Magnetic Mandrel Assembly for Precise Lamination Sector Stacking
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Solution Overview
Problem
The use of lamination sectors increases manufacturing complexity in lamination stacks due to difficulties in aligning and stacking, as outward radial nudge separates the sectors, making it challenging to achieve a precise and efficient assembly.
Innovation Solution
A mandrel-based device with magnetizable bars and alignment pins is used to align and stack lamination sectors, utilizing magnetic attraction to hold sectors in place during assembly, allowing for automated and precise positioning without the need for realignment or additional fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lamination sectors are stacked using conventional mandrels, then the manufacturing process becomes simpler, but the alignment precision deteriorates because outward radial nudge separates the sectors
Solution Approach 1:
The patent replaces the conventional mechanical expansion system with a magnetic field-based system. Magnetizable bars mounted on the mandrel generate magnetic fields that attract and hold lamination sectors in precise positions during stacking, eliminating the need for mechanical radial nudge while maintaining alignment precision.
Solution Approach 2:
The patent changes the physical state or property used for holding sectors from mechanical contact force to magnetic field interaction. By utilizing the magnetic properties of the bars and their interaction with the lamination sectors, the system achieves both precise alignment and easy manufacturing.
2Manufacturing precision
If lamination sectors are held together during stacking, then alignment precision improves, but the device complexity increases due to additional holding mechanisms
Solution Approach 1:
The magnetizable bars serve multiple functions: they act as structural support elements on the mandrel, generate magnetic fields for holding sectors, and provide alignment references. This multi-functionality reduces the need for separate holding mechanisms, thereby limiting device complexity while maintaining precision.
Solution Approach 2:
The lamination sectors themselves become part of the holding system through their interaction with the magnetic field. The sectors are attracted to and held by the magnetic fields generated by the bars, eliminating the need for external clamping or fastening mechanisms.
3Device complexity
If conventional mandrels are used for stacking, then the device cost is lower, but the productivity decreases due to manual alignment operations
Solution Approach 1:
By replacing manual alignment operations with automated magnetic field-based positioning, the system significantly increases stacking speed. The magnetic fields automatically guide and hold sectors in correct positions, eliminating time-consuming manual alignment while keeping the mandrel structure relatively simple.
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
The device facilitates easy and cost-effective assembly of lamination stacks by minimizing cutting waste, enabling the use of different sheet metals for rotors and stators, and ensuring precise alignment without the need for additional alignment tools, thus simplifying the manufacturing process.
Implementation Method 1
the bars being magnetizable, a magnetization system for the bars... The sectors of a lamination need not be connected to each other... the magnetization system magnetizes the bars, which, when magnetized, can then attract the lamination sectors
Data Source
AI summary
Device for manufacturing a lamination stack (E) for a rotating electrical machine, each lamination having a plurality of lamination sectors with notches. The laminations providing a central bore. The device including a mandrel for receiving the stacked lamination sectors, in which the mandrel includes a mandrel body provided with longitudinal slots, bars received in the longitudinal slots of the mandrel body, the bars being magnetizable, a magnetization system for the bars, and alignment pins intended to be received in the notches of the laminations to align the notches.