Laser Processing Insulating Elements for Stator Rotor Base Bodies
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Solution Overview
Problem
Existing methods for manufacturing insulating elements for stator or rotor base bodies require separate tools for different shapes and dimensions, limiting design freedom and increasing costs due to the need for custom cutting and embossing tools.
Innovation Solution
A method using a laser device to process insulating material based on pre-measured data, allowing for precise cutting and weakening of the material to create adjustable insulating elements that can fit various shapes and dimensions without the need for multiple tools, utilizing a single tool to produce multiple insulating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate tools are used for each different shape and dimension of stator base body, then the insulating elements can be correctly placed with proper cutting edges and fold edges, but the device complexity increases and design freedom is restricted
Solution Approach 1:
The laser device serves as a universal tool that can process insulating material for different stator base body shapes and dimensions using software-controlled parameters. Instead of requiring separate physical tools for each configuration, the same laser device adapts its cutting and embossing patterns through digital programming, eliminating the need for multiple dedicated tools while maintaining precision for various insulating element geometries
Solution Approach 2:
The patent replaces traditional mechanical cutting blades and embossing rolls with a laser-based processing system. The laser device uses optical energy to cut and emboss the insulating material according to digitally defined paths, substituting mechanical contact tools with a non-contact energy field approach that is controlled by software rather than physical tooling
2Manufacturing precision
If separate tools are used for different stator base body configurations, then accurate insulating elements can be produced, but the manufacturing cost increases
Solution Approach 1:
The laser processing system functions as a universal manufacturing tool that can produce accurate insulating elements for different stator configurations without requiring expensive dedicated tooling for each variant. The software-controlled laser adapts to different geometries through digital programming, eliminating the need to invest in multiple sets of specialized cutting and embossing tools
Solution Approach 2:
The invention changes the controlling parameters of the laser device (power, speed, pattern, focal position) based on the specific insulating element geometry required, rather than changing physical tools. This parameter-based adaptation allows the same hardware to produce different insulating element shapes and features, reducing manufacturing costs by eliminating tooling changes
3Ease of manufacture
If embossing rolls and cutting blades are used, then insulating elements can be created from paper web, but the design freedom of the paper is restricted
Solution Approach 1:
The laser device replaces the mechanical constraints of embossing rolls and cutting blades with a flexible optical processing system. The laser can create complex 2D and 3D patterns on the insulating material without being limited by the physical geometry of mechanical tools, allowing greater design freedom for insulating element shapes while maintaining ease of manufacture from continuous material web
Solution Approach 2:
The laser processing system is dynamic and adaptable, allowing the processing parameters and patterns to be changed on-the-fly through software control. This enables the system to accommodate varying insulating element designs without requiring physical reconfiguration of tooling, providing both ease of manufacture and design versatility
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
Enables the quick, cost-effective, and precise manufacturing of insulating elements that can be tailored to different stator or rotor base body configurations, ensuring safe and reliable insulation without the need for tool switching, while minimizing measurement effort and ensuring compliance with insulation standards.
Implementation Method 1
a laser device (14) is provided. The laser device (14) is configured for processing the insulating material (4) based on the processing data
Data Source
AI summary
The present invention relates to a method for producing an insulating element for a stator base body or a rotor base body or a single tooth base body, comprising the steps of: providing an insulating material, receiving or generating or retrieving processing data based on which the insulating material has to be processed in order to manufacture the insulating element, and processing the insulating material by means of a laser device according to the processing data for producing the insulating element from the insulating material, wherein the processing data define at least one interface for cutting the insulating material and/or at least one weakening site for weakening the insulating material, and wherein the processing comprises cutting the insulating material along the interface and/or weakening the insulating material along the weakening site.