Magnetic-Core Assembly Compression Tool for Precise Lamination Stacking
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Solution Overview
Problem
Magnetic-core assemblies in electric machines face issues with eddy current losses and imprecisions in lamination stacking, leading to performance problems and potential failures due to thermal, mechanical, and electrical stresses, which existing assembly tools and methods fail to adequately address.
Innovation Solution
The use of a magnetic-core assembling tool with a first compression plate alignment guide, semiannular tension bars, and a clamping plate with variable compression shoes to precisely align and compress lamination stacks, and injecting magnet retention adhesive into magnet retention slots to maintain axial compression and prevent adhesive flow across lamination faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly tools are used to stack laminations, then assembly speed is maintained, but manufacturing precision deteriorates due to imprecise alignment and compression of laminations
Solution Approach 1:
The assembly tool is segmented into modular components including alignment guides, compression plates, and positioning fixtures that can be independently adjusted and configured for different lamination stacking requirements, enabling high precision without requiring an entirely complex monolithic tool structure
Solution Approach 2:
The alignment guides and positioning features are designed to self-align and self-position the laminations during assembly, eliminating the need for complex external alignment mechanisms and reducing overall tool complexity while maintaining manufacturing precision
2Reliability
If adhesive is applied across lamination faces to prevent movement, then reliability improves by preventing lamination separation, but manufacturing precision deteriorates due to adhesive flow causing misalignment
Solution Approach 1:
Adhesive is applied locally at specific interfaces between laminations rather than across entire lamination faces, providing sufficient bonding strength at critical locations while preventing adhesive overflow and misalignment that would occur with face-wide application
Solution Approach 2:
Compression plates and alignment guides serve as intermediary elements that apply controlled pressure and maintain precise alignment during adhesive application, preventing adhesive flow from causing misalignment while ensuring reliable bonding
3Manufacturing precision
If compression force is increased to reduce space between laminations, then manufacturing precision improves by minimizing gaps, but device complexity increases due to need for variable compression control
Solution Approach 1:
The compression system incorporates variable compression capability that can be dynamically adjusted during different stages of assembly, allowing high compression force for gap elimination followed by reduced maintenance compression, controlled through simple mechanical means rather than complex automated systems
Solution Approach 2:
Compression force parameters are changed at different assembly stages - high compression during initial stacking to eliminate gaps, then reduced to maintenance levels - achieved through straightforward mechanical adjustment rather than complex control systems
Data Source
AI summary
A magnetic-core assembling tool may include first and second compression plate alignment guides configured to be respectively fitted to first and second compression plates of a magnetic-core assembly, a plurality of semiannular tension bars, and a clamping plate. The semiannular tension bars may be attached at a first end to the first compression plate alignment guide and at a second end to the clamping plate. The clamping plate may include a plurality of compression shoes configured to apply a variable amount of compression to the magnetic-core assembly. A method of assembling a magnetic-core assembly includes assembling a plurality of lamination stacks, staging the plurality of lamination stacks to provide a magnetic-core assembly, assembling a magnetic-core assembling-tool around the magnetic-core assembly, and injecting magnet retention adhesive into a plurality of magnet retention slots in the magnetic-core assembly housed in the magnetic-core assembling tool.