Laminated Stator Core Recess Fitting for Material Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing laminated stator cores from strip material are limited in achieving high yield due to constraints in ear piece layout and gap sizing, which restricts the reduction of material scraps and optimization of punching die size.
Innovation Solution
The method involves forming stator core sheets with chevron-shaped ear pieces and annular yoke pieces, where recesses are created in the ear and yoke pieces to allow for precise fitting and narrowing of gaps between sheets, enabling improved material yield and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the gap between adjacent stator core sheets is reduced to improve material yield, then the material yield improves, but the ear pieces of adjacent sheets interfere with each other (overlap)
Solution Approach 1:
The invention places one ear piece inside the recess of an adjacent ear piece, creating a nested configuration. This allows the ear pieces to occupy the same spatial envelope without interference, enabling the gap between sheets to be reduced to minimal values while maintaining proper ear piece function and avoiding overlap issues.
Solution Approach 2:
The invention introduces a recess feature that adds dimensional complexity to the ear piece geometry. By creating a recess in one ear piece and fitting another ear piece within it, the solution transforms a two-dimensional layout problem into a three-dimensional nesting problem, allowing tighter packing of adjacent sheets.
2Loss of substance
If the strip material width is reduced to improve material yield, then the material yield improves, but the punching die size must be reduced
Solution Approach 1:
The nested ear piece configuration allows more stator core sheets to be arranged within the same strip material width, effectively increasing the material yield without requiring a proportional reduction in punching die size. The nesting efficiency compensates for the reduced working area.
Solution Approach 2:
The invention changes the geometric parameters of the ear pieces by introducing recesses, which allows for more efficient space utilization in the strip material layout. This parameter change enables tighter packing of sheets while maintaining manufacturability with appropriately sized punching dies.
3Manufacturing precision
If recesses are formed in ear pieces to enable tight fitting, then the gap between sheets is narrowed, but the manufacturing process becomes more complex
Solution Approach 1:
The recesses are formed as integral features of the ear pieces during the initial punching process, rather than being added as separate operations. This preliminary action approach incorporates the gap-control feature into the base manufacturing step, minimizing additional process complexity while achieving precise gap control.
Data Source
AI summary
A method of manufacturing a laminated stator core and a laminated stator core manufactured by the method, the method capable of forming a recess 21 over one or both of (a) a lateral portion of an ear piece C of the stator core sheet A to be formed adjacent to the stator core sheet B and (b) a peripheral portion of the annular yoke piece D continuing to the lateral portion, the peripheral portion beside the ear piece C; fitting one ear piece E of the stator core sheet B with a gap in the recess 21; and thereby improving a material yield when the stator core sheets 13 are formed from the strip material 14.