Stator Core Punching Layout for Material Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of stator cores with projections at their outer periphery results in reduced material yield and irregularly shaped remaining steel sheets, making production unstable due to the inefficiencies in punching out core members from electrical steel sheets.
Innovation Solution
A method involving the punching out of core members with projections from electrical steel sheets, where the portions of the sheets are arranged in three rows with projections inclined at specific angles to optimize material usage and prevent interference, allowing for improved yield and uniformity in the production of stator cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core members with projections are punched out from electrical steel sheet, then the stator core can be formed with connecting projections for assembly, but the material yield is reduced due to large amount of material left around the punched regions
Solution Approach 1:
The patent transitions from conventional single-row punching layout to a multi-row arrangement where punched portions are distributed across three rows. This dimensional reorganization allows projections from different rows to interlock and fill gaps, reducing wasted material while maintaining the necessary connecting projections for assembly.
Solution Approach 2:
The patent employs asymmetric arrangement of punched portions across three rows, where the positioning and orientation of projections in each row are deliberately different. This asymmetric layout optimizes material utilization by allowing projections from different rows to complement each other, minimizing the total amount of wasted material while preserving assembly functionality.
2Ease of manufacture
If core members with projections are punched out from electrical steel sheet, then the stator core can be formed with connecting projections, but the remaining steel sheet has irregular shape causing difficulty in stabilizing production
Solution Approach 1:
By distributing the punching operations across three rows rather than a single row, the patent transforms the irregular waste pattern into a more controlled and predictable multi-row layout. This dimensional expansion allows for better management of the remaining steel sheet shape, improving production stability.
Solution Approach 2:
The patent applies different punching patterns and projection orientations to different rows (local areas) of the steel sheet. Each row is optimized independently, with projections inclined at specific angles relative to the width direction, allowing the overall system to achieve both assembly capability and production stability.
3Loss of substance
If projections are punched out at various orientations, then material yield is improved, but the complexity of arranging and aligning core members increases
Solution Approach 1:
The patent assigns specific projection orientations to specific rows (local areas), with projections in different rows inclined at different angles from the width direction. This localized differentiation optimizes material yield in each row while maintaining overall system manageability through systematic variation rather than random complexity.
Data Source
AI summary
A method of manufacturing a stator core includes punching out core members from an electrical steel sheet in three rows arrangement side by side along a width direction of the electrical steel sheet. Each of the core members has connecting projections. The connecting projections project radially outward from an outer periphery of the core member. The punched out core members are stacked to form the stator core. Each of the core members in two of the three rows arrangement have a connecting projection angled at a first angle from the width direction of the electrical steel sheet. Each of the core members in a third row having a connecting projection angled at a different second angle from the width direction of the electrical steel sheet.