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Technical and economical optimisation of high speed laser blanking in high variant electrical machine production
2001 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Punching is presently the manufacturing method of magnetic core laminations for electrical motors at ABB Industry AG in Switzerland. Main cost factors are big punching machines, punching tools, tool maintenance and long set-up times. The last two factors have a negative impact on the response to market needs. Alternative method in lamination production is laser cutting, where no tools are required. CAD and CNC integration in laser cutting leads to full flexibility and full response to customer order. With this technology, many disadvantages in punching technology are left out. The punching process at ABB Industry is presently split up into two steps: blanking (pre punching) followed by slot notching and the idea of replacing punching technology with laser cutting technology for the blanking step has turned up. In this thesis, various configurations of possible laser cutting systems as well as technical and economical calculations for these have been carried out to form a basis for a replacement of the blanking step. The thesis is initialised with a creation of an empirical model for calculation of cutting time for all different motor types at ABB Industry. The model is based on contour information about all motor types received from ABB Industry as well as on laser cutting experiments made on a linear motor driven state-of-the- art laser cutting machine. Since laser cutting machines on the market don’t have the capacity and configuration required to meet the demands in core manufacturing, conceptual multiple head systems have been considered. For three selected potential laser cutting systems, the throughput-, floor space and hourly rate calculation has been carried out. The calculated cutting times for the whole product range as well as performance of machine loading and deloading systems are inputs to the throughput calculations. It is concluded, that the blanking step can fully be performed by a four head laser cutting system within 4696 hours per year. The investment cost for this system is estimated to 2.040 kEUR. The throughput calculations have shown that two motor models stand for 37% to 46% of the total process time. The possible low risk investment decision to partly replace the punching process with a two head laser cutting system is considered as an alternative to the full replacement solution. The investment cost for the two head laser system is estimated to 1.340 kEUR. The precision of cutting time and throughput models is estimated to be 5%.

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Keyword [sv]
URN: urn:nbn:se:ltu:diva-56042ISRN: LTU-EX--01/169--SELocal ID: cd7dfd78-940a-436c-aa27-55677e82ac91OAI: diva2:1029428
Subject / course
Student thesis, at least 30 credits
Educational program
Mechanical Engineering, master's level
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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