Motor Core Block Assembly With Separator Plates for Lower Eddy Currents
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Solution Overview
Problem
The existing method for manufacturing motor cores, which involves welding blocks together, leads to increased eddy currents and reduced motor performance due to the increased joining area between iron core pieces.
Innovation Solution
A method that forms motor cores by stacking iron core pieces with overlapping tabs and using separator plates to prevent adjacent blocks from joining, then press-fitting the tabs to form the core without welding, utilizing a progressive press device to control the formation of tabs and through-holes in the separator plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join blocks together in the core forming step, then the blocks can be strongly joined to each other, but eddy currents increase and motor performance decreases
Solution Approach 1:
The motor core is divided into multiple blocks that are stacked together. Each block contains iron core pieces with tabs that overlap and press-fit to each other. The separator plates are inserted between blocks to prevent direct joining, segmenting the magnetic path and reducing eddy current loops while maintaining structural integrity through mechanical press-fitting of tabs.
Solution Approach 2:
Separator plates are introduced as intermediary elements between adjacent blocks. These plates have through-holes that prevent the tabs of iron core pieces from directly joining across block boundaries. The separator plates act as mediators that maintain block separation, preventing harmful eddy currents while allowing mechanical assembly through tab insertion.
2Loss of energy
If separator plates with through-holes are used to prevent block joining, then eddy currents are reduced, but the complexity of the manufacturing process increases
Solution Approach 1:
The separator plates are integrated into the block stacking process itself. The plates are punched from the same material as the iron core pieces and are stacked together with the blocks in a sequential automated process. This merging of separator plate insertion with the main assembly process reduces the need for separate operations, simplifying the overall manufacturing complexity.
Solution Approach 2:
The separator plates are designed to be automatically positioned and inserted during the block stacking process. The through-holes in the separator plates align with the tabs of iron core pieces, allowing the assembly process to self-regulate the positioning. This self-alignment mechanism reduces the need for complex positioning systems and manual intervention.
3Loss of energy
If tabs are press-fitted to join iron core pieces, then the joining area is reduced compared to welding, but the joining strength may be insufficient
Solution Approach 1:
The tabs are pre-formed on the iron core pieces during the punching process, before assembly. The tabs are designed with specific dimensions and shapes that enable them to be inserted into corresponding holes in adjacent pieces. This preliminary preparation ensures that the press-fitting operation can achieve strong joining without requiring excessive force or complex tooling during assembly.
Solution Approach 2:
The joining mechanism transitions from welding (high temperature, large joining area) to press-fitting (mechanical force, localized joining). The tab dimensions, hole sizes, and press-fitting forces are optimized parameters that ensure sufficient joining strength while minimizing the joining area. The mechanical press-fitting parameters are carefully controlled to achieve strong joints without creating large eddy current paths.
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
This method reduces the need for welding, minimizing eddy currents and enhancing motor performance by strengthening the joining of blocks through precise tab press-fitting, thereby improving the motor's efficiency.
Implementation Method 1
stacking the iron core pieces such that the tabs overlap with each other, and joining the blocks to each other by press-fitting the tabs to each other
Data Source
AI summary
A method for manufacturing a motor core includes forming multiple blocks and forming the motor core. When a first separator plate is stacked on iron core pieces, a tab of the first separator plate is aligned with tabs of the iron core pieces. When a second separator plate is stacked on the first separator plate, a tab of the second separator plate is aligned with a through-hole of the first separator plate. When the iron core pieces are stacked on the second separator plate, the tabs are aligned with the tab of the second separator plate. The forming the motor core includes: stacking the blocks such that the tab of the first separator plate of one of any two blocks adjacent to each other and the tab of the second separator plate of the other block overlap with each other; and in this state, joining the blocks together.