Rotary Electric Machine Core Using Additive Manufacturing
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Solution Overview
Problem
The existing manufacturing methods for rotary electric machine cores, which involve punching and stacking electromagnetic steel sheets, are costly, limit design freedom, and result in inefficiencies such as torque nonuniformity and high eddy current losses.
Innovation Solution
A core for a rotary electric machine is formed by stacking shaping layers of solidified metal powder, which eliminates the need for punching molds and allows for improved design flexibility and manufacturing efficiency, with features like slits and non-overlapping connecting portions to reduce eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If punching molds are used to form core members and stack them through caulking or adhesion, then core members can be manufactured with standard processes, but manufacturing costs increase and design freedom is limited
Solution Approach 1:
The patent changes the material state from solid steel sheets to metal powder, enabling additive manufacturing processes that provide both manufacturing efficiency and design flexibility. The metal powder can be selectively melted and solidified to create complex three-dimensional core structures without requiring punching molds or assembly operations.
Solution Approach 2:
The patent replaces traditional mechanical punching and assembly operations with a thermal processing system that melts and solidifies metal powder layer by layer. This substitution eliminates the need for punching molds, caulking tools, and adhesion processes, thereby reducing manufacturing costs and enabling greater design freedom.
2Productivity
If punching molds are used to form core members, then mass production is possible, but manufacturing costs increase and delivery time extends
Solution Approach 1:
The patent performs preliminary actions by preparing metal powder layers in advance and selectively melting only the required portions before solidification. This approach allows for efficient layer-by-layer construction of core members without requiring extensive post-processing or assembly operations, thereby reducing delivery time while maintaining productivity.
Solution Approach 2:
The patent replaces mechanical punching and assembly operations with a thermal processing system that melts and solidifies metal powder layer by layer. This substitution eliminates the need for punching molds, caulking tools, and adhesion processes, thereby reducing manufacturing costs and enabling greater design freedom.
3Strength
If core members are stacked through caulking or adhesion, then structural integrity is achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges multiple manufacturing steps (forming, connecting, and assembling core members) into a single additive manufacturing process. The metal powder is selectively melted and solidified to create integrated core structures with built-in connectivity, eliminating the need for separate caulking or adhesion operations and thereby reducing manufacturing complexity while maintaining structural integrity.
Solution Approach 2:
The patent replaces mechanical punching and assembly operations with a thermal processing system that melts and solidifies metal powder layer by layer. This substitution eliminates the need for punching molds, caulking tools, and adhesion processes, thereby reducing manufacturing costs and enabling greater design freedom.
4Productivity
If traditional stacking methods are used, then core members can be assembled, but torque nonuniformity and eddy current losses increase
Solution Approach 1:
The patent changes the material state from solid steel sheets to metal powder, enabling additive manufacturing processes that provide both manufacturing efficiency and design flexibility. The metal powder can be selectively melted and solidified to create complex three-dimensional core structures without requiring punching molds or assembly operations.
Solution Approach 2:
The patent replaces traditional mechanical punching and assembly operations with a thermal processing system that melts and solidifies metal powder layer by layer. This substitution eliminates the need for punching molds, caulking tools, and adhesion processes, thereby reducing manufacturing costs and enabling greater design freedom.
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 approach reduces costs, enhances design freedom, and minimizes torque nonuniformity and iron losses by allowing for the precise shaping and stacking of core members, effectively reducing eddy current and hysteresis losses.
Implementation Method 1
a plurality of shaping layers 54 and 56 formed by melting and solidifying a metal powder are integrally stacked
Implementation Method 2
a first shaping layer 54 is formed by melting and solidifying a metal powder; a second shaping layer 56 is formed by melting and solidifying the metal powder supplied on the first shaping layer 54
Data Source
AI summary
The present invention is a core for a rotary electric machine comprising a stacked body where a plurality of shaping layers formed by solidifying a metal powder is integrally stacked.