Motor Core Block Stacking Using Press-Origin Identification
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Solution Overview
Problem
In existing methods for manufacturing motor cores using progressive press devices, misalignment between the center of the outer perimeter and the center hole of iron core pieces leads to inconsistencies in dimensional accuracy and motor performance due to mixing blocks formed in different rows.
Innovation Solution
A method that includes forming identifying portions on the iron core pieces, specifically in the second iron core piece, to identify the progressive press device, and using a detection device to ensure only blocks from the same press device are stacked, thereby maintaining dimensional accuracy and reducing performance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple progressive press devices punch iron core pieces simultaneously from the same base material, then productivity increases, but misalignment between center of outer perimeter and center hole varies between rows causing dimensional accuracy variation
Solution Approach 1:
The invention forms identifying portions on iron core pieces during the punching process itself, before stacking. This preliminary action enables subsequent detection and sorting to ensure only blocks from the same progressive press device are stacked together, preventing mixing of blocks with different alignment characteristics and maintaining dimensional accuracy while allowing parallel production
Solution Approach 2:
The invention introduces a detection device that reads identifying portions on iron core pieces to determine which progressive press device formed each block. This feedback mechanism enables selective stacking based on device origin, ensuring consistent alignment characteristics are maintained throughout the stacked body while preserving the productivity benefits of multiple simultaneous press devices
2Productivity
If blocks from different progressive press devices are mixed and stacked, then productivity is maximized, but variation in motor performance increases due to inconsistent dimensional accuracy
Solution Approach 1:
The identifying portions are formed on iron core pieces during the punching process, before stacking occurs. This preliminary marking enables subsequent detection and sorting to ensure only blocks from the same progressive press device are stacked together, preventing mixing of blocks with different alignment characteristics and maintaining dimensional accuracy while allowing parallel production
Solution Approach 2:
The detection device reads identifying portions on iron core pieces to determine which progressive press device formed each block. This feedback mechanism enables selective stacking based on device origin, ensuring consistent alignment characteristics are maintained throughout the stacked body while preserving the productivity benefits of multiple simultaneous press devices
Data Source
AI summary
A method for manufacturing a motor core includes forming multiple blocks, stacking the blocks to form a stacked body, and detecting an identifying portion with a detection device. The forming the blocks includes forming, only in the iron core piece that forms one end face of each block, an identifying portion for identifying the progressive press device that forms that block. The forming, only in the iron core piece that forms one end face of each block, the identifying portion includes forming the identifying portion in a surface of the iron core piece that forms the one end face of the block. The stacking the blocks to form the stacked body includes stacking, to form the stacked body, only the blocks formed by the progressive press device corresponding to the detected identifying portion among the multiple blocks.