Stator Lamina Stacking via Gravity and Guide Container
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Solution Overview
Problem
The existing manufacturing process for stator segments in electrical generators is inefficient due to the manual handling and alignment of lamina elements, which requires extensive manual labor and time, even with the use of conveyor belts and robots.
Innovation Solution
A method that combines the cutting and stacking of lamina elements using gravitational force, where the cut-out elements automatically fall into a container, reducing the number of steps and manual intervention, and includes a container with a guide mechanism for precise alignment and potential additional features like insulating layers and staggered cutting to address non-uniform foil thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual handling and alignment of lamina elements is used, then alignment precision can be achieved, but manufacturing time and labor cost increase significantly
Solution Approach 1:
The container is designed with guide elements that automatically align lamina elements as they are deposited into the container. The guide elements include guide surfaces and positioning features that passively guide each lamina element into its correct position without requiring manual alignment operations, thereby achieving precise alignment while eliminating time-consuming manual handling
Solution Approach 2:
The container is pre-configured with guide elements, positioning features, and alignment mechanisms before the lamina elements are deposited. This preliminary preparation ensures that as each lamina element is placed into the container, it is automatically guided and positioned correctly, eliminating the need for subsequent manual alignment operations and reducing manufacturing time
2Productivity
If conveyor belts and robots are used for transportation, then productivity increases, but device complexity and operational difficulty increase
Solution Approach 1:
The cutting device and container are integrated into a single system where the container is positioned to receive lamina elements directly from the cutting device. The container includes guide elements that automatically align elements as they are cut and deposited, eliminating the need for separate conveyor belts and robotic handling systems, thereby maintaining productivity while reducing system complexity
Solution Approach 2:
The container serves as an intermediary device between the cutting device and the final stacked product. It receives lamina elements directly from the cutting device and uses its built-in guide elements to automatically align and position them, replacing the need for complex robotic intermediaries and conveyor systems
3Manufacturing precision
If multiple separate operations are used for cutting and stacking, then manufacturing precision can be maintained, but manufacturing time increases
Solution Approach 1:
The cutting device and container are integrated into a single operational unit where the container is positioned to receive lamina elements directly from the cutting device. The container includes guide elements that automatically align elements as they are cut and deposited, allowing cutting and stacking to occur in a continuous, integrated process that maintains precision while improving productivity
Solution Approach 2:
The integrated system allows for continuous operation where lamina elements are cut and immediately deposited into the container with automatic alignment. The container can be continuously filled with stacked lamina elements without interruption, eliminating the need to stop for separate alignment operations and maintaining continuous productive action
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 simplifies and speeds up the manufacturing process, reducing costs and improving the alignment and stability of the lamina element stacks, leading to more efficient production of stator segments for electrical generators.
Implementation Method 1
transferring the first cut out lamina element to a container by utilizing the gravitational force
Data Source
AI summary
It is described a method for producing and stacking lamina elements in an aligned manner, in particular lamina elements for a stator of an electrical generator. The method cutting out a first lamina element from a foil, transferring the first lamina element to a container by utilizing the gravitational force, cutting out a second lamina element from the foil or from a further foil, and transferring the second lamina element to the container on top of the first lamina element by utilizing the gravitational force. It is further described a cutting machine for producing lamina elements, a container for stacking lamina elements in an aligned manner and a system for producing and stacking lamina elements in an aligned manner.