Rotary Unit for Stacked Lamination Geometric Tolerance
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Solution Overview
Problem
Existing methods for producing stacks of laminations, especially non-rotationally symmetrical ones, struggle to achieve optimal geometric and electrical properties due to geometric tolerances and rolling direction compensation, limiting the efficiency of end products in electric motors or generators.
Innovation Solution
The method involves rotating non-rotationally symmetrical laminations about an axis outside the stack using a rotary unit, allowing them to lie congruently and minimizing geometric tolerances, thereby improving mechanical and electrical properties of the end product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If non-rotationally symmetrical laminations are stacked without rotation, then the stacking process is simple, but geometric tolerances deteriorate and rolling direction effects cannot be compensated
Solution Approach 1:
The patent introduces a rotary unit that dynamically rotates non-rotationally symmetrical laminations about their normal axis before stacking. This dynamic rotation allows the laminations to be oriented at specific angles (e.g., 90 degrees) relative to the previous lamination, enabling geometric tolerance compensation and rolling direction balancing without requiring complex fixed positioning mechanisms for each lamination.
Solution Approach 2:
The rotary unit performs preliminary rotation of each lamination about its normal axis before the lamination is stacked in the stack. By pre-rotating the laminations to the desired orientation, the system eliminates the need for complex post-stack adjustment mechanisms and ensures precise geometric tolerance compensation is achieved during the stacking process itself.
2Manufacturing precision
If rotationally symmetrical laminations are rotated, then geometric tolerances improve and rolling direction is compensated, but non-rotationally symmetrical laminations cannot be rotated
Solution Approach 1:
The rotary unit is designed with universal applicability to handle both rotationally symmetrical and non-rotationally symmetrical laminations. The rotation mechanism about the normal axis works effectively for any lamination shape, making the system versatile enough to process different lamination types without requiring separate handling mechanisms, thereby improving geometric tolerances and compensating for rolling direction effects across all lamination types.
3Productivity
If laminations are stacked without rotation, then the stacking process is fast, but mechanical and electrical properties deteriorate due to rolling direction effects
Solution Approach 1:
The rotary unit introduces dynamic rotation about the normal axis during the stacking process, allowing laminations to be oriented at optimized angles to compensate for rolling direction effects. This dynamic adjustment improves mechanical and electrical properties without significantly impacting stacking speed, as the rotation occurs seamlessly during the lamination feeding process.
Solution Approach 2:
The system changes the orientation parameter of each lamination by rotating it about its normal axis before stacking. By adjusting the rotation angle parameter (e.g., 90 degrees between successive laminations), the system optimizes the mechanical and electrical properties of the stacked assembly while maintaining production efficiency through automated rotation control.
Data Source
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AI summary
To produce end products from stacks of lamellae, non-rotationally symmetrical lamellae are punched from a sheet metal strip (2). They are stacked on top of each other and joined together. After the punching stroke, each or at least some of the lamellae are rotated about an axis located outside the stack of lamellae to be formed, so that the lamellae are congruent with each other. For this purpose, the device is equipped with a rotary unit whose axis of rotation lies outside the end product formed in the rotary unit. Since at least some of the lamellae within the stack of lamellae are congruent with each other despite being rotated, the end product has excellent product quality due to only small geometric tolerances and/or due to compensation of the rolling direction of the sheet metal strip (2) within the stack of lamellae.