Rotor Core Lamination Stacking for Straight Key Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of rotor cores for rotating electric devices, such as motors, faces challenges in aligning keys in a straight line and coupling lamination segments in a circular shape without additional coupling means, which affects the efficiency and precision of the rotor assembly.
Innovation Solution
A method of stacking lamination sheets with keys aligned vertically and using interlocking tabs or adhesive coupling to ensure straight-line alignment and circular shape formation, eliminating the need for separate coupling means, and calculating angles (θ1 and θ2) to optimize the stacking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lamination sheets are stacked to form a rotor core, then the rotor core can be manufactured, but the keys on the lamination sheets cannot be aligned in a straight line
Solution Approach 1:
The patent applies preliminary action by pre-forming keys on the lamination sheets at specific positions before stacking. The keys are positioned at predetermined angles (θ1 and θ2) on each lamination sheet, ensuring that when the sheets are stacked according to the calculated angular relationships, the keys automatically align in a straight line without requiring post-stack adjustment or complex alignment mechanisms.
2Manufacturing precision
If additional coupling means are used to align keys, then key alignment can be achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent implements self-service by designing the lamination sheets with self-aligning features. The keys are positioned at predetermined angles (θ1 and θ2) on each sheet, and when the sheets are stacked according to these angular relationships, the keys automatically align in a straight line through their own geometric configuration. This eliminates the need for external coupling means or complex alignment mechanisms, allowing the structure to self-align through its inherent design.
3Shape
If lamination segments are coupled in a circular shape, then the rotor structure is formed, but separate coupling means are required
Solution Approach 1:
The patent applies merging by integrating the coupling function directly into the lamination sheets themselves. The sheets are designed with interlocking features and precise angular positioning (θ1 and θ2) that enable them to couple with each other and form a circular rotor structure. The coupling mechanism is merged with the structural elements of the lamination sheets, eliminating the need for separate, additional coupling components.
4Productivity
If conventional stacking methods are used, then rotor cores can be manufactured, but material waste increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-positioning the keys on the lamination sheets at specific angles (θ1 and θ2) before stacking. This preliminary positioning ensures that the sheets can be stacked directly without requiring trial-and-error adjustments or rework, thereby reducing material waste and improving manufacturing efficiency. The precise pre-planning of key positions allows for optimized material utilization.
Data Source
AI summary
An embodiment rotor includes a stacked core including stacked lamination sheets. The lamination sheets include lamination segments arranged in a circle, the stacked core has an upper layer lamination segment coupled to a lower layer lamination segment with a phase difference therebetween of a first angle with respect to a center of the stacked core, the stacked lamination segments have keys arranged in a straight line on an inner surface of the stacked core so that the keys are inserted into a key way disposed in a motor shaft in an axial direction, the lamination segments have a substantially identical shape and are arranged with an interval of a second angle with respect to a center of the rotor thus having a substantially identical pattern, and the lamination segments include upper and lower layer coupling portions repeatedly disposed at intervals of the second angle in a circumferential direction.