Sheet Metal Stacking with Integrated Release Agent Punching
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Solution Overview
Problem
The existing methods for applying a separating agent between sheet metal parts to facilitate separation in laminated cores are complex and require precise positioning, leading to dimensional inaccuracies and increased process complexity.
Innovation Solution
The separating agent is punched free from an endless belt and applied during the stamping process, allowing for precise and reproducible application directly on the sheet metal parts, decoupling it from potential tolerances in preceding steps and simplifying the handling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separating agent is applied on the electrical strip before progressive punching, then separation between stacked sheet metal parts is facilitated, but positioning complexity increases and manufacturing precision deteriorates due to feed deviations
Solution Approach 1:
The separating agent is applied in advance on the electrical strip at a defined position before punching, but the key innovation is that the application position is determined relative to the punch position rather than absolute strip position. This preliminary action is performed at a stage where positioning is more controllable, and the separating agent will be at the correct location when needed for separation.
Solution Approach 2:
The patent introduces an intermediary reference system (the punch position or tooling reference) between the separating agent application and the final sheet metal stacking. Instead of directly positioning the separating agent on the moving strip with absolute precision, the system uses the punch tool position as an intermediary reference that is more stable and controllable, thereby mediating the positioning accuracy issue.
2Ease of operation
If a separate process step is added for applying the separating agent, then separation is improved, but device complexity and process complexity increase
Solution Approach 1:
The patent combines the separating agent application process with the existing progressive punching process. By integrating the separating agent application into the punching tooling or process flow, rather than adding a separate dedicated application step, the system achieves separation functionality without proportionally increasing device complexity. The separating agent application is merged with the punching operation that already exists in the process.
Solution Approach 2:
The punching tool or tooling system is given multiple functions: it not only performs the punching operation but also serves as the reference for positioning and applying the separating agent. This multi-functionality eliminates the need for separate dedicated application equipment, thereby reducing overall device complexity while still achieving the separation objective.
3Ease of manufacture
If the separating agent is applied in a preceding step, then the process is simpler, but positioning accuracy deteriorates due to tolerances in preceding steps
Solution Approach 1:
The separating agent is applied in a preliminary step before final stacking, but the application is positioned relative to the punch tool rather than using absolute coordinates from earlier process steps. This preliminary application benefits from the simplicity of early process steps while avoiding accumulation of tolerances by using the punch position (a later, more controlled reference) as the positioning基准.
Solution Approach 2:
The punch tool position serves as an intermediary reference that decouples the separating agent positioning from the tolerances of preceding strip feeding steps. By using this intermediary reference that is established closer to the separation point, the system achieves better positioning accuracy without requiring complex compensation for earlier tolerance accumulations.
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 ensures dimensionally accurate separation of sheet metal parts, reducing the need for additional process steps and control circuits, resulting in more reproducible and stable laminated cores suitable for electrical applications.
Implementation Method 1
a separating agent being provided at least between two stacked sheet metal parts in order to facilitate the separation of the integrally bonded sheet metal parts into sheet metal packages
Data Source
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AI summary
A device (1) and a method for joining sheet metal parts (2) to form a sheet metal stack (3) are shown, in which sheet metal parts (2) are punched out from an electrical steel strip (5), the punched-out sheet metal parts (2) are stacked and joined to form several sheet metal stacks (3) at least by a material bond, wherein a release agent (20) is provided at least between two stacked sheet metal parts (2) to facilitate the separation of the materially bonded sheet metal parts (2) into sheet metal stacks (3). In order to make the application of a release agent reproducible and simple, it is proposed that the release agent (20) is both punched out from an endless strip (21) and provided on the sheet metal part (2) by the punching stage (18, 118) for punching out the sheet metal part (2).