Magnetic Lamination Stack Printing for Joint Sintering Alignment
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Solution Overview
Problem
The existing methods for manufacturing electric machines with stacks of magnetic laminations are complex, expensive, and require individual processing and alignment of thousands of laminations, which is time-consuming and inefficient.
Innovation Solution
A method where a stack of green blanks is printed with a separating layer, allowing multiple green blanks to be jointly sintered, eliminating the need for individual sintering and alignment, and enabling the manufacture of electric machines with improved precision and cost-effectiveness by printing and sintering the stack in parallel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual magnetic laminations are processed separately through printing, sintering, and assembly, then each lamination can be individually optimized, but the manufacturing process becomes complex, time-consuming, and expensive
Solution Approach 1:
The patent merges multiple individual lamination processing steps into a single integrated process. Multiple green blanks are stacked and sintered together in one operation, eliminating the need for separate sintering and alignment steps for each lamination. This combining of operations reduces manufacturing complexity while maintaining precision through the printing process's inherent alignment capabilities.
Solution Approach 2:
The patent applies preliminary action by printing all green blanks with their final patterns and designs before stacking and sintering. The alignment and positioning are established during the printing stage, and the subsequent sintering process preserves this pre-established arrangement, eliminating the need for post-sintering alignment operations.
2Reliability
If thousands of individual magnetic laminations are transported, stored, and assembled separately, then each component can be quality-controlled, but the manufacturing time and costs increase significantly
Solution Approach 1:
The patent combines multiple laminations into a single stacked structure that is sintered as one unit. This merging eliminates the need for separate transport, storage, and assembly operations for thousands of individual components, dramatically increasing productivity while maintaining quality control through the integrated process.
Solution Approach 2:
The patent creates multiple identical or variant green blanks through the printing process, which are then stacked and sintered together. This copying approach allows for批量 production of laminations with consistent quality characteristics, reducing the need for individual handling and quality checks of each separate component.
3Manufacturing precision
If individual sintering of green blanks is performed, then each lamination can be independently processed, but the overall manufacturing process becomes slower and more expensive
Solution Approach 1:
The patent merges multiple sintering operations into a single batch sintering process. Multiple green blanks are stacked and sintered simultaneously in one furnace cycle, reducing total manufacturing time from thousands of individual sintering operations to one collective operation, while still achieving the desired lamination properties through controlled sintering parameters.
4Manufacturing precision
If complex alignment of sintered laminations is required, then precise stack formation is achieved, but the process becomes more complicated and time-consuming
Solution Approach 1:
The patent performs preliminary alignment during the printing stage, where green blanks are printed with precise positioning. This pre-alignment is preserved through the stacking and sintering processes, eliminating the need for complex post-sintering alignment operations and simplifying the overall manufacturing process.
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 method simplifies and accelerates the production of electric machines with precise magnetic lamination stacks, enhancing electrical efficiency and reducing production costs by eliminating the need for complex alignment and separate processing of individual laminations.
Implementation Method 1
the resulting green body is transformed into a metal lamination by thermal treatment, i.e., binder removal and sintering
Implementation Method 2
the resulting green body is transformed into a metal lamination by thermal treatment, i.e., binder removal and sintering
Data Source
AI summary
A method for manufacturing an electric machine having a stack of magnetic laminations including a stack of green blanks. A first green blank of the stack is printed. A separating layer is applied to the first green blank. At least a second green blank of a magnetic lamination is printed onto the first green blank with the separating layer. The green blanks are jointly sintered.