Laminated Core Manufacturing Thickness Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing laminated cores with varying core piece thicknesses struggle to maintain uniform thickness, leading to inconsistencies in the final product, especially when combining core pieces of different shapes, which complicates the manufacturing process and requires complex control programs to correct for variations.
Innovation Solution
A method involving a progressive die that stamps out core pieces of different shapes, stacks them to form laminate blocks, changes the lamination order, and integrates them, allowing for adjustment of the last laminate block's thickness to ensure the final product meets tolerance requirements without needing intricate control programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core pieces are simply laminated based on predetermined stacking numbers, then the manufacturing process is simple, but the thickness of the laminate cannot be controlled within tolerance due to variations in core material thickness
Solution Approach 1:
The patent applies preliminary action by measuring the thickness of each core piece before lamination and calculating the required stacking numbers in advance. This allows the system to compensate for thickness variations proactively, ensuring the final laminate thickness falls within the specified tolerance range while maintaining a relatively simple manufacturing process.
2Manufacturing precision
If the number of sheets to be laminated is corrected using a control program, then the laminate thickness can be controlled, but the manufacturing process becomes more complex
Solution Approach 1:
The control program performs preliminary calculations to determine the optimal stacking numbers for each core piece type based on measured thickness data. By pre-calculating the required number of sheets to achieve the target thickness, the system simplifies the control logic while maintaining precise thickness control, avoiding the need for complex real-time adjustments during lamination.
3Adaptability or versatility
If core pieces of different shapes are combined in a laminated core, then the functional requirements are met, but the manufacturing process becomes more complex and thickness control becomes difficult
Solution Approach 1:
The patent segments the lamination process by dividing core pieces of different shapes into separate stacking sequences. Each shape type is processed independently with its own calculated stacking numbers, allowing for precise thickness control of each segment. The control program then integrates these segments into the final laminated core, managing the complexity through systematic organization rather than handling all variations simultaneously.
4Manufacturing precision
If the thickness of each core piece is measured and stacking numbers are calculated, then the laminate thickness can be controlled within tolerance, but the manufacturing time increases
Solution Approach 1:
The system performs thickness measurements and stacking number calculations as preliminary actions before the actual lamination process. By pre-determining the optimal stacking configuration based on measured data, the system avoids time-consuming adjustments during lamination. The control program efficiently processes the calculations and outputs the stacking sequence, minimizing the impact on overall manufacturing cycle time while ensuring precise thickness control.
Data Source
AI summary
A method of manufacturing a laminated core is provided. The manufacturing method includes the steps of feeding a belt-like sheet of core material to a progressive die, stamping out core pieces having a first shape from the core material, stacking more than one of the core pieces having the first shape to obtain a first laminate block, stamping out core pieces having a second shape from the core material, stacking more than one of the core pieces having the second shape to obtain a second laminate block, discharging a laminate including the first laminate block and the second laminate block from the progressive die, changing the lamination order of the laminate blocks constituting the laminate, and integrating the laminate after the lamination order of the laminate blocks are changed.