after binding which adds process complexity and risk of damage
Solution Approach 1:
The invention extracts the temporarily-interlocking portions from the workpieces after the laminate is permanently bound with resin material. These portions are removed radially outward or inward from the laminated core, eliminating the need for complex fixture removal processes while maintaining manufacturing ease.
Solution Approach 2:
The temporarily-interlocking portions are formed in advance during the stamping process of the workpieces. This preliminary formation allows the workpieces to be easily integrated before permanent binding, and subsequently removed without adding process complexity.
2Ease of operation
If temporarily-interlocking portions are removed radially outward or inward, then the ease of handling is improved, but the process must ensure the laminated core does not fall apart during removal
Solution Approach 1:
The resin material is used to permanently bind the workpieces to each other and to the yoke part before the temporarily-interlocking portions are removed. This preliminary permanent binding ensures the laminated core maintains its structural integrity during the removal process, preventing it from falling apart while allowing easy handling.
3Productivity
If conventional swaging or welding is used to fasten magnetic metal pieces, then cost and work efficiency are improved, but torque and iron loss performance may be compromised
Solution Approach 1:
The invention applies different fastening methods to different parts of the laminated core. Conventional swaging or welding is used for the main fastening of magnetic metal pieces to ensure cost-effectiveness and efficiency, while resin material is used for permanent binding of workpieces to ensure high torque and low iron loss performance. This local differentiation of fastening quality resolves the contradiction between productivity and motor performance.
Data Source
AI summary
This disclosure relates to a method for manufacturing a laminate used for manufacturing a laminated core including a circumferential yoke part and a plurality of magnetic pole parts radially extending from the yoke part. This method includes: feeding a metal sheet drawn from a roll thereof to a progressive die; stamping out a plurality of workpieces from the metal sheet in the progressive die, wherein each of the workpiece comprises a temporarily-interlocking portion between adjacent magnetic pole portions; and stacking the workpieces to integrate these workpieces together by the temporarily-interlocking portion to obtain the laminate.