Wound Core Bending Conditions for Continuous Low Iron Loss Production
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Solution Overview
Problem
Existing wound core producing apparatuses struggle to continuously produce wound cores with suppressed iron loss.
Innovation Solution
A wound core producing apparatus that includes a bending device with a die and punch for press working, where the punch shifts in the conveyance direction relative to the die, and specific conditions such as temperature and pressure are maintained to suppress deformation twins and iron loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wound core producing apparatuses are used, then production can be performed, but continuous production of wound cores with suppressed iron loss cannot be achieved
Solution Approach 1:
The die is pre-heated to a specific temperature range (150-500°C) before the bending operation to ensure the steel sheet reaches the optimal temperature for suppressing deformation twins. This preliminary heating action guarantees consistent iron loss suppression during continuous production.
Solution Approach 2:
The apparatus maintains continuous heating of the die and implements uninterrupted bending operations at controlled speeds, ensuring the steel sheet consistently remains within the optimal temperature range throughout the production process, enabling continuous production of high-quality wound cores.
2Productivity
If the steel sheet is bent without temperature control, then production speed can be increased, but deformation twins increase and iron loss is not suppressed
Solution Approach 1:
The die temperature is controlled within the specific range of 150-500°C to change the physical state of the steel sheet, making it more ductile and resistant to deformation twin formation. This parameter control allows faster bending speeds without increasing iron loss.
Solution Approach 2:
The die is pre-heated to the optimal temperature range before bending operations begin, ensuring the steel sheet immediately reaches the state needed to suppress deformation twins, enabling high-speed production without compromising on iron loss suppression.
3Device complexity
If the punch and die are stationary relative to each other, then the apparatus structure can be simplified, but wound cores cannot be continuously produced
Solution Approach 1:
The punch is designed to move in the conveyance direction of the steel sheet relative to the die, creating a dynamic bending system that can continuously process steel sheets. This dynamic configuration enables continuous production while maintaining relatively simple apparatus structure.
Solution Approach 2:
The relative movement between the punch and die in the conveyance direction allows uninterrupted bending operations as steel sheets are continuously fed, enabling continuous production without requiring complex reconfiguration of the apparatus.
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
The apparatus stably produces wound cores with suppressed iron loss, ensuring consistent performance even during continuous production.
Implementation Method 1
a pressure applied to the steel sheet by the feed roll is denoted by p MPa, and the following formulas (1) and (2) are satisfied
Implementation Method 2
the temperature at a position 20 mm away from a boundary between the curved portion and the flat portion in a direction opposite to the conveyance direction is denoted by T° C.
Data Source
AI summary
This wound core producing apparatus (40) includes a bending device (20) that bends a steel sheet (21), and a feed roll (60) that feeds the steel sheet (21) to the bending device (20), in which the bending device (20) includes a die (22) and a punch (24), the die (22) includes a curved portion (51) disposed at an end portion on the punch (24) side, and a flat portion (52) continuously connected to the curved portion (51) from a direction opposite to the punch (24) side and in contact with the steel sheet (21), and when a distance from a center of the feed roll (60) to an end surface on the die (22) side of the punch (24) along a conveyance direction (25) of the steel sheet (21) is denoted by L mm, a diameter of the feed roll (60) is denoted by R mm, a pressure applied to the steel sheet (21) by the feed roll (60) is denoted by p MPa, and a temperature at a position 20 mm away from a boundary between the curved portion (51) and the flat portion (52) in a direction opposite to the conveyance direction (25) is denoted by T° C., predetermined formulas are satisfied.