Laser Correction of Motor Material Layers for Tooth Alignment
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Solution Overview
Problem
Material layers produced by existing methods, such as those described in patent specification EP 3 595 148 A1, often have geometric tolerances issues, particularly in the alignment of teeth, leading to decreased groove channel width and reduced current-conducting material in dynamoelectric machines, resulting in lower performance and increased torque ripple.
Innovation Solution
A method for correcting material layers with a layer thickness between 0.5 and 500 μm, involving the use of an optical unit to ascertain and compare actual and target geometries, followed by partial plastic deformation, such as thermal plastic deformation or partial melting, using a light source like a laser to correct deviations, ensuring accurate alignment and geometry conformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material layers are produced by conventional methods (suspension application through template, debinding, sintering), then manufacturing capability is achieved, but geometric precision and location tolerance of teeth deteriorate
Solution Approach 1:
The patent applies preliminary action by performing geometric correction of teeth positions after layer production but before final assembly. The method measures actual tooth positions, calculates deviations from target positions, and applies compensatory deformations to correct these deviations beforehand, ensuring precise alignment when layers are stacked to form the microstructure.
Solution Approach 2:
The patent employs parameter changes by utilizing thermal plastic deformation through controlled heating. The material layer is heated to a temperature range that enables plastic deformation, allowing the teeth to be reshaped and repositioned to achieve target geometries and location tolerances that cannot be obtained through conventional manufacturing alone.
2Ease of manufacture
If teeth of individual material layers are not located congruently due to location tolerance deviations, then assembly is simplified, but groove channel width and current-conducting material volume deteriorate
Solution Approach 1:
The patent replaces mechanical alignment methods with an optical measurement and computational correction system. An optical unit measures the actual positions of teeth, a computing unit calculates the deviations and determines correction parameters, and a heating unit applies thermal plastic deformation to correct the positions, thereby achieving precise groove channel dimensions without complex mechanical alignment procedures.
3Manufacturing precision
If optical measurement and thermal plastic deformation correction methods are applied, then manufacturing precision and location tolerance are improved, but device complexity and processing time increase
Solution Approach 1:
The patent achieves universality by designing a correction system that can handle various tooth geometries and layer configurations through a single integrated process. The optical measurement unit, computing unit, and thermal correction unit work together in a universal manner to correct different types of geometric deviations without requiring device reconfiguration, thereby managing complexity through functional integration.
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 significantly improves dimensional accuracy, reduces location tolerances, simplifies and automates the assembly of material layer microstructures, and results in lower torque ripple, higher performance, and reduced vibration in dynamoelectric machines, making them quieter and more efficient.
Implementation Method 1
partially melting the material layer by means of a light source to correct the deviation
Implementation Method 2
the partial plastic deformation is a partial thermal plastic deformation. The plastic deformation is thus advantageously accompanied by heating
Data Source
AI summary
In a method for correcting a portion, in particular a tooth, of a material layer of a dynamoelectric machine, with the material layer including a soft-magnetic material and having a layer thickness between 0.5 and 500 μm, an actual geometry of the portion of the material layer is ascertained and compared to a target geometry. A deviation of the actual geometry from the target geometry is determined. Before the deviation is corrected by partially plastically deforming the material layer using a light source, the material layer is partially heated by a further light source.