Magnetic Lamination Stacking Sequence for Rotor and Stator Tolerances
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Solution Overview
Problem
Existing methods for manufacturing magnetic laminations for electric machines, such as screen and stencil printing, often result in manufacturing tolerances that hinder the achievement of operationally critical specifications due to variations in geometric dimensions, density, microstructure, and magnetic properties.
Innovation Solution
A method that involves recording physical properties of individual magnetic laminations, determining a setpoint value for a stack, and ascertaining an optimal stacking sequence using artificial intelligence to minimize deviations from the setpoint values, with the option to adapt or exchange elements to achieve the desired properties, and utilizing additive manufacturing for the stacking aid and laminations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen and stencil printing methods are used to manufacture magnetic laminations, then manufacturing process simplicity is maintained, but manufacturing precision deteriorates due to troublesome tolerances in geometric dimensions, density, microstructure, and magnetic properties
Solution Approach 1:
The patent applies preliminary action by measuring and recording physical properties of individual magnetic laminations before stacking, and by using computer-based optimization to determine the stacking sequence in advance. This allows the system to compensate for manufacturing variations by strategically arranging laminations with different properties to achieve target stack characteristics, thereby resolving the contradiction between simple manufacturing processes and precise final product specifications.
2Manufacturing precision
If artificial intelligence and optimization methods are applied to determine stacking sequence, then manufacturing precision of the stack is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by measuring the actual physical properties of individual magnetic laminations, comparing them against target values, and using this information to optimize the stacking sequence. The computer system calculates the deviation of actual stack properties from setpoint values and adjusts the stacking arrangement accordingly, creating a closed-loop system that improves precision while managing complexity through algorithmic optimization.
Solution Approach 2:
The patent applies parameter changes by varying the stacking sequence of magnetic laminations based on their measured physical properties. Instead of using a fixed stacking order, the system optimizes the arrangement by changing parameters such as lamination position, orientation, and grouping to minimize stack property deviations, thereby achieving high precision without requiring complex manufacturing processes for each individual lamination.
3Reliability
If individual lamination properties are measured and optimized stacking is implemented, then reliability of electric machine operation is improved, but loss of time increases due to measurement and optimization processes
Solution Approach 1:
The patent applies preliminary action by performing measurements and optimization calculations before the stacking process. By determining the optimal stacking sequence in advance based on measured lamination properties, the system ensures reliable achievement of operational specifications while minimizing time loss during actual manufacturing. The computer-based optimization is performed offline, allowing rapid calculation without delaying production.
Data Source
AI summary
Various embodiments include a method for manufacturing a stack of magnetic laminations for a rotor and/or stator of an electric machine. The method includes: recording a respective physical property of each respective magnetic lamination from a plurality of magnetic laminations; determining a setpoint value for a physical variable of the stack of magnetic laminations; ascertaining a stacking sequence of the individual magnetic laminations of the plurality reducing a deviation of an actual value for the physical variable of the stack with the ascertained stacking sequence from a setpoint value in relation to stacks with other stacking sequences of magnetic laminations; and stacking the plurality of the magnetic laminations in the ascertained stacking sequence.