Segmented Motor Core Assembly for Rotatable Laminated Segments
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Solution Overview
Problem
Existing methods for producing ferromagnetic cores of electric motors face challenges such as difficulty in segment rotation, reduced productivity, and rapid tool wear due to interference coupling and separate assembly steps.
Innovation Solution
A process involving blanking and crimping laminations to form segments with complementary concave-convex portions and auxiliary layers with pins and slots, allowing for reciprocal rotation and translation between segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If interference coupling (pin-hollow) is used to join laminations and segments, then structural strength is improved, but segment rotation becomes difficult and productivity decreases
Solution Approach 1:
The invention divides the coupling system into two distinct types: interference coupling (crimping-hollow) for joining laminations within a segment to ensure structural strength, and clearance coupling (protrusion-slot) for joining segments together to enable easy rotation and reconfiguration. This segmentation of coupling types resolves the contradiction by assigning different coupling mechanisms to different functional requirements.
Solution Approach 2:
The auxiliary layers with protrusions and slots act as intermediary elements between segments. These intermediaries provide the clearance coupling mechanism that facilitates segment rotation while maintaining structural integrity through the lamination-level interference coupling. The intermediary coupling system mediates between the conflicting requirements of strength and rotatability.
2Ease of manufacture
If pins are punched on all lamination layers to form segments, then segment formation is achieved, but productivity reduces and tool wear increases
Solution Approach 1:
The invention extracts the pin-forming operation from all lamination layers and concentrates it only in the auxiliary layers. By removing the unnecessary pin-forming steps from regular lamination layers, the process achieves segment formation while significantly reducing productivity loss and tool wear. This extraction principle eliminates redundant operations that do not contribute to the core function.
Solution Approach 2:
The auxiliary layers are positioned and configured in advance during the blanking process to provide the necessary protrusions and slots for segment coupling. This preliminary arrangement of coupling elements eliminates the need for subsequent pin-punching operations on all layers, streamlining the manufacturing process and improving productivity while maintaining ease of segment formation.
3Manufacturing precision
If segments are joined in closed circular configuration during blanking, then manufacturing precision is improved, but conversion to open rectilinear configuration becomes more difficult
Solution Approach 1:
The invention creates a dynamic coupling system using clearance coupling (protrusion-slot) at the segment interfaces, which allows the core structure to transition between fixed (closed circular) and flexible (open rectilinear) states. The dynamic nature of the clearance coupling enables easy reconfiguration while the interference coupling within laminations maintains manufacturing precision during the blanking process.
Data Source
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AI summary
A process for producing a ferromagnetic core for electric motors formed by a plurality of laminated segments (SI-SN) arranged in closed circular configuration is described. The ferromagnetic core comprises a first auxiliary layer (L1; LM; Lj') of laminations having a projecting pin (23, 43) near a convex portion (21, 41) at one end of the yoke base (12) of the laminations that form each of the laminated segments and a concave portion (22, 32, 42) at the opposite end of the yoke base (12) of the laminations that form each of the laminated segments in the first auxiliary layer (L1; LM; Lj') of laminations, and a second auxiliary layer(L2; LM; Lj') of laminations having an opening (33) near the convex portion (31) at one end of the yoke base (12) of the laminations that form each of the laminated segments. The pins of the first auxiliary layer (L1; LM; Lj') of laminations are engaged in the openings (33) of the second auxiliary layer (L2; LM; Lj') of laminations.