Lamination Lamellas with Connecting Tabs for Face Processing
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Solution Overview
Problem
Existing methods for manufacturing lamellas for lamination stacks, such as transformer cores or electric motor components, do not allow for separate processing of the main faces of the lamellas without individually handling them, which is inefficient and prone to errors.
Innovation Solution
A method where individual lamellas are only partially cut loose from sheet material, leaving connecting tabs or bridges, allowing the lamellas to remain connected and be processed separately without direct handling. The lamellas are eventually cut loose by severing these bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lamellas are completely cut loose from sheet material during blanking, then individual handling is required for processing main faces, but this increases complexity and risk of errors
Solution Approach 1:
The cutting process is segmented into two stages: first, holes are pierced along the outer contour leaving connecting bridges; second, the lamellas are completely separated by cutting through the bridges. This segmentation allows intermediate handling of connected lamellas while enabling final separation for individual processing.
Solution Approach 2:
The holes are pierced in advance along the outer contour of the lamellas before complete separation, creating connecting bridges that maintain structural integrity during intermediate handling and processing steps.
2Device complexity
If lamellas remain fully connected to sheet material, then handling is simplified, but separate processing of main faces becomes impossible
Solution Approach 1:
The connection between lamellas and sheet material is partially segmented by piercing holes along the outer contour while leaving connecting bridges intact, allowing both collective handling and separate processing capabilities.
Solution Approach 2:
The connection state transitions dynamically from fully connected to fully separated through the intermediate stage of connecting bridges, allowing the system to adapt between collective handling and individual processing modes as needed.
3Ease of manufacture
If multiple punching steps are performed before blanking, then holes for shafts and magnets are formed, but the sequence of operations becomes complex
Solution Approach 1:
The punching steps for forming holes and the blanking step for separating lamellas are merged into a single integrated process where holes are pierced along the outer contour during the blanking operation itself, eliminating separate punching steps.
Data Source
AI summary
The present invention relates to a method for manufacturing lamellas (20) from sheet metal (30) for a stack of such lamellas (20), i.e. a lamination, such as the core of a transformer or of a rotor or a stator of an electric machine. According to the present invention, in a first manufacturing step (A), the individual lamellas (20) are only partly cut loose from the sheet material (30), while connecting tabs (32) are left between the lamellas (20) and a remaining frame part (31) of the sheet material (30). As a result, the lamellas (20) can be subsequently processed (SP) separately, favorably without requiring the individual and/or direct handling thereof. Only thereafter, in second manufacturing step according to the present invention (B), the lamellas (20) are completely cut loose from the frame part (31) of the sheet material (30) by cutting the said connecting tabs (32) there between.