Laminated Stator Core Edge Heating for Ridge Recovery
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Solution Overview
Problem
The structural ridges formed by cut edges in laminated cores of electric motor stators, which affect electromagnetic properties and require lengthy and resource-intensive heating processes, lead to inefficiencies and degradation of insulating coatings.
Innovation Solution
A method using induction heating to induce eddy currents selectively at the cut edges of laminated stator cores, allowing for rapid and localized heating to heal structural ridges while preserving insulating coatings, using a system with clamping and induction devices to control heating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous annealing furnace heating is used to heal structural ridges, then electromagnetic properties are improved, but heating time increases and insulating coatings degrade
Solution Approach 1:
The patent applies induction heating to selectively heat only the cut edge regions of the laminated core where structural ridges are present, rather than heating the entire component. This localized heating approach heals the structural ridges while minimizing exposure time and protecting insulating coatings in non-affected areas from thermal degradation.
Solution Approach 2:
The induction heating process uses periodic alternating current to generate eddy currents that rapidly heat the cut edges. This periodic electromagnetic action enables quick heating cycles (seconds instead of minutes or hours) to heal structural ridges without prolonged thermal exposure that would degrade insulating coatings.
2Reliability
If continuous annealing furnace heating is used to heal structural ridges, then electromagnetic properties are improved, but energy consumption increases
Solution Approach 1:
Induction heating concentrates energy only in the cut edge regions requiring healing, rather than heating the entire laminated core or using a continuous annealing furnace. This localized energy application significantly reduces total energy consumption while achieving the same therapeutic effect on structural ridges.
Solution Approach 2:
The induction heating process rapidly heats cut edges through induced eddy currents in a matter of seconds, skipping the lengthy heating and cooling cycles required by continuous annealing furnaces. This rushed heating approach reduces energy consumption by minimizing the duration of the heating process.
3Productivity
If stamping process is used to create steel sheets, then manufacturing efficiency is improved, but structural ridges are formed affecting electromagnetic properties
Solution Approach 1:
The patent converts the harmful structural ridges created by stamping into a treatable condition by applying induction heating. Rather than avoiding stamping (which would reduce productivity), the process intentionally creates ridges that are then healed through localized induction heating, maintaining manufacturing efficiency while restoring electromagnetic properties.
Solution Approach 2:
The stamping process is performed first to efficiently create steel sheets, and then induction heating is applied as a subsequent preliminary treatment to heal the structural ridges before final assembly. This sequence maintains manufacturing efficiency while ensuring electromagnetic properties are restored.
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 enhances electromagnetic properties by healing structural ridges efficiently, reduces power consumption, and minimizes waste, while maintaining insulation and adhesive integrity.
Implementation Method 1
At least cut edges of the clamped laminated core accommodated in the receptacle are heated by a heating device in such a way that eddy currents are induced in at least one external portion of the laminated core
Implementation Method 2
the induction heating method can be used to heat the laminated core of the stator to desired temperatures for extremely short periods of time
Data Source
AI summary
The disclosure relates in general to a method and a system for producing a stator for an electric machine. The stator has a laminated core with individual adjacently arranged steel sheets along an axial direction of the stator. At least some portion of the steel sheets has an electric insulating material. The steel sheets of a laminated core of a stator are stamped out of a raw material. The steel sheets are stacked along the axial direction of the stator to form the laminated core. The steel sheets of the laminated core are clamped along the axial direction of the stator. The clamped laminated core is accommodated in a receptacle. Cut edges of the clamped laminated core accommodated in the receptacle are heated by a heating device in such a way that eddy currents are induced in at least one external portion of the laminated core.