Stacked Iron Core Manufacturing with Phase-Offset Welding
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Solution Overview
Problem
The manufacturing of stacked iron cores for vehicle drive motors is costly due to the need for dedicated equipment for swaging and laminating, and involves a complex configuration with multiple components and assembly processes, especially when key components are attached to keyways.
Innovation Solution
A method involving a pressing process to form a carrier-attached single sheet with circular arc-shaped iron core pieces, a stacking process to phase-offset the pieces, and a welding process to align key protrusions along the stacking direction, reducing the need for dedicated swaging equipment and simplifying assembly by integrating key protrusions within the iron core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated equipment is used for swaging and laminating iron core pieces, then manufacturing precision and structural integrity are improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the swaging and laminating operations into a single integrated process. Ring-shaped iron core pieces are swaged and laminated together in one step to form the stacked iron core body, eliminating the need for separate dedicated swaging and laminating equipment. This reduces manufacturing cost while maintaining structural integrity through the integrated process design.
2Strength
If key components are attached to keyways, then mechanical connection and positioning are improved, but the number of components and assembly processes increases
Solution Approach 1:
The patent integrates the key protrusions directly into the iron core pieces themselves, rather than attaching separate key components. The key protrusions are formed as integral features of the circular arc-shaped iron core pieces during the swaging and laminating process, eliminating the need for separate key components and their attachment processes, thereby reducing overall device complexity while maintaining mechanical connection strength.
Solution Approach 2:
The iron core pieces serve multiple functions: they provide the magnetic core structure, form the ring-shaped stacked body through swaging and laminating, and simultaneously create the key protrusions for mechanical connection. This multi-functionality eliminates the need for separate key components, reducing the total number of parts while maintaining both structural and mechanical connection requirements.
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 method reduces manufacturing costs and the number of components and assembly processes required for vehicle drive motors by eliminating the need for dedicated swaging equipment and simplifying the assembly of rotor components.
Implementation Method 1
a pressing process of pressing a strip-shaped magnetic steel sheet so as to manufacture a carrier-attached single sheet in which a plurality of circular arc-shaped iron core pieces are coupled together
Implementation Method 2
a welding process of welding each layer of the circular arc-shaped iron core pieces, which are phase-offset with respect to each other in the circumferential direction, along the stacking direction at a plurality of locations arranged around the circumferential direction of an inner circumferential portion or an outer circumferential portion of the stacked iron core body
Data Source
AI summary
In a method for manufacturing a stacked iron core, a stacked iron core body is manufactured by stacking so as to be phase-offset with respect to each other in the circumferential direction plural ring-shaped iron core pieces respectively configured by plural circular arc-shaped iron core pieces arranged into ring shapes. Next, each layer of the circular arc-shaped iron core pieces, which are phase-offset with respect to each other in the circumferential direction, is welded together along a stacking direction at plural locations (plural weld portions) arranged around the circumferential direction of an inner circumferential portion or an outer circumferential portion of the stacked iron core body. A pair of key protrusions is formed on inner circumferential portions of the stacked iron core at positions opposing each other, and so key components are rendered unnecessary when assembling a rotor of a vehicle drive motor.