Spiral Laminated Core Winding With Fixed End Positioning
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Solution Overview
Problem
The manufacturing efficiency of laminated cores is decreased due to the variability in the circumferential positions of the winding start and finish ends of the iron core piece forming member, requiring manual alignment in each manufacturing process.
Innovation Solution
A method involving a punching, stacking, first cutting, and second cutting process to ensure consistent circumferential positioning of the winding ends, allowing for efficient spiraling of the iron core piece forming member, with specific cutting steps to align the start and finish ends, and joining in the stacking direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the winding start end position is changed for each laminated core to achieve even distribution of connecting portions, then the connecting portions are arranged evenly in the circumferential direction, but the manufacturing efficiency decreases due to required alignment operations
Solution Approach 1:
The invention applies preliminary action by pre-establishing fixed reference marks (first and second reference marks) on the iron core piece forming member at defined positions relative to the winding start and finish ends. These reference marks are created during the punching step before winding, enabling automatic positioning during stacking without requiring post-manufacturing alignment operations. This preliminary positioning action resolves the contradiction by maintaining precise circumferential positioning while eliminating time-consuming alignment steps.
Solution Approach 2:
The invention uses reference marks as intermediary elements that mediate between the winding process and the stacking process. The first reference mark (at the winding start end) and second reference mark (at the winding finish end) serve as intermediary positioning features that enable automatic alignment during stacking. These intermediaries transfer positional information from the winding operation to the stacking operation, allowing consistent circumferential positioning of connecting portions without manual intervention.
2Manufacturing precision
If manual alignment is performed for each laminated core, then the circumferential position of winding start end is aligned, but the manufacturing time increases
Solution Approach 1:
The invention implements self-service by designing the iron core piece forming member with self-positioning reference marks that automatically guide the stacking process. The first reference mark at the winding start end and second reference mark at the winding finish end enable the workpiece to self-align during stacking without requiring external alignment operations. This self-service mechanism eliminates manual alignment time while maintaining precise circumferential positioning.
3Productivity
If the iron core piece forming member is wound in a spiral shape, then the laminated core is formed efficiently, but the end portion may turn up causing positioning variability
Solution Approach 1:
The invention applies preliminary anti-action by creating reference marks that prevent the turning up of end portions before it can affect positioning. The first reference mark at the winding start end and second reference mark at the winding finish end are established during punching to counteract the tendency of end portions to turn up during spiral winding. These preliminary protective measures maintain the stability of end portion positions while preserving the efficient spiral winding process.
Data Source
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AI summary
A method of manufacturing a laminated core (1) includes: a punching step of punching a steel sheet (80) in a plate shape to form an iron core piece forming member (81) including a back yoke portion (21) extending in one direction and a plurality of tooth portions (22); a stacking step of deforming the iron core piece forming member (81) to one side in the width direction and spirally winding the iron core piece forming member (81), and stacking the back yoke portion (21) and the tooth portions (22) in an overlapping manner in the axial direction, respectively; a first cutting step of cutting the iron core piece forming member (81) in the width direction at a position (CT1) separated by a first distance rearward in a winding direction from a winding start end (81a) of the iron core piece forming member (81) when the iron core piece forming member (81) stacked in the axial direction is viewed in the axial direction to form a winding finish end (81b) on the iron core piece forming member (81); and a second cutting step of cutting the iron core piece forming member (81) in the width direction at a position (CT2) overlapping the winding start end (81a) as viewed in the axial direction to form the winding start end (81a) of the iron core piece forming member (81) to be spirally wound next.