Lamination Pack Edge Fusion for High-Silicon Electrical Steel
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Solution Overview
Problem
Existing methods for connecting laminations in electric motor or generator components, such as rotors and stators, face challenges with complex processes, detachment issues, and difficulty in welding silicon-aluminum alloys with high silicon or aluminum content, especially when coated with EC3 insulation varnish.
Innovation Solution
The method involves locally plasticizing the material of laminations using friction heat generated by a rotatably driven welding tool, allowing for material fusion and reliable connection independent of material composition, with adjustable tool movements to control weld seam width and depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding method is used to connect laminations, then connection strength is improved, but welding becomes difficult with high silicon or aluminum content materials and EC3 insulation varnish coated laminations
Solution Approach 1:
The invention changes the connection method from welding to friction-based plasticizing and material fusion. By applying friction heat through a rotating tool and combining it with axial pressing force, the laminations are locally plasticized and fused together without requiring welding, thus solving the welding difficulty with high silicon/aluminum content materials and EC3 coated laminations
Solution Approach 2:
The invention replaces the welding process (thermal-chemical joining) with a mechanical friction-based process. The rotating tool generates friction heat that plasticizes the lamination material, and the axial pressing force forces plasticized material into gaps between laminations, creating a mechanical interlock and material fusion connection instead of a weld
2Device complexity
If form-fit connection is used to connect laminations, then manufacturing complexity is reduced, but connection reliability deteriorates due to potential detachment during transport or storage
Solution Approach 1:
The invention creates a composite connection structure where plasticized material from multiple laminations fuses together to form a unified connection zone. The plasticized material acts as a bonding agent that mechanically interlocks with the lamination gaps, creating a composite structure that is more reliable than simple form-fit connections
Solution Approach 2:
The invention applies local plasticizing only at the edge regions of the laminations where gaps exist. The friction heat and pressing force are concentrated at these specific locations to plasticize and fuse the material locally, creating strong connection points without affecting the entire lamination structure
3Reliability
If screws or rivets are used to fixedly connect laminations, then connection reliability is improved, but manufacturing complexity and process time increase
Solution Approach 1:
The invention extracts and eliminates the need for separate fastening elements like screws or rivets. The connection is achieved directly through the lamination material itself, which is plasticized and fused at the edges to create an integrated connection structure, removing the complexity of inserting and securing fasteners
Solution Approach 2:
The lamination material serves its dual function: it is both the structural component and the bonding agent. The edge regions of the laminations are plasticized and fused together, allowing the material itself to create the connection without requiring external fasteners or additional bonding materials
4Manufacturing precision
If laminations are rotated to ensure constant height, then lamination pack uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The friction-based connection method is universally applicable to laminations of various heights and configurations. The rotating tool can accommodate different lamination pack heights through adjustable axial pressing force, eliminating the need for specific rotation angles or height-matching procedures required by other methods
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 approach enables a simple, cost-effective, and reliable connection of laminations, minimizing magnetic losses and preventing detachment, even with high silicon content materials, while maintaining the integrity of the lamination pack.
Implementation Method 1
the material of the laminations is locally plasticized in the edge region by generating friction heat by means of at least one tool
Implementation Method 2
the material, at least of neighboring laminations, is mixed by means of the tool so that, after cooling of the plasticized material, these laminations are connected to each other by material fusion
Data Source
AI summary
A device for performing a method for producing a lamination pack, wherein in the method laminations are cut from an electric strip or sheet; the laminations are placed on top of each other to form a lamination stack; the laminations are connected by material fusion to each other by: locally plasticizing a material of the laminations in an edge region of the laminations by generating friction heat by a tool; mixing the locally plasticized material, at least of the laminations neighboring each other, with the tool; and allowing the plasticized material to cool and fuse the laminations in the edge region to form the lamination pack. The device has a punch press and/or a receptacle for one or a plurality of lamination stacks. The device further has a welding tool that is rotatably driven about an axis of the welding tool and moveable transverse to the axis of rotation.