Electric motor assemblies and systems and methods associated with joining wires of electric motor assemblies

Abstract

A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Description

technical field [0001] The present invention generally relates to systems and methods related to connecting leads for electric motor assemblies. Background technique [0002] In a bar-wound electric motor assembly, the wires are typically welded together to assemble the stator. High quality welds are required because if one fails the motor will fail. Since a single motor may require hundreds of welds, it is important that the welding process is highly robust and efficient to ensure the quality of the welds while minimizing the time of the welding process. Problems with current soldering methods include lack of quality solder due to misalignment of the wires, and inefficient processes used to align the wires or increase the robustness of the soldering. [0003] The free ends of the wires often require some alignment aids in preparation for the soldering process. For example, robotic end effectors (fingers) are used to hold wire pairs together. Use two fingers to position ...

AI Technical Summary

Problems solved by technology

Problems with current soldering methods include lack of quality solder due to misaligned wires and inefficient processes used to align wires or increase soldering robustness

[0004] In summary, if the wire pairs are not aligned precisely, the resulting bond may be defective

However, robotic end effectors and other sophisticated wire positioning tools that have been employed to align wire pairs prior to welding are expensive and complex

Images