Motor Laminated Core Squareness and Bonding via Caulking
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Solution Overview
Problem
Existing laminated cores for motors face challenges in maintaining squareness and securing a strong bonding force between sheets and split cores, leading to inefficient motor performance due to uneven air gaps and increased manufacturing costs from additional welding or bonding processes.
Innovation Solution
A laminated core structure featuring contact protrusions and grooves with a connection caulking part that crosses these features, formed by stamping, laminating, bending, and caulking adjacent yoke parts to ensure accurate positioning and enhanced bonding, thereby maintaining squareness and increasing the bonding force between sheets and split cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If caulking is applied to combine sheets of the core, then squareness is maintained, but bonding force at connected parts of split cores is insufficient
Solution Approach 1:
The core sheets are divided into multiple split cores that are connected through contact protrusions and grooves. This segmentation allows each split core to be independently positioned while maintaining overall squareness through the modular connection structure.
Solution Approach 2:
The contact protrusion of one split core fits into the contact groove of the adjacent split core, creating a nested interlocking structure. This nesting mechanism ensures precise positioning and maintains squareness while the caulking process subsequently provides the necessary bonding force.
2Strength
If additional welding or bonding members are used to secure bonding force, then bonding strength is improved, but manufacturing expenses increase
Solution Approach 1:
The positioning function (contact protrusion and groove) and the bonding function (caulking) are merged into a single integrated process. The contact features guide the caulking operation, eliminating the need for separate welding or bonding members while maintaining both squareness and bonding force.
Solution Approach 2:
The contact protrusions and grooves on the split cores serve dual purposes: they automatically position the components during assembly (self-positioning) and guide the caulking process (self-alignment). This self-service mechanism eliminates the need for additional positioning fixtures or bonding members, reducing manufacturing complexity and cost.
3Strength
If laser welding is applied to combine sheets, then bonding force is improved, but squareness must be secured first which complicates the process
Solution Approach 1:
The contact protrusions and grooves are pre-formed on the split cores during stamping, establishing the positioning geometry before any bonding operation. This preliminary action ensures squareness is built into the component design itself, eliminating the need for separate squareness-securing steps before welding or caulking.
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 proposed solution effectively secures squareness and bonding force between laminated core sheets and split cores, enhancing motor performance by maintaining uniform air gaps and reducing manufacturing expenses through a more efficient bonding method.
Implementation Method 1
caulking is carried out whenever each sheet of the core is stacked, and hence, caulking is widely used because it is effective in keeping squareness
Data Source
AI summary
A method for manufacturing a laminated core for a motor comprises the steps of: stamping a sheet of a core of a straight form to have a form that a plurality of split cores are connected; laminating sheets of the core perpendicularly; bending the sheets of the core in a round form; and forming a connection caulking part at contact parts of yokes, which are adjacent to each other, of the bended core.