Laminated Core Stacking to Reduce Tilt in Thin Motor Cores
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Solution Overview
Problem
Conventional stacked core production methods for rotary electric machines require costly equipment and large press machines due to the need for cutting and overlapping electromagnetic steel sheets, leading to inefficiencies and increased costs.
Innovation Solution
A method involving the alternate stacking and fixation of first and second core sheets with varying thicknesses, stamped from an electromagnetic steel sheet, to form a stacked core with reduced tilt and improved efficiency, using a stamping, alignment, and fixation process that minimizes equipment size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electromagnetic steel sheets are thinned to reduce core size, then the size of the rotary electric machine is reduced, but the number of stacked sheets increases causing increased tilt due to sheet thickness deviation
Solution Approach 1:
The patent divides the stacked core into two groups: first core sheets stamped from the first region of the electromagnetic steel sheet and second core sheets stamped from the second region. These two groups are alternately stacked to compensate for thickness deviations, thereby reducing overall tilt while maintaining reduced core size through thin sheets.
Solution Approach 2:
The patent applies different sheet regions with different thickness characteristics to different positions in the stacked core. The first region and second region of the electromagnetic steel sheet have different thickness deviations, and by alternately stacking sheets from these regions, the local thickness variations compensate each other, reducing cumulative tilt.
2Manufacturing precision
If conventional cutting and overlapping methods are used to reduce sheet thickness deviation, then manufacturing precision is improved, but equipment cost and press machine size increase
Solution Approach 1:
The patent performs preliminary classification of electromagnetic steel sheets into first and second regions based on their thickness characteristics before stamping. This preliminary sorting allows subsequent stamping operations to produce core sheets with compensated thickness deviations, achieving high manufacturing precision without requiring complex cutting and overlapping equipment.
Solution Approach 2:
The patent changes the approach from physically modifying sheet thickness through cutting and overlapping to selecting and alternating between different sheet regions with inherent thickness variations. This parameter-based solution (using regional thickness differences) replaces complex mechanical processing with a simpler sorting and alternating stacking method.
Data Source
AI summary
A stacked core is formed by stacking a plurality of first core sheets and second core sheets stamped from an electromagnetic steel sheet. Each first core sheet is formed such that a sheet thickness thereof increases from one side toward another side. Each second core sheet is formed such that a sheet thickness thereof increases from the other side toward the one side. The first core sheets and the second core sheets are alternately stacked per predetermined number of sheets.