Rotary Machine Laminated Core Rectilinear Pressing
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Solution Overview
Problem
Conventional rotary electric machine laminated cores experience efficiency reduction and increased torque pulsation due to shape accuracy issues and machining strain, and the lancing method generates scrap and damages pressing dies during core segment assembly.
Innovation Solution
The laminated core design includes notch portions near rotating shafts and a gap between adjacent projecting and recess portions, allowing for rectilinear pressing without lancing, reducing machining strain and scrap generation, and improving material yield and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lancing method is used to form interfitting contacting portions of core segments, then the core segments can be coupled together, but warping arises in portions corresponding to the bending fulcrum of lancing, reducing shape accuracy and increasing torque pulsation
Solution Approach 1:
The core segments are divided into multiple parts with projecting portions and recess portions that can be assembled together. This segmentation allows each part to be manufactured separately with better precision control, avoiding the warping issues that occur when trying to form interfitting portions in a single piece through lancing.
Solution Approach 2:
The projecting portions and recess portions are extracted as separate features from the core segment body. By pre-forming these interfitting features as distinct elements and then assembling them, the patent avoids the warping problems associated with forming these features through lancing operations on the main core segment structure.
2Ease of manufacture
If the lancing method is used to form interfitting contacting portions, then core segments can be coupled, but machining strain increases and efficiency is reduced
Solution Approach 1:
The projecting portions and recess portions are pre-formed on the core segments before final assembly. This preliminary formation of interfitting features eliminates the need for high-strain lancing operations during assembly, as the coupling features are already prepared in advance with minimal machining strain.
3Ease of manufacture
If the lancing method is used for core segment assembly, then core segments can be joined, but scrap is generated and pressing die damage occurs
Solution Approach 1:
By segmenting the core into multiple parts with projecting and recess portions, the patent enables assembly without lancing operations. This eliminates the scrap generation and pressing die damage that occur when lancing is used to form interfitting portions, as the coupling features are formed as separate elements rather than through material removal.
Data Source
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AI summary
In a rotary electric machine laminated core, a rotating shaft portion is disposed closer to an outer circumferential surface than an inner circumferential surface of a back yoke portion. A notch portion is disposed on at least one of first and second end portions of the back yoke portion so as to form a gap between a vicinity of the rotating shaft portion of a projecting portion and a recess portion when core segments are arranged in an annular shape or a circular arc shape. The first end portion and the second end portion of the back yoke portion are configured such that a predetermined gap that connects from the outer circumferential side to the inner circumferential side is formed between adjacent projecting portions and recess portions when the core segments are expanded rectilinearly such that magnetic pole tooth portions are parallel to each other.