Stator Core Lateral Side Gluing via Spray Nozzle
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Solution Overview
Problem
The existing methods for manufacturing stator cores, such as rivet stacking and inter-chip gluing, face issues like insulation damage, increased thickness, and prolonged processing time due to the need for thinner silicon steel sheets and higher precision in gluing, which hinder productivity and increase costs.
Innovation Solution
A device and method for gluing the lateral sides of stator cores using a silicon steel sheet stacking mold with glue spray nozzles that uniformly apply glue to the inner or outer sides of the cores, allowing for efficient stacking and punching without the need for rivets or precise inter-chip gluing, thereby simplifying the process and reducing equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rivet stacking process is used, then processing time is reduced and productivity is enhanced, but insulation damage occurs due to riveting points breaking thin silicon steel sheets
Solution Approach 1:
The patent removes the riveting points from the silicon steel sheets entirely, extracting the harmful element that causes insulation damage. Instead of punching holes for rivets, the sheets are stacked directly and bonded using external clamping and adhesive mechanisms, eliminating the source of insulation failure while maintaining stacking efficiency.
Solution Approach 2:
The patent introduces adhesive agents as intermediaries between the silicon steel sheets to achieve bonding without mechanical rivets. The adhesive acts as a mediator that provides the necessary bonding strength while preserving the insulation integrity of the thin sheets, resolving the conflict between fast processing and insulation protection.
2Reliability
If inter-chip gluing process is used, then insulation problems are avoided, but stacking thickness increases due to glue layers
Solution Approach 1:
The patent applies adhesive agents in a controlled, partial manner rather than as continuous thick layers. The adhesive is applied only at specific bonding interfaces where needed, using minimal quantities to achieve sufficient bonding strength, thereby avoiding excessive thickness increase while maintaining insulation integrity.
3Loss of energy
If more stator chips are used to reduce iron losses with thinner sheets, then iron losses are reduced, but processing time increases due to more inter-chip gluing operations
Solution Approach 1:
The patent combines multiple stacking operations into a single integrated process. Multiple silicon steel sheets are stacked simultaneously in one operation rather than being glued one by one, and then bonded collectively using adhesive agents. This merging of operations dramatically reduces processing time while allowing the use of many thin sheets to minimize iron losses.
4Productivity
If higher accuracy glue dispenser is used to enhance productivity with thinner sheets, then processing speed increases, but equipment cost increases
Solution Approach 1:
The patent employs adhesive agents that can be applied through simple dispensing mechanisms without requiring high-precision control systems. The adhesive formulation and application method are designed to be self-regulating, allowing accurate bonding even with basic dispensing equipment, thereby achieving high productivity without expensive specialized equipment.
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 productivity by reducing production time, avoiding insulation issues, and maintaining a high iron core stacking coefficient, while optimizing the process flow to save tools and time, thus improving efficiency and reducing costs.
Implementation Method 1
Glue is uniformly sprayed on the inner sides or outer sides of the stacked stator core by using a glue spray nozzle
Data Source
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Figure 3~5
AI summary
The present invention relates to a device for gluing lateral sides of stator cores and a gluing method, wherein stator cores are stacked in order by using a mold; glue is uniformly sprayed on the inner sides or outer sides of the stacked stator core by using a glue spray nozzle. Compared with the prior art, the present invention improves the productivity of the stator cores and overcomes defects of the inter-chip gluing process.