Selective Electrophoretic Coating for Strip Stator Core Rolling Accuracy
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Solution Overview
Problem
The use of electrophoretic coating on strip stator cores leads to increased dimensions and machining errors during rolling, resulting in low qualification rates and high scrap rates, thereby increasing manufacturing costs due to size deviations and material wastage.
Innovation Solution
The strip stator core design involves partially or completely covering the tooth parts with an electrophoretic protective film while leaving the yokes uncovered, maintaining the original dimensions and preventing size deviations during rolling, thus improving the qualification rate and reducing material scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrophoretic coating is applied to the entire surface of strip stator cores including yokes, then protective coverage is improved, but dimension accuracy deteriorates due to increased external dimensions and machining errors
Solution Approach 1:
The patent applies electrophoretic coating selectively to specific regions (tooth parts) while excluding other regions (yokes), creating non-uniform local quality. This resolves the contradiction by providing protection where needed (tooth parts) while maintaining dimensional accuracy where precision is critical (yokes), thus achieving both reliability and manufacturing precision simultaneously
2Reliability
If electrophoretic coating is applied to strip stator cores, then surface protection is improved, but qualification rate deteriorates due to size deviations after rolling
Solution Approach 1:
By applying coating only to tooth parts and excluding yokes, the patent achieves local quality differentiation that protects surfaces where needed while preventing size deviations in critical dimensions, thereby improving both surface protection and qualification rate
3Reliability
If electrophoretic coating is applied to strip stator cores, then protective film coverage is improved, but material waste increases due to high scrap rates
Solution Approach 1:
The selective coating approach applies protective film only to tooth parts where protection is needed, rather than coating the entire surface including yokes. This reduces coating material consumption and prevents defective products from consuming additional materials, thereby improving protective film coverage efficiency while reducing material waste
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 effectively prevents size deviations in the rolled stator core, enhances the qualification rate, reduces material waste, and lowers manufacturing costs by maintaining the original dimensions of the yokes and ensuring precise rolling.
Implementation Method 1
electrophoretic coating processes are used for the surface coating of the iron core... immersing conductive coated materials in a certain concentration of cathodic electrophoretic coating tank as the cathode, and placing a corresponding anode in the tank. A certain amount of direct current is applied between the cathode and the anode, so that a uniform and water insoluble coating film forms on the coated materials
Data Source
AI summary
A strip stator core, including: a plurality of interconnected stator core units. Each of the plurality of stator core units includes a yoke and a tooth part protruding from an inner side or an outer side of the yoke. The tooth part includes an outer surface partially or completely covered with an electrophoretic protective film and the yokes of the plurality of interconnected stator core units are coiled to form a ring.