Stacked Stator Core Manufacturing Using Pilot Pin Positioning
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Solution Overview
Problem
The manufacturing of stacked stator cores is challenging due to the narrow distance between tooth portions, making it difficult to wind coils effectively, and existing methods require complex steps and equipment for forming pilot holes and blanking metal plates.
Innovation Solution
A method and apparatus that involve forming pilot holes and press-fitting processed metal plates, using multiple punches and pilot pins to create blanked members, which are then stacked and processed to form a stacked core, with a controller managing the intermittent feeding and punching processes to improve efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pilot hole is formed in the metal plate before blanking to position the metal plate by a pilot pin, then the positioning accuracy is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by forming the pilot hole and inserting the pilot pin before the blanking operation. This ensures the metal plate is properly positioned and restrained during subsequent processing steps, preventing displacement and ensuring manufacturing precision without adding excessive complexity to the overall process
2Manufacturing precision
If the metal plate is processed by a second punch in a state where a pilot pin is inserted, then the positioning accuracy is improved, but the production time increases due to intermittent feeding and repositioning
Solution Approach 1:
The pilot hole is formed and the pilot pin is inserted before the second punching operation, ensuring that the metal plate is already positioned correctly. This preliminary positioning action prevents the need for repositioning during subsequent operations, maintaining high positioning accuracy while minimizing interruptions to the production flow
3Strength
If a worked portion of the metal plate is press-fitted into the metal plate during the manufacturing process, then the structural integrity is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The press-fitting operation is merged into the sequence of operations that already include pilot hole formation and blanking. By integrating the press-fitting step into the existing manufacturing flow rather than treating it as a separate process, the patent improves structural integrity while minimizing the increase in manufacturing complexity
Data Source
AI summary
A method of manufacturing a stacked core includes forming a first pilot hole in a metal plate, forming a worked portion of the metal plate in a state in which a first pilot pin is inserted into the first pilot hole, the worked portion being displaced relative to a plane of the metal plate, press-fitting the worked portion of the metal plate to reposition the worked portion to extend along the plane of the metal plate, forming a second pilot hole in the metal plate after press-fitting the worked portion of the metal plate, and forming a blanked member by blanking the metal plate in a state in which a second pilot pin is inserted into the second pilot hole, the blanked member including the worked portion.