Stator welding fixture system and method

Abstract

Systems and methods for securing hairpins for connection by welding are provided. A clamp system includes an outer structural ring conductor end secured relative to an inner structural ring and engaged with a component around its hairpin conductor end. A dielectric ring is disposed between the conductor pairs. A clamping ring is disposed on opposite sides of the dielectric ring. One clamping ring and one dielectric ring define an opening for receiving one conductor pair. Another clamping ring and another dielectric ring define another receiving another conductor pair. The clamping rings are movable toward each other to align and compress the conductor pair between the clamping ring and the dielectric ring prior to welding.

Description

Technical Field

[0001] The present disclosure relates generally to electric machine manufacturing tools for welding conductors, and more particularly to systems and methods including securing features that provide improved orientation and alignment of the conductors in preparation for welding. Background Art

[0002] The growing demand for electric motors, including in vehicle applications, is driving the development of smaller, lighter and more powerful electric motors. To achieve these goals, hairpin-type motor wires are increasingly being used. Hairpins are solid rods, usually rectangular in shape, made of copper, that are used to replace traditional round windings. Hairpins are pre-formed and a large number of them are locked in place, such as in slots in a stator lamination stack, and have exposed ends that usually need to be connected to an adjacent hairpin or multiple hairpins.

[0003] One way to join conductors together involves making the connection via welding, such as arc welding. Wire joining is often a complex and time-consuming operation. Challenges include producing a high-quality joint while minimizing thermal impact on other parts of the product. The heat associated with welding can affect electrical isolation coatings and can leave unwanted deposits that can cause electrical shorts in the assembly. The complexity and time involved in welding hairpins becomes a barrier to increasing productivity in motors that use this type of conductor.

[0004] Therefore, the ability to produce high quality welds during motor conductor connection is desirable. Furthermore, the ability to do so in an uncomplicated, efficient and rapid manner is desirable. Moreover, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and introduction. Summary of the invention

[0005] Systems and methods for fixing motor components for conductor connection, such as by welding, are provided. In many embodiments, a conductor group is included in a component of a motor. A clamp system includes an inner structural ring configured to mate with the component on one side of the conductor group. An outer structural ring is fixed in place relative to the inner structural ring. The outer structural ring is configured to mate with the component on the other side of the conductor group. At least one dielectric ring is configured to engage the component between a first conductor pair and a second conductor pair. A clamping ring is configured to engage the component between the inner structural ring and the first conductor pair and is movable relative to the inner structural ring. Another clamping ring is configured to engage the component between the outer structural ring and the second conductor pair and is movable relative to the outer structural ring. One clamping ring and at least one dielectric ring define an opening configured to receive one conductor pair. Another clamping ring and at least one dielectric ring define another opening configured to receive another conductor pair. The clamping rings are configured to move toward each other to align and squeeze the conductor pair between the clamping ring and at least one dielectric ring.

[0006] In further embodiments, a welding machine is included to connect each conductor pair together at their respective ends after the conductor pairs are aligned and pressed together.

[0007] In further embodiments, a scanner is included to determine the location of the ends of the conductor pairs.

[0008] In further embodiments, a drive is included to move the clamping rings toward each other.

[0009] In a further embodiment, the opening has a width on a side facing the component and a smaller width on a side facing away from the component, so that the opening is tapered.

[0010] In further embodiments, the one or more dielectric rings include a plurality of pins configured to extend into the conductor set.

[0011] In another embodiment, one structural ring comprises a sliding member, a clamping ring is fixed to the sliding member, and another structural ring comprises another sliding member, another clamping ring is fixed to the other sliding member.

[0012] In further embodiments, the dielectric ring is made of a material having a dielectric strength sufficient to electrically separate the conductor pairs from each other without conducting electricity during operation of the component.

[0013] In further embodiments, each clamping ring comprises a series of segments arranged in an annular shape.

[0014] In further embodiments, the clamping ring is non-conductive.

[0015] In further embodiments, the conductor is a hairpin type stator winding.

[0016] In many other embodiments, a method for welding conductors of a conductor group contained by an electric machine component is provided. A clamping system is formed by an inner structural ring. An outer structural ring is fixed in place relative to the inner structural ring. The outer structural ring and the inner structural ring cooperate with the component so that the inner structural ring is located on a first side of the conductor group and the outer structural ring is located on a second side of the conductor group. The component is engaged with at least one dielectric ring disposed between two conductor pairs. The component is engaged with a clamping ring disposed between the inner structural ring and the first conductor pair, and the clamping ring is movable relative to the inner structural ring. The component is engaged with another clamping ring disposed between the outer structural ring and the second conductor pair, and the other clamping ring is movable relative to the outer structural ring. One conductor pair is accommodated in an opening defined by one clamping ring and one dielectric ring. The second conductor pair is accommodated in another opening defined by another clamping ring and another dielectric ring. The clamping rings move toward each other to align and squeeze the conductor pairs between the respective clamping rings and the respective dielectric rings.

[0017] In other embodiments, a welding machine connects the conductor end pairs after each conductor pair is aligned and pressed together.

[0018] In further embodiments, a scanner determines the position of the conductor end, and the welding machine uses the determined position to guide the welding beam.

[0019] In further embodiments, the drive moves the clamping rings towards each other.

[0020] In other embodiments, the opening is formed to have a width on a side facing the component and a smaller width on a side facing away from the component, so that the opening is tapered.

[0021] In further embodiments, the dielectric ring includes a plurality of pins extending into the conductor set.

[0022] In other embodiments, one clamping ring is secured to a slide contained by the inner structural ring, and another clamping ring is secured to another slide contained by the outer structural ring.

[0023] In other embodiments, each clamping ring is formed as a series of segments arranged in a ring.

[0024] In many other embodiments, a clamp system is provided for welding conductors of a conductor set contained by an electric machine component. An inner structural ring engages the component on one side of the conductor set. An outer structural ring is fixed in position relative to the inner structural ring and engages the component on the other side of the conductor set. A dielectric ring engages the component between one conductor pair and a second conductor pair. Another dielectric ring engages the component between the second conductor pair and a third conductor pair. A clamping ring engages the component between the inner structural ring and the one conductor pair and is movable relative to the inner structural ring. Another clamping ring engages the component between the outer structural ring and the third conductor pair and is movable relative to the outer structural ring. One clamping ring and one dielectric ring define an opening to accommodate one of the conductor pairs. The two dielectric rings define another opening to accommodate the other conductor pair. Another clamping ring and one dielectric ring define a third opening to receive the third conductor pair. The clamping rings are movable toward each other to align and compress the conductor pairs, one pair between one clamping ring and the dielectric ring, another pair between the two dielectric rings, and the third pair between the other clamping ring and one of the dielectric rings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Exemplary embodiments will be described below in conjunction with the following drawings, wherein like reference numerals represent like elements, and wherein:

[0026] Figure 1 is a schematic diagram of a welding fixture system including a fixture, a manipulator, and a motor workpiece according to various embodiments;

[0027] Figure 2 According to various embodiments Figure 1 A schematic diagram of a welding fixture system, wherein the fixture is positioned on a motor, a drive system engages the fixture, and a vision system;

[0028] Figure 3 According to various embodiments Figure 1 A schematic diagram of a welding fixture system, including a fixture and a welding system;

[0029] Figure 4 According to various embodiments Figure 1 A schematic diagram of a conductor pair connected after operation of the welding fixture system;

[0030] Figure 5 According to various embodiments Figure 1 A perspective view of a portion of a welding fixture system;

[0031] Figure 6 According to various embodiments Figure 1 A partial cross-sectional view of a welding fixture system;

[0032] Figure 7 According to various embodiments Figure 6Detailed plan view of the ring;

[0033] Figure 8 According to various embodiments Figure 1 A perspective view of the welding fixture system and motor;

[0034] Fig. 9 According to various embodiments Figure 1 a detailed perspective view of a portion of a welding fixture system, shown inverted; and

[0035] Fig.10 According to various embodiments Figure 1 Flow chart of the operating process of the welding fixture system. DETAILED DESCRIPTION

[0036] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

[0037] As used herein, the term module refers to any hardware, software, firmware, electronic control component, processing logic and / or processor device, alone or in any combination, including but not limited to: application specific integrated circuits, electronic circuits, processors (shared, dedicated or grouped) and memory that execute one or more software or firmware programs, combinational logic circuits and / or other suitable components that provide the described functionality.

[0038] Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. It should be understood that such block components may be implemented by any number of hardware, software, and / or firmware components configured to perform a specified function. For example, embodiments of the present disclosure may employ various integrated circuit components, such as storage elements, digital signal processing elements, logic elements, lookup tables, etc., which may perform various functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any number of various systems, and the system described herein is merely an example embodiment of the present disclosure.

[0039] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the system (and the various operating components of the system) may not be described in detail herein. In addition, the connecting lines shown in the various figures included herein are intended to represent example functional relationships and / or physical connections between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0040] In various embodiments, systems and methods include a fixture that aligns and squeezes together conductor ends of an electric machine for welding the ends together. The fixture includes multiple features to accurately and tightly squeeze the conductor ends from multiple directions. Dielectric rings can be applied between and around the pairs of conductor ends to be connected, which assists in alignment and squeezing. Rigid components of the fixture provide clamping force and rigidity. The fixture moves and holds the conductor ends in a specified position and orientation. The fixture can be an enabler of a three-dimensional vision system, wherein the system is capable of providing reference surfaces and index data to coordinate various aspects of the entire system. The system includes features that can improve manufacturing quality in terms of conductor alignment, welding, insulation protection, weld spatter protection and / or visual inspection / inspection.

[0041] refer to Figure 1-4 , shows a welding fixture system 20 operating on a motor component, in this case, a stator 22. Generally speaking, the welding fixture system 20 may include a fixture 24 that engages the stator 22 and is operated by a manipulator 26, a vision system 28, a drive system 30, and / or a connection system 32. The stator 22 includes a plurality of conductors, represented by conductors 40, 42, which require connection, such as at their respective tips / ends 44, 46. In the current embodiment, the stator 22 is a stator assembly having a lamination stack 48 containing the conductors 40, 42. It should be understood that the stator 22 may include any type of motor component other than a stator that includes conductors that require connection to achieve electrical continuity. Typically, the fixture 24, which is moved by the manipulator 26, aligns and squeezes the conductors 40, 42. The alignment and squeezing is accomplished with the assistance of the driver system 30. The vision system 28 cooperates with the overall welding fixture system 20 to provide a reference surface for indexing and welding directionality. As shown Figure 4 As shown, the connection system 32 fuses the ends 44 , 46 together, connecting the conductors 40 , 42 .

[0042] In the current embodiment, the stator 22 is configured to hold a winding arrangement, which can be implemented as a hairpin type. The lamination stack 48 may include a plurality of slots that accommodate a plurality of hairpin conductors 40, 42, etc. to form an armature winding arrangement. In other embodiments, another form of conductor may be used. The conductors 40, 42, etc. are inserted into the lamination stack 48 and have a plurality of ends 44, 46, etc. (welding ends) that need to be connected. The conductors 40, 42 typically have an insulating coating 50 for electrical insulation, which has stripped or non-coated ends 44, 46 when prepared for joining. The conductors 40, 42, etc. are arranged around the lamination stack 48 in a size, stripping, spacing, and number determined according to the specifications of the stator 22. For example, a three-phase motor stator will have a row of three radially aligned conductor pairs 40, 42, which are concentrically arranged in a ring around the lamination stack 48. The ends 44, 46 of the same phase are arranged in pairs, adjacent to each other for connection. Other embodiments may show different conductor arrangements and different numbers of pairs per row for connection. When the conductors 40, 42 are assembled with the stator or lamination stack 48, manufacturing and tolerance variations may cause the position of the end pairs 44, 46 to have some degree of positional difference compared to other pairs. For high quality welding results, accurate positional data is beneficial.

[0043] like Figure 1 As shown, the fixture 24 presents a size and shape that matches the stator 22. The manipulator 26 can be implemented as an automatic robot, a manual auxiliary device, or a combination thereof to move the fixture 24 in three-dimensional space. The manipulator 26 can include a control system having a controller 52 and any number of actuators 54 to lift, move, and place the fixture 24. Typically, the fixture 24 is placed and mated with the stator 22 before welding, and is removed after welding.

[0044] like Figure 2 As shown, the fixture 24 is placed on the stator 22, and as a result, the ends 44, 46 are aligned and pressed together so that they are in contact or nearly in contact. Having aligned and pressed the ends 44, 46, the vision system 28 can determine their positions in three-dimensional space, and can include a controller 56 and any number of actuators 58 to move and operate the laser scanner 60. In other embodiments, a camera or other type of vision system / scanner can be used. Data about the position, size and other characteristics of the conductor ends 44, 46 is collected. The controllers 52, 56 can be communicatively coupled to work in cooperation, including sharing data. In some embodiments, the controllers 52, 56 can be a common controller.

[0045] Likewise Figure 2As shown, the driver system 30 includes a controller 62 and any number of actuators 64 to manipulate and operate an inner driver 66 and an outer driver 68. In general, the inner driver 66 and the outer driver 68 operate to move portions of the clamp 24, such as by driving screws, to align and compress the conductor ends 44, 46, etc. after the clamp 24 is placed on the stator 22. The inner driver 66 can include a plurality of drive heads 70 extending around the inner circumference of the clamp 24, and can drive multiple features / screws simultaneously to apply a clamping force to the conductors 40, 42, etc. from the inside to the outside. The outer driver 68 can be annular to extend around the clamp 24. The outer driver 68 can include a plurality of drive heads 72 extending around the outer circumference of the clamp 24, and can drive multiple features / screws simultaneously to apply a clamping force to the conductors 40, 42, etc. from the outside to the inside. Through the operation of the clamp 24 driven by the drivers 66, 68, each conductor pair represented by the conductor pairs 40, 42 is aligned and pressed together in preparation for welding.

[0046] In such Figure 3 In the current embodiment shown, the connection system 32 is of the laser welding type. In other embodiments, another type of connection system can be used. Compared with other types of welding, the use of a laser type welding machine can speed up the production rate of the stator 22. The laser 76 generates a beam 78 that transmits a focused heat source. The beam 78 is concentrated in a narrow area of ​​the ends 44, 46 and provides a high welding rate. The beam 78 can be in the range of 40-500 microns, while the ends 44, 46 are significantly larger, such as a thickness of 1.5 mm or more. Therefore, the collected data about the position of the ends 44, 46 is referenced for determining the direction and application of the beam 78, and the beam 78 moves during the welding of a conductor pair. The connection system 32 includes a controller 80 and any number of actuators 82 to control the position and operation of the laser 76. The controller 80 is coupled to the controller 56 and can refer to the data collected by the vision system about the three-dimensional position of the ends 44, 46. The 3D position provides information about the relative position between the two conductor ends 44 and 46. The joining system 32 uses available data and programming to deliver heat in the form of a beam 78 to weld the ends 44, 46 together, as shown. Figure 4 As shown, the weld 79 results in fusion and conduction between the ends 44, 46 through the weld 79. The connection system 32 generates a path for the light beam 78, which is determined by the controller 80 based on the 3D information of the two conductor ends 44, 46 to provide the heat required to produce a suitable weld 79 at a specified location. The weld 79 produced has a cross-section and height required relative to the 3D alignment of the two ends 44, 46 to provide a desired weld strength between the two welded conductors 40, 42.

[0047] In other embodiments, any number of controllers may be used in place of the controllers 52, 56, 62, 80, and in some embodiments, only one controller may be used to provide all functions. For the purposes of the current embodiment, the controllers 52, 56, 62, 80 control the operation of the welding fixture system 20, including the fixture 24, the vision system 28, the drive system 30, and the connection system 32. The operation is controlled by actuating the actuators 54, 58, 64, 82 and the laser 76. One or more actuators 54, 58, 64, 82 may be multi-axis positioning actuators to move objects through various heights, positions, and directions, or any other type of actuator sufficient for a given application. One or more controllers 52, 56, 62, 80 may include any number of electronic control modules and may receive various input variables of current operating conditions and other parameters. The inputs are analyzed and operating parameters, such as the operation of the fixture 24, the vision system 28, the drive system 30, the connection system 32, and others, are calculated based on the data and applied appropriately to various actuators and other response devices. One or more controllers 52, 56, 62, 80 may receive various signals, including signals from various sensors (not shown) that provide information about the various controlled systems, analyze them, and send control signals to various destinations, including the actuators 54, 58, 64, 82, and the laser 76. Sensors, including laser scanners, may sense various aspects of the motor components, the fixture 24, the laser scanner 60, the drivers 66 and 68, and the laser 76. The sensors may include any number of sensors for monitoring the operation / status of the welding fixture system 20 and for determining weld quality.

[0048] Each of the controllers 52, 56, 62, 80 can be configured to meet functional requirements, and the controller 80 will be described in more detail, it should be understood that each of the other controllers one or more controllers 52, 56 and 62 can include similar components. The controller 80 includes a processor 84 and a memory device 86, and is coupled to a storage device 88. The processor 84 performs the computing and control functions of the controller 80, and executes one or more programs during operation, and can use data, each of which can be contained in the storage device 88, or received from other sources, and as such, the processor 84 controls the general operation of the controller 80 in performing the processes described herein. The memory device 86 can be any type of suitable memory or combination of memory devices capable of storing data, some of which represent executable instructions used by the controller 80. In the illustrated embodiment, the memory device 86 can store the above-mentioned programs and one or more stored data values, such as for short-term data access. The storage device 88 stores data, such as for long-term data access for automatically controlling the welding fixture system 20, and can be any suitable type of storage device. In an exemplary embodiment, the storage device 88 includes a source from which the memory device 86 receives programs and data. The program represents executable instructions used by the controller 80 to process information and control the welding fixture system 20 and its subsystems and devices. The processor 84 can generate control signals for the welding fixture system 20 based on logic, calculations, methods and / or algorithms.

[0049] refer to Figure 5 , the basic structural elements of the clamp 24 are shown disposed on the stator 22, with some portions of the clamp 24 omitted for clarity. The lamination stack 48 contains conductors 40, 42, etc. In the current embodiment, the motor component is a stator assembly of a three-phase motor having hairpin-type conductors / windings. The stripped ends 44, 46 appear in pairs, with six conductors / three pairs shown in a given row 90. The six conductors in each row 90 are arranged in a radially extending row arrangement, and multiple rows are provided in an annular collection around the circumference of the stator 22. In general, the conductors 40, 42, etc. form a conductor group 91. The conductors 40, 42, etc. extend from the lamination stack, and the ends 44, 46, etc. are used for connection.

[0050] The clamp 24 includes a rigid inner structural ring 92 surrounding an inner peripheral side 94 of the conductor group 91, and includes a rigid outer structural ring 98 surrounding an outer peripheral side 96 of the conductor group 91. The inner structural ring 92 is fixed together with the outer structural ring 98 by a plurality of rigid brackets 100, which hold the components in place and together. The inner structural ring 92, the outer structural ring 98 and the brackets 100 are made of a material that provides strength and rigidity, such as metal, and in many embodiments may be made of steel. When moved into position, the clamp 24 is fixed relative to the stator 22, in this embodiment fixed by fasteners 102, which extend through the tie rod holes (tie rod holes) of the lamination stack 48. In other embodiments, an automated clamping system, such as a clamping member, may be used to fix the clamp 24 relative to the stator 22.

[0051] The inner structural ring 92 includes a plurality of sliding grooves 106, each of which is arranged in a radially extending direction and opens radially outward toward the inner peripheral side 94 of the conductor group 91. A screw 108 extends from the inner circumference 110 of the inner structural ring 92 into each sliding groove 106. The screw 108 is formed by Figure 2 The actuator 66 is operated to move the components of the fixture 24 toward or away from the inner peripheral side 94 of the conductor set 91, as further described below. The outer structural ring 98 includes a plurality of slide slots 112 that are arranged in a radially extending direction and open radially inward toward the outer peripheral side 96 of the conductor set 91. A screw 114 extends from the outer circumference 116 of the outer structural ring 98 into each slide slot 112. The screw 114 is formed by Figure 2 The actuator 68 is operated to move the components of the clamp 24 toward or away from the outer peripheral side 96 of the conductor group 91, as further described below. As described below, these parts of the moving clamp 24 provide a clamping action to squeeze (press together) the conductors 40, 42 through multiple intermediate portions of the clamp 24.

[0052] refer to Figure 6 , the intermediate components are shown in the fixture 24, which is shown assembled separately from the stator 22 for clarity. The inner structural ring 92 is spaced apart from the outer structural ring 98, defining a cavity 118 for receiving the conductor ends 44, 46, etc. of the conductor set 91. The intermediate portion including the dielectric rings 120, 122 and the clamping rings 124, 126 extends through the top of the cavity 118 (as shown). Figure 6 Not visible in but in Figure 7As shown in FIG. 1 , the dielectric rings 120, 122 and the clamping rings 124, 126 can each include a protrusion 128 that is received in a socket 129 of an adjacent ring and aligns the rings 120, 122, 124, 126 relative to each other. For example, when the rings 120, 122, 124, 126 are put together, the protrusions 128 and sockets 129 can have matching triangular ridge / groove guide alignments because each row of openings 130, 132, 134 is defined by two adjacent rings 120, 122, 124, 126. Each opening 130, 132, 134 is tapered, having a larger width 136 at the end facing the stator 22 and a relatively smaller width 138 at the end facing away from the stator 22. This helps capture the corresponding conductor pairs 40 , 42 within the larger width 136 as the clamp 24 is positioned and moved toward the stator 22 , and the tapered moving conductor pairs 40 , 42 are drawn together in an aligned manner.

[0053] The clamp 24 grasps the clamp ring 124 so as to be movable relative to the inner structural ring 92 using the slide slots 106. Each slide slot 106 contains a slide 140 to which the inner clamp ring 124 is attached, for example, by a cover plate 142, a slide plate 143 and bolts 144. Figure 8 , Figure 8 The clamp 24 is shown positioned on the stator 22, and each slide 140 is engaged by one of the screws 108 to selectively move the clamping ring 124 toward or away from the conductor group 91 depending on the rotation direction of the screw 108. In addition, the clamp 24 grasps the clamping ring 126 so as to be movable relative to the outer structural ring 98 using the slide slot 112. Each slide slot 112 contains a slide 146, and the outer clamping ring 126 is attached to the slide 146, such as by a cover plate 148, a slide plate 149 and bolts 150. Each slide 146 is engaged by one of the screws 114 to selectively move the clamping ring 126 toward or away from the conductor group 91 depending on the rotation direction of the screw 114.

[0054] Rings 120, 122, 124, 126 Fig. 9, and are shown inverted and in an aligned position relative to each other. The dielectric rings 120, 122 are made of a single-piece annular structure and include a polymer material having dielectric resistance and high temperature resistance. The selected material can have a rated temperature of up to about 200 degrees Celsius, and a non-exclusive example is polyamide. In the current embodiment of a three-phase stator assembly with six conductor ends per row, two dielectric rings 120, 122 are used. In applications with four conductor ends per row, one ring 120 can be used. In applications with more than six conductor ends per row, more than two dielectric rings can be used, each dielectric ring being disposed between two adjacent pairs of conductor ends. Because the rings 120, 122 remain in place in the assembled motor, the dielectric properties of the rings 120, 122 are selected to have sufficient dielectric strength to separate electrical properties in three independent phases of the motor / motor during operation without experiencing electrical breakdown and becoming conductive. The dielectric rings 120, 122 include protruding pins 154 located between each row of adjacent openings 130, 132, 134. Figure 6 As shown, the pins 154 extend into the stator 22 , providing positioning and alignment of the dielectric rings 120 , 122 and the conductors 40 , 42 .

[0055] like Fig. 9 As shown, the clamping ring 124 is composed of a series of segments 161-164, etc., forming a segmented annular ring. Similarly, the clamping ring 126 is composed of a series of segments 165-168, etc., forming a segmented annular ring. Figure 6 As shown, each segment 161-168 is held apart by its respective structural ring 92, 98 and is movable with its respective slide 140, 146 under the action of its respective screw 108, 114 to apply a clamping load to the conductor group 91. The screws can be adjusted manually or automatically so that multiple screws for the inner and outer slides can be operated simultaneously. There is sufficient clearance between adjacent segments to allow radial movement. The segments 161-168 and therefore the clamping rings 124, 126 are made of a non-conductive, relatively tough material, an example of which is ABS. After welding, the clamping rings 124, 126 are removed from the stator 22 and therefore do not have the same insulation requirements as the dielectric rings 120, 122. In addition, once loaded into the fixture 24 for application, the clamping rings 124, 126 can be reused for multiple welding cycles.

[0056] To help retain the segments 161-168, each segment has a protrusion 170 that fits into a corresponding opening 172, 174 in the corresponding slide plate 143, 149. For example, the segments 163, 167 are shown in an initial position with the screws 108, 114 initially retracted to expand the segments 163, 167 relative to the dielectric rings 120, 122. To releasably retain the initial position, the slides 140, 146 may be biased, such as by a spring (not shown), to the initial position, may be connected to the screws 108, 114, may be held in place by friction, such as against the cover plates 142, 148, or by other means. As the screws 108, 114 are rotated clockwise, the segments 161-168 are driven together and move toward the dielectric rings 120, 122 to the position of the segments 161, 165. This movement squeezes the hairpin ends 44, 46 together for connection, and the shape of the openings 130, 132, 134 helps align and position the ends 44, 46 and maintain proper separation between the pairs. The rings 120, 122, 124, 126 provide a seal for the winding / hairpin to prevent the ingress of welding byproducts such as weld spatter. In addition, a portion of the rings 120, 122, 124, 126 is positioned around the insulation 176 of the conductors 40, 42, etc., and the remaining top covers a portion of the stripped portion 178, such as Figure 8 As shown, the insulating coating is protected during the welding process.

[0057] refer to Fig.10 , shows a process 200 that can be performed using the welding fixture system 20 and any or all of its subsystems. The order of operations within the process 200 is not limited to Fig.10 The process 200 is not performed in the order shown, but may be performed in one or more different orders where applicable and depending on the selected application. In addition, steps may be omitted, or other steps may be included. The process 200 begins with the assembly 202 of the motor component / stator 22, wherein the conductors 40, 42, etc. are assembled to the lamination structure 48, and the ends 44, 46 are stripped or exposed to establish conductivity between them. In the current embodiment, the motor component is the stator 22, but in other applications, another type of component may be operated by the process 200. The conductors 40, 42, etc. include a conductor group 91, and the ends 44, 46, etc. appear in pairs for connection.

[0058] Continuing with process 200, dielectric rings 120, 122 are added 204 to the assembled stator 22 with pins 154 extending into the assembly, such as between conductors 40, 42. Dielectric rings 120, 122 are aligned with the aid of protrusions 128 and sockets 129. Clamping rings 124, 126 are added to fixture 24. For example, segments 161-168 are loaded 206 onto sliding plates 143, 149 with protrusions 170 entering openings 172, 174, and bolts 144, 150 are tightened, capturing segments 161-168 beneath cover plates 142, 148 and defining clamping rings 124, 126. Segments 161-168 are all located 208 by Fig. 9 The initial expanded position shown in segments 163 and 167.

[0059] like Figure 2 As shown, under the control of the controller 52, the clamp 24 is grasped and moved by, for example, the manipulator 26, and the actuator 54 is operated to position 210 the clamp 24 onto the motor component / stator 22. The clamp 24 is, for example, Figure 5 The fastener 102 is shown secured 212 to the stator 22. The manipulator 26 may be withdrawn 214 and the driver system 30 operated 216, wherein the drivers 66, 68 are brought into position by the controller 62 operating the actuator 64. The drive heads 70, 72 are operated 216 to rotate the screws 108, 114, thereby moving the slides 140, 146 and the corresponding attachment segments 161-168, applying 218 a clamping load between each pair of opposing segments, such as segments 161, 165. This applies a clamping load to the dielectric rings 120, 122 and squeezes each pair of conductor ends together. When the openings 130, 132, 134 are each defined around a pair of conductor ends, such as conductor ends 44, 46, alignment is aided by means of the protrusions 128 and sockets 129. After applying the clamping load, the driver system 30 may withdraw 220 the drivers 66, 68 from the fixture 24.

[0060] The physical position and shape of the aligned and squeezed conductor end pairs 44, 46 are determined 222 by scanning the conductor set 91, for example, by the vision system 28 under the operation of the controller 56 and the actuator 58. The vision system 28 can use the laser scanner 60 to collect 224 data, and the controller 56 saves the data. The data is transmitted to the controller 80. The connection system 32 moves 226 to the welding position, for example, under the control of the controller 80 and the operation of the actuator 82. The laser 76 responds to the controller 80 and generates a beam 78 to weld 228 the conductor ends 44, 46, etc. together. The controller 80 uses the data collected by the vision system 28 to effectively and efficiently direct the beam 78 to aim at the ends 44, 46 to be fused together by the weld 79.

[0061] When all conductor end pairs are welded, the process 200 continues with the retraction 230 of the laser 76. The clamp 24 is unlocked 232 from the stator 22. Under control of the operation of the controller 52 and the actuator 54, the clamp 24 is grasped and moved, for example, by the manipulator 26, to retract 234 the clamp 24 from the motor component / stator 22. The clamping rings 124, 126 are retracted with the clamp 24, and the dielectric rings 120, 122 remain in place in the stator 22. The process 200 is complete, and the remaining assembly of the motor using the stator 22 can begin.

[0062] With the embodiments disclosed herein, a fixture aligns and squeezes together the conductor ends of an electric machine for welding the ends together. The fixture includes multiple features to accurately and tightly squeeze the conductor ends from multiple directions. Dielectric rings are applied between and around the conductor end pairs to be connected to assist in alignment and squeezing. The rigid components of the fixture provide clamping force and rigidity. The fixture secures the conductor ends in a specified position and orientation for connection by welding. The fixture can be scanned by a vision system to collect position data for use by a welding machine. The system includes features that can improve manufacturing quality in terms of conductor alignment, laser welding, insulation protection, weld spatter protection and / or visual inspection / inspection.

[0063] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing one or more exemplary embodiments for those skilled in the art. It should be understood that various changes may be made to the function and arrangement of elements and / or steps without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A clamp system for welding conductors of a conductor set comprised by a component of an electric machine, the clamp system comprising: an internal structural ring configured to mate with the component on a first side of the conductor set; an outer structural ring fixed in position relative to the inner structural ring, the outer structural ring being configured to mate with the component on a second side of the conductor set; at least one dielectric ring; a first clamping ring, the first clamping ring being movable relative to the inner structural ring; a second clamping ring, said second clamping ring being movable relative to said outer structural ring, wherein the first clamping ring and the at least one dielectric ring define a plurality of first openings, the plurality of first openings being configured to respectively receive a portion of the conductors in the conductor set and surround ends of the portion of the conductors, wherein the second clamping ring and the at least one dielectric ring define a plurality of second openings, the plurality of second openings being configured to respectively receive another portion of the conductors in the conductor set and surround ends of the another portion of the conductors, wherein the first clamping ring and the second clamping ring are configured to move toward each other to align and compress the portion of the conductor between the first clamping ring and the at least one dielectric ring, and to align and compress the other portion of the conductor between the second clamping ring and the at least one dielectric ring; Wherein, the at least one dielectric ring includes protruding pins extending into the component to provide positioning and alignment of the at least one dielectric ring and the conductor set.

2. The clamp system according to claim 1, comprising: Welding machines, wherein the portion of conductors has a first pair of conductor ends, wherein the other portion of conductors has a second pair of conductor ends, and The welding machine is configured to connect the first pair of conductor ends together and connect the second pair of conductor ends together after the one portion of the conductor and the other portion of the conductor are aligned and squeezed together.

3. The clamp system according to claim 1, comprising: Scanner, A portion of the conductors has a first pair of conductor ends, The other portion of the conductors has a second pair of conductor ends, Wherein the scanner is configured to determine the positions of the first pair of conductor ends and the second pair of conductor ends. 4 . The clamp system of claim 1 , comprising a drive, wherein the drive is configured to move the first clamping ring and the second clamping ring toward each other.

5. The clamp system of claim 1, wherein: The plurality of first openings have a first width on a first side facing the component and a second width on a second side facing away from the component, The first width is greater than the second width, so that the plurality of first openings are tapered.

6. The fixture system according to claim 1, wherein: The at least one dielectric ring includes a plurality of pins configured to extend into the conductor set.

7. The clamp system according to claim 1, comprising: a first sliding member contained by the inner structural ring, the first clamping ring being secured to the first sliding member; and A second slide is contained by the outer structural ring, the second clamping ring being fixed to the second slide.

8. A method for welding conductors of a conductor set comprised by a component of an electric machine, the method comprising: Constructing a fixture system with internal structural rings; securing the outer structural ring in position relative to the inner structural ring; mating the outer structural ring and the inner structural ring with the component such that the inner structural ring is located on a first side of the conductor set and the outer structural ring is located on a second side of the conductor set; engaging the component with at least one dielectric ring disposed between a portion of the conductors and another portion of the conductors of the conductor set; engaging the component with a first clamping ring disposed between the inner structural ring and the portion of the conductor, the first clamping ring being movable relative to the inner structural ring; engaging the component with a second clamping ring disposed between the outer structural ring and the further portion of the conductor, the second clamping ring being movable relative to the outer structural ring; receiving the portion of the conductor in a plurality of first openings defined by the first clamping ring and at least one dielectric ring, respectively, and the plurality of first openings surround ends of the portion of the conductor; receiving the other conductor portions in a plurality of second openings defined by the second clamping ring and at least one dielectric ring, respectively, and the plurality of second openings surround ends of the other conductor portions; and moving the first clamping ring and the second clamping ring toward each other to align and compress the portion of the conductor between the first clamping ring and at least one dielectric ring and to align and compress the other portion of the conductor between the second clamping ring and at least one dielectric ring; Wherein, the at least one dielectric ring includes protruding pins extending into the component to provide positioning and alignment of the at least one dielectric ring and the conductor set.

9. The method according to claim 8, comprising: securing said first clamping ring to a first slide contained by said inner structural ring; and The second clamping ring is secured to a second slide contained by the outer structural ring.

10. The method of claim 8, comprising forming the first clamping ring and the second clamping ring each as a series of segments arranged in an annular shape.

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