Stator Core Stacking with Parallel Sheet Separation and Centering
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Solution Overview
Problem
Conventional manual stator core stacking processes are inefficient, labor-intensive, prone to human error, and lack flexibility, leading to high error rates and long production times, which affect product quality and workshop scheduling.
Innovation Solution
An automatic stator-core stacking system utilizing a stacking and positioning table, robots, feeding mechanisms, sheet separation mechanisms, and centering tables to perform separation, centering, and stacking in parallel, ensuring accurate and efficient stacking of silicon steel sheets, with visual detection and adjustable positioning to accommodate multiple stator core types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking process is used, then workers can separate and inspect sheets, but work efficiency is low and workload is large
Solution Approach 1:
The system uses automated robots and machines to perform sheet separation, inspection, and stacking operations that were previously done manually by workers. The stacking machine automatically feeds sheets, the robot separates and inspects them, and the stacking device assembles them, eliminating the need for manual labor in these repetitive tasks.
Solution Approach 2:
Manual mechanical operations are replaced with automated mechanical systems. The patent introduces a stacking machine with automated feeding mechanisms, a robot with vision systems for inspection, and an automated stacking device, replacing the manual mechanical actions of workers with automated mechanical systems.
2Reliability
If manual inspection and stacking is performed, then quality control can be maintained, but error rate increases due to technical level differences
Solution Approach 1:
The system incorporates vision inspection systems that detect sheet quality and provide feedback to the control system. The robot uses vision feedback to identify and separate defective sheets, ensuring consistent quality control without human error. The automated inspection provides real-time feedback on sheet condition.
Solution Approach 2:
Manual inspection is replaced with automated vision inspection systems. The patent employs optical sensors and cameras that objectively detect sheet defects without being influenced by worker technical level or fatigue, providing consistent and accurate quality control.
3Productivity
If multiple workers cooperate for stacking, then complex stacking operations can be completed, but station personnel requirements increase
Solution Approach 1:
Multiple functions previously performed by different workers are merged into a single integrated automated system. The stacking machine combines feeding, separation, inspection, and stacking operations in one automated workflow, eliminating the need for multiple workers to cooperate manually.
Solution Approach 2:
The automated system performs all stacking operations independently without human intervention. The machine feeds sheets automatically, the robot separates and inspects them autonomously, and the stacking device assembles them without worker cooperation, reducing personnel requirements to minimal supervision.
4Manufacturing precision
If single-path stacking operation is used, then stacking station can be dedicated, but production time span increases
Solution Approach 1:
The automated system enables continuous operation without interruptions for worker breaks, shifts, or coordination. The stacking machine operates continuously, feeding and stacking sheets without停顿, maximizing productive time and reducing total production time while maintaining precision through automated control.
Solution Approach 2:
Manual stacking operations are replaced with automated mechanical systems that operate faster and more consistently. The automated feeding and stacking mechanisms reduce the time required for each operation while maintaining or improving stacking accuracy through precise mechanical control.
5Reliability
If stacking station is occupied for entire stator core stacking, then complete stacking can be achieved, but workshop station scheduling flexibility decreases
Solution Approach 1:
The stacking process is divided into modular segments that can be independently controlled. The automated system can complete stacking operations in discrete, manageable units, allowing for better scheduling and allocation of stacking stations to different products or orders, improving workshop flexibility while ensuring complete stacking.
Solution Approach 2:
The automated stacking system provides dynamic control over the stacking process, allowing for flexible scheduling and allocation of resources. The system can be programmed to handle different product types and can be dynamically assigned to different tasks based on production priorities, improving adaptability while maintaining reliable completion.
Data Source
Figure 1
AI summary
The application discloses an automatic stator-core stacking system and an automatic stator-core stacking method, belonging to the field of production and manufacturing for the stator core of the generator. The system includes a stacking and positioning table, stacking robot(s), feeding mechanism(s), sheet separation mechanism(s), centering table(s), iron-sheet tray station(s) and ventilation-slotted-plate tray station(s). In the system, the separation, the centering and the stacking of the silicon steel sheets are performed in parallel, so that the stacking time of the stator core is greatly shortened, thereby improving the overall stacking efficiency. The system can realize the stacking operation of the multi-machine stator cores by replacing the positioning device of the stacking and positioning table, adjusting the position of the clamp sucker, and replacing the stacking program, thereby improving the processing and manufacturing capability of the stacking system.