Claims:We claim.

1. A lamination pack (100) or a core assembly for a magneto stator assembly and an EV motor armature assembly and the process of manufacturing thereof,
characterized in that,
the process of manufacturing the said lamination pack (100) comprises the steps of :
a. using steel sheet as raw material (102) to make individual lamination sheet (104);
b. Stamping process done to obtain plurality of individual lamination sheets (104) that are designed to allow for interlocking of the lamination sheets in a correct manner and the laminations are split into 9 parts;
c. stacking of the plurality of individual lamination sheets (104) together in appropriate orientation one above the other and pressing with press tool to obtain stacked lamination sheets (106) also known as split core assembly (110);
d. assembling the split core assembly (110) as per the assembly sequence to form the core assembly;
e. adding rivets (108) to the core assembly (100) by riveting process to keep the core assembly intact to obtain the final lamination pack (100) or the core assembly (100) with less percentage of scrap (112) generated.

2. The lamination pack (100) as claimed in claim 1, wherein the steel sheet used as raw material (102) is of 0.1 to 1 mm thickness and preferably of 0.5 mm thickness.

3. The lamination pack (100) as claimed in claim 1, wherein steel sheet used as raw material (102) is electrical steel having silicon added to it to increase its electrical resistance, improves the ability of magnetic fields to penetrate it, and reduces the steel’s hysteresis loss.

4. The lamination pack (100) as claimed in claim 1, wherein the split core assembly (110) are many in number and they are assembled together to form the final lamination pack (100).

5. The lamination pack (100) as claimed in claim 1, wherein the Dove tail design is used for locking purpose is the final assembly.

6. The lamination pack (100) as claimed in claim 1, wherein the lamination pack (100) or the Core assembly is then powder coated or bobbin assembly is added & copper winding is done onto it to obtain the final Stator assembly or the EV motor armature assembly.

7. The lamination pack (100) as claimed in claim 1, wherein the diameter of the lamination pack (100) or the core assembly is between 80-150 mm and for magneto rotor assembly, the diameter of the core assembly is preferably 95 mm and for EV motor armature assembly the diameter of the core assembly is preferably 100 mm.

8. The lamination pack (100) as claimed in claim 1, wherein the said lamination pack has reduced percentage scrap cost that leads to substantial material and cost saving.

, Description:FIELD OF INVENTION
The present invention in general relates to a lamination pack and more particularly it relates to a lamination pack for a magneto stator assembly and EV motor armature assembly and the process of manufacturing thereof.

BACKGROUND OF THE INVENTION

Electromagnetic machines such as electric motors, generators, and traction motors are useful for converting energy from one form to another. Such electromagnetic machines often include an element such as a rotor which is rotatable about an axis. The rotatable element or rotor may be coaxial with a static element or stator, and energy may be converted via relative rotation between the rotor and the stator. Lamination pack forms an integral component of the rotor or stator assembly.
In the conventional rotors and stators, the lamination pack is currently formed by punching circular sectors from the sheet metal strip or coil and later stacking together the sectors. According to another prior art method, the whole annulus is punched and the portion inside the annulus is recovered to obtain smaller-diameter laminations. These methods involve high manufacturing costs for the lamination packs due to a number of reasons, including : creation of unrecoverable off-cuts (only recoverable as scrap) of high cost material, with more or less performing sheet metal being increasingly required; high pack formation costs, due to the stacking required for joining the sectors even with small or medium diameters; if the lamination packs are required to have inclined slots, they cannot be automatically formed during the punching step; a special circular die is required for lamination die, which involves huge investments both for the number and the size of the dies. Because of more percentage of scrap generated by the conventional methods and high manufacturing costs, there is felt a need to provide an improved lamination pack for stator assembly and EV motor armature assembly.
These objects and advantages are achieved by the process for making a stator or rotor lamination pack for a large-diameter electric machine according to this invention, which is characterized as defined in the annexed claims.

OBJECTIVES OF THE INVENTION
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present invention is to provide a lamination pack for magneto stator assembly and EV motor armature assembly.
Another object of the present invention is to provide a lamination pack with less percentage of scrap generated and scrap cost saving.
Another object of the present invention is to provide a lamination pack having low manufacturing and material cost.
Another object of the present invention is to provide a lamination pack that is suitable for mass production.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

SUMMARY OF THE INVENTION
Before the present invention is described, it is to be understood that present invention is not limited to particular methodologies and materials described, as these may vary as per the person skilled in the art. It is also to be understood that the terminology used in the description is for the purpose of describing the particular embodiments only, and is not intended to limit the scope of the present invention.
The present invention describes a lamination pack or a core assembly for magneto stator assembly and EV motor armature assembly and the process of manufacturing thereof. The core assembly is required in any DC Motor or AC generator for Coil winding for AC Current generation. Core assembly is usually created with individual laminations stacked together with pressing operation. Additionally, rivets are added to keep the Core assembly Intact/Firm. Steel sheet is used as raw material to make individual lamination sheet. The Laminations are split into many parts and stamping process is done to get the individual lamination sheets. The plurality of individual lamination sheets are stacked together in appropriate orientation one above the other and are pressed with press tool to obtain a stacked lamination sheets. These are split lamination pack or core assembly that are further assembled. The split core assembly are assembled as per the assembly sequence to form the core assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be made by reference to the following detailed description which is to be taken in conjugation with the accompanying drawing. The accompanying drawing, which is incorporated into and constitutes a part of the specification, illustrates one or more embodiments of the present invention and, together with the detailed description, it serves to explain the principles and implementations of the invention.
FIG.1 is the front perspective view of the lamination pack for the magneto stator assembly and EV motor armature assembly according to an embodiment of the invention;
FIG.2 is the exploded view of one split core assembly of lamination pack for the magneto stator assembly and EV motor armature assembly as shown in FIG.1 according to the embodiment of the invention; and
FIG.3 is the steps in the process of manufacturing the lamination pack for the magneto stator assembly and EV motor armature assembly as shown in FIG.1 according to the embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION

Before the present invention is described, it is to be understood that this invention is not limited to particular methodologies described, as these may vary as per the person skilled in the art. It is also to be understood that the terminology used in the description is for the purpose of describing the particular embodiments only, and is not intended to limit the scope of the present invention. Throughout this specification, the word “comprises”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results.

LIST OF REFERENCE NUMERALS:

Sr. No. Description of the part
100 Lamination pack (core assembly)
102 Raw material Sheet
104 Individual lamination sheets /Sheet Punching Pattern
106 Stacked lamination sheets
108 Rivet
110 Split core assembly
112 Scrap

The present invention describes a lamination pack or a core assembly for magneto stator assembly and EV motor armature assembly and the process of manufacturing thereof. The core assembly is required in any DC Motor or AC generator for Coil winding for AC Current generation. Core assembly is usually created with individual laminations stacked together with pressing operation. Additionally, rivets are added to keep the Core assembly Intact/Firm. Individual Laminations are manufactured with CRNGO/CRCA Steel Sheet by Stamping Operation. Laminations are created by using electrical steel laminations. Silicon Steel, also known as electrical steel, is steel with silicon added to it. Adding silicon to steel increases its electrical resistance, improves the ability of magnetic fields to penetrate it, and reduces the steel’s hysteresis loss. Silicon steel is used in many electrical applications where electromagnetic fields are important, such as electrical stators/rotors and motors, coils, magnetic coils and transformers.
According to the embodiment of the invention, while the silicon in silicon steel can help to reduce corrosion, the primary purpose of adding silicon is to improve the steel’s hysteresis loss. Hysteresis is the lag between the time when a magnetic field is first generated or applied to the steel and when the field fully develops. The addition of silicon to steel makes the steel more efficient and faster in terms of building and maintaining magnetic fields. Thus, silicon steel improves the efficiency and effectiveness of any device using steel as a magnetic core material.
According to the embodiment of the invention, the FIG. 1 and FIG. 2 describe the lamination pack (100) for magneto stator assembly and EV motor assembly. The lamination pack(100) also known as core assembly is mainly manufactured by stacking a plurality of individual lamination sheets or sheet punching pattern (104) one over the other and placing a plurality of rivets (108) in predetermined positions to secure the stacked lamination sheets (106).
According to the embodiment of the invention, FIG.3 describes the steps in the process of manufacturing the lamination pack (100) for the magneto Stator assembly and the EV motor armature assembly. The steps in the process of manufacturing are as follows:
A. Steel sheet of 0.1 to 1 mm thickness is used as raw material sheet (102) to make individual lamination sheet (104). Preferably, steel sheet of 0.5 mm thickness is used a raw material.
B. The Laminations are split into many parts and stamping process is done to get the individual lamination sheets (104). These sheets (104) are designed so as to allow for interlocking of the lamination sheets in a correct manner. Plurality of such individual lamination sheets (104) are made by the stamping operation.
C. The plurality of individual lamination sheets (104) are stacked together in appropriate orientation one above the other and are pressed with press tool to obtain a stacked lamination sheets (106). These are split lamination pack(110) or core assembly that are further assembled.
D. The split core assembly (110) are assembled as per the assembly sequence to form the core assembly. Dove tail design is used for locking purpose.
E. Rivets (108) are added to the core assembly (100) by riveting process to keep the core assembly intact.
F. The final assembled lamination pack (100) is thus obtained with less manufacturing cost. The Core assembly is then Powder Coated or Bobbin assembly is added & copper winding is done onto it to obtain the final Stator assembly or the EV motor armature assembly.
G. The scrap (112) generated is of less percentage.
According to the embodiment of the invention, the diameter of the lamination pack (100) or the core assembly is between 80-150 mm. For magneto rotor assembly, the diameter of the core assembly is preferably 95 mm and for EV motor armature assembly the diameter of the core assembly is preferably 100 mm.

According to the embodiment of the present invention, the improved lamination pack (100) or the core assembly for the magneto stator assembly and the EV motor armature assembly has various advantages. The improved assembly has reduced percentage scrap cost and that leads to substantial material and cost saving. The manufacturing process as described above is suitable for mass production also.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.