Motor winding welding method and welding tool

Abstract

This invention relates to the field of welding technology, and more particularly to a welding fixture for motor windings. It includes a welding support base plate, a welding clamping mechanism, a motor winding cover, a welding auxiliary mechanism, and a locking welding mechanism. A structural support frame is fixedly installed on the upper side of the welding support base plate. The welding clamping mechanism includes two sets of symmetrically arranged synchronous electric telescopic rods and a structural support cover. An inner arc clamping plate is fixedly connected to the inner side of the structural support cover, and an electromagnet plate is fixedly installed on the inner side of the inner arc clamping plate. Air outlets are symmetrically opened on the sides of the structural support cover. The motor winding cover is positioned between the two sets of inner arc clamping plates and includes a left clamp and a right clamp. This invention achieves rapid clamp closure through electromagnetic adsorption positioning and self-locking. The gaps in the wire harness are filled by induction heating soldering and dynamically compacted, and then laser sealing is used to form a permanent integral collar, achieving triple connection protection and significantly improving the electrical reliability and vibration resistance durability of the joint.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a method for welding motor windings and a welding fixture. Background Technology

[0002] Motor winding wiring is a critical process in motor manufacturing. After the enameled wire ends are stripped, they need to be gathered and connected to a common conductor to achieve centralized power supply or point-to-point connection. In existing technologies, the wiring scheme using copper sleeves / terminals is one common choice: one method is to insert the multi-strand wire ends into the copper sleeve and then braze the wire ends to the copper sleeve as one piece; another method is to use a cold extrusion process to press the copper sleeve onto the outside of the wire harness, using the plastic deformation of the metal to achieve mechanical locking and electrical contact.

[0003] However, the aforementioned copper sleeve / terminal solutions suffer from a fundamental technical flaw: their connection mechanisms all rely on the interface contact between the inner wall of the copper sleeve and the outer surface of the wire harness to achieve electrical conductivity. In the brazing solution, solder fills the space between the copper sleeve and the wire harness to form a metallurgical bond, but the multiple wire ends remain in mechanical contact rather than fusion. The copper sleeve wall becomes the necessary channel for the main conductive path, requiring current to be transmitted through multiple stages: "wire core - copper sleeve interface - copper sleeve body." In the cold-pressing solution, the contact between the copper sleeve and the wire harness is maintained solely by physical pressure. Under the thermal cycling and vibration conditions of motor operation, the interface contact pressure gradually relaxes due to material creep, and the contact resistance irreversibly increases. Regardless of the method, as long as the contact state at the interface between the copper sleeve and the wire harness deteriorates, the electrical performance of the entire joint faces the risk of failure, and the long-term stability of this interface is difficult to guarantee. Therefore, there is an urgent need for a new wiring structure and tooling that can achieve tight bonding of multiple wire ends within the bundle, so that the main conductive path does not rely on a single copper sleeve-wire harness interface contact.

[0004] We propose a method for welding motor windings and a welding fixture. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a method and fixture for welding motor windings.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A welding fixture for motor windings includes a welding support base plate, a welding clamping mechanism, a motor winding cover, a welding auxiliary mechanism, and a locking welding mechanism. A structural support frame is fixedly installed on the upper side of the welding support base plate. The welding clamping mechanism includes two sets of symmetrically arranged synchronous electric telescopic rods and a structural support cover. An inner arc clamping plate is fixedly connected to the inner side of the structural support cover. An electromagnet plate is fixedly installed on the inner side of the inner arc clamping plate. Air outlets are symmetrically opened on the side of the structural support cover. The motor winding cover is disposed between the two sets of inner arc clamping plates. The motor winding cover includes a left clamping sleeve and a right clamping sleeve. A tin plate interlayer is provided on the inner side of both the left and right clamping sleeves. A snap-fit ​​groove is provided at the end of the left clamping sleeve, and snap-fit ​​teeth are evenly distributed on the snap-fit ​​groove. A mating snap-fit ​​groove is provided at the end of the right clamping sleeve.

[0008] Furthermore, the welding auxiliary mechanism includes an electric push rod and a structural cylinder. The electric push rod and the structural cylinder are located on both sides of the structural support cover. A lower clamping plate is fixedly installed on the output end of the electric push rod, and an upper clamping plate is provided on the upper side of the lower clamping plate. An electromagnetic heating coil is sleeved on the outer wall of the structural cylinder, and an infrared temperature sensing probe is provided at the rear axis position of the structural cylinder. The outer side of the infrared temperature sensing probe is coated with a heat-insulating and magnetic-insulating coating.

[0009] Furthermore, the locking welding mechanism includes a structural ring, on which structural folding seats are symmetrically fixedly installed on the upper and lower sides. A shaft seat is fixedly installed on the inner side of the structural folding seat, and a rotating block is rotatably installed on the inner side of the shaft seat. A laser welding head is fixedly installed on the rotating block.

[0010] Furthermore, the synchronous electric telescopic rod is fixedly installed on the inner wall of the structural support frame, and an installation plate is screwed onto the output end face of the synchronous electric telescopic rod. A pressure sensor is fixedly installed on the side of the installation plate, and a middle support plate is fixedly connected between the pressure sensor and the structural support cover. A controller and a terminal block are fixedly installed on the outer wall of the structural support frame.

[0011] Furthermore, a number of snap-fit ​​grooves are evenly distributed on the inner side of the docking slot, a cooling fan is fixedly installed on the side of the structural support cover, the air outlet of the cooling fan is connected to the inside of the structural support cover, a dustproof net is provided at the air inlet of the cooling fan, a dustproof net plate is fixedly installed at the air outlet port, and the air outlet duct is symmetrically inclined.

[0012] Furthermore, a heat insulation interlayer is provided between the electromagnet plate and the inner arc clamping plate, a number of heat dissipation fins are evenly distributed on the back of the electromagnet plate, an inspection top cover is screwed onto the top of the structural support cover, and an arc-shaped rear extension is fixedly installed on the rear side of the structural support cover.

[0013] Furthermore, a support folding plate is fixedly connected to the bottom of the electric push rod, and the support folding plate is screwed onto the upper side of the welded support base plate. An electric lifting rod is fixedly installed at the bottom of the lower clamping plate. The output end of the electric lifting rod slides through the lower clamping plate and extends to its upper side. A tension sensor is fixedly connected between the output end of the electric lifting rod and the upper clamping plate. Rubber pads are fixedly adhered to the inner sides of both the lower and upper clamping plates.

[0014] Furthermore, the structural cylinder has symmetrically arranged flared arc openings at both ends. The structural cylinder is made of high-strength ceramic material. Several support rods are fixedly connected to the bottom of the structural cylinder. A base is fixedly installed at the bottom of the support rod. The base is screwed onto the upper side of the welded support base plate. A bent rod is fixedly connected to the rear end of the structural cylinder. An end seat is fixedly connected to the end of the bent rod. The infrared temperature sensing probe is fixedly installed on the end seat.

[0015] Furthermore, the structural ring is fixedly sleeved on the outer wall of the output end of the synchronous electric telescopic rod, an electric motor is fixedly installed on the outer wall of the shaft seat, the output end of the electric motor is fixedly connected to the rotating shaft of the rotating block, and the emitting end of the laser welding head is aligned with the butt joint formed after the left and right sleeves are closed, for laser welding of the closed butt joint.

[0016] The present invention also includes a method for welding motor windings as described above, comprising the following steps:

[0017] S1: Place the left and right clips inside the two sets of inner arc plates respectively. The controller starts the electromagnet plate to generate magnetic attraction, which attracts the left and right clips to the inner sides of the inner arc plates on both sides respectively.

[0018] S2: The controller drives two sets of symmetrically arranged synchronous electric telescopic rods to extend synchronously, causing the structural support cover to move closer to each other, so that the snap-fit ​​groove at the end of the left jacket and the docking snap-fit ​​groove at the end of the right jacket mate with each other, and the snap-fit ​​teeth and the snap-fit ​​groove on the inner side of the docking snap-fit ​​groove engage to form a mechanical self-locking; during the closing process, the pressure sensor monitors the closing pressure in real time and feeds it back to the controller.

[0019] S3: Pass the multi-strand wire end that has been de-varnished through the space between the lower clamp and the upper clamp, and feed it forward into the closed left and right clamps, so that the wire end protrudes from the front end of the clamp.

[0020] S4: The controller restarts the synchronous electric telescopic rod, continuing to close it according to the preset pre-clamping force, so that the inner walls of the left and right jackets apply radial pre-pressure to the internal multi-strand wire ends; after the pre-clamping is completed, the controller starts the electric lifting rod to push the upper clamping plate towards the lower clamping plate, so that the rubber clamping pad clamps the wire harness; then, the controller controls the electromagnet plate to de-energize and drives the synchronous electric telescopic rod to retract slightly, so that the inner arc clamping plate slightly opens.

[0021] S5: The electric push rod extends, moving the wire harness and the closing sleeve as a whole backward. The horn-shaped opening guides the closing sleeve to slide into the structural cylinder. The electromagnetic heating coil is energized to generate an alternating magnetic field, which induction heats the closing sleeve. The heat is conducted from the sleeve body to the tin plate interlayer on its inner wall, causing the tin layer to melt. The liquid tin, under capillary action, wets and fills the tiny gaps between the multiple wire ends. The infrared temperature sensor collects the sleeve temperature in real time and feeds it back to the controller.

[0022] S6: After heating is complete, the electric push rod retracts, pushing the wire harness and closing sleeve out of the structural cylinder. The arc-shaped rear extension guides the closing sleeve to slide between the inner arc plates on both sides. The synchronous electric telescopic rod closes again according to the preset secondary closing pressure, and the wire harness is compacted a second time under the dynamic condition that the molten solder has not completely solidified. Subsequently, the electric motor drives the rotating block to swing back and forth on the shaft seat, driving the laser welding head to scan and weld along the butt joint trajectory of the closing sleeve, and weld the closing joint of the left and right sleeves into an integral collar.

[0023] Compared with related technologies, the technical solution of the present invention has the following beneficial effects:

[0024] In this invention, a method and fixture for welding motor windings utilizes a welding clamping mechanism. Two sets of symmetrically arranged synchronous electric telescopic rods drive the structural support cover closer together, energizing the electromagnet plate inside the inner arc clamping plate to attract the left and right clamps, achieving rapid positioning and pre-closing of the clamps. A pressure sensor monitors the closing pressure in real time, ensuring precise and controllable closing force. The locking teeth and the locking grooves inside the mating slots interlock, forming a mechanical self-locking mechanism upon initial closing. This ensures the left and right clamps remain closed throughout subsequent heating, transfer, and pressing processes, avoiding the uneven wire distribution problems caused by inaccurate manual positioning and unstable closing force in traditional copper sleeve solutions. Meanwhile, the heat insulation layer thermally isolates the electromagnet plate from the inner arc plate. Combined with the active heat dissipation channel formed by the heat dissipation fins and heat dissipation fan, it effectively prevents the electromagnet plate from overheating due to heat radiation during induction heating, which would cause the magnetic force to weaken. This ensures that the jacket is reliably attracted and positioned throughout the entire cycle of heating, transfer and secondary closing, providing a precise positional reference for subsequent soldering and laser welding.

[0025] In this invention, a method and fixture for welding motor windings are described. Through a welding auxiliary mechanism, an electric push rod drives the lower and upper clamping plates to hold the wire harness. An electric lifting rod and a tension sensor work together to control the clamping force, preventing damage to the wire ends while ensuring the wire harness remains stable during transport. The structural cylinder is made of high-strength ceramic material. An electromagnetic heating coil on its outer wall generates an alternating magnetic field when energized, inductively heating the closing clamping sleeve inside the structural cylinder. The heat is conducted from the sleeve body to the tin plate interlayer on its inner wall, causing the tin layer to melt uniformly. The liquid tin, under capillary action, wets and fills the tiny gaps between the multiple wire ends, achieving metallurgical filling inside the wire harness—solving the problem of traditional copper sleeve cold pressing methods. The fundamental defects of the wire ends being only mechanical point contact with high contact resistance are addressed by placing an infrared temperature sensor at the rear axis of the structural cylinder to collect the jacket temperature in real time and feed it back to the controller. This enables closed-loop precise control of the heating temperature, preventing overheating and oxidation of the tin layer or insufficient wetting due to underheating. After heating, the electric push rod pulls the wire bundle and the closing jacket back between the inner arc plates. Simultaneously, the electric telescopic rod performs a second closing at a preset pressure. Under dynamic conditions where the molten tin has not yet completely solidified, the wire bundle is compacted a second time, squeezing out excess molten tin and air bubbles. This ensures a dense contact interface between the wire bundles and between the wire bundle and the inner wall of the jacket, thereby achieving tight consolidation within the multi-strand wire bundle while protecting the copper wires from high-temperature annealing.

[0026] In this invention, a method and fixture for welding motor windings are described. A locking welding mechanism is used, with a structural ring fitted onto the outer wall of the output end of a synchronous electric telescopic rod and moving with it. This ensures that the emitting end of the laser welding head remains aligned with the butt joint formed after the left and right jackets are closed. An electric motor drives a rotating block to swing on a shaft seat, causing the laser welding head to rapidly scan and weld along the butt joint trajectory, fusing the closure joint of the two half-jackets into a permanent integral collar. This laser sealing step makes the jacket a closed, rigid whole, with a mechanical locking capability far exceeding the interface pressure maintained by elastic deformation in traditional cold-pressed terminals. It prevents stress relaxation under high-frequency vibration and thermal cycling conditions during motor operation. Simultaneously, it integrates the internal conductive core formed by solder wetting with the external rigid sheath, achieving a triple connection guarantee mechanism of "solder filling conductivity + snap-fit ​​mechanical self-locking + laser sealing solidification," significantly improving the long-term electrical reliability and vibration resistance of the joint. Attached Figure Description

[0027] Figure 1 This is a three-dimensional structural diagram of a motor winding welding fixture proposed in this invention. Figure 1 ;

[0028] Figure 2 This is a three-dimensional structural diagram of a motor winding welding fixture proposed in this invention. Figure 2 ;

[0029] Figure 3 This is a schematic diagram of the three-dimensional structure of some components of a motor winding welding fixture proposed in this invention. Figure 1 ;

[0030] Figure 4 This is a schematic diagram of the three-dimensional structure of some components of a motor winding welding fixture proposed in this invention. Figure 2 ;

[0031] Figure 5 This is a three-dimensional disassembled structural diagram of a component of a motor winding welding fixture proposed in this invention;

[0032] Figure 6 This is a three-dimensional structural breakdown diagram of the welding clamping mechanism;

[0033] Figure 7 A three-dimensional structural breakdown diagram of the motor winding sleeve;

[0034] Figure 8 Schematic diagram of the three-dimensional structure of the structural support cover Figure 1 ;

[0035] Figure 9 A three-dimensional structural breakdown diagram of the structural support cover;

[0036] Figure 10 Schematic diagram of the three-dimensional structure of the structural support cover Figure 2 ;

[0037] Figure 11 A three-dimensional sectional view of the structural support cover;

[0038] Figure 12 A three-dimensional structural diagram of the welding auxiliary mechanism;

[0039] Figure 13 Schematic diagram of the three-dimensional structure of some components of the welding auxiliary mechanism Figure 1 ;

[0040] Figure 14 Schematic diagram of the three-dimensional structure of some components of the welding auxiliary mechanism Figure 2 ;

[0041] Figure 15 Schematic diagram of the three-dimensional structure of some components of the welding auxiliary mechanism Figure 3 ;

[0042] Figure 16 This is a three-dimensional structural diagram of the locking welding mechanism.

[0043] In the diagram: 1. Welding support base plate; 2. Structural support frame; 3. Controller; 4. Terminal block; 5. Welding clamping mechanism; 51. Synchronous electric telescopic rod; 52. Mounting plate; 53. Pressure sensor; 54. Central bearing plate; 55. Structural support cover; 56. Inspection top cover; 57. Left sleeve; 58. Right sleeve; 59. Tin plate interlayer; 510. Snap-fit ​​groove; 511. Snap-fit ​​teeth; 512. Butt joint groove; 513. Inner arc clamping plate; 514. Thermal insulation interlayer; 515. Electromagnetic plate; 516. Heat dissipation fins; 517. Cooling fan; 518. Air outlet; 519. Dustproof mesh plate; 520. Arc-shaped rear extension; 6. Welding auxiliary mechanism; 61. Support folding plate; 62. Electric push rod; 63. Lower clamping plate; 64. Electric lifting rod; 65. Upper clamping plate; 66. Rubber clamping pad; 67. Base; 68. Support rod; 69. Structural cylinder; 610. Trumpet-shaped arc mouth; 611. Electromagnetic heating coil; 612. Bending rod; 613. End seat; 614. Infrared temperature sensor; 7. Locking welding mechanism; 71. Structural ring; 72. Structural folding seat; 73. Shaft seat; 74. Rotating block; 75. Electric motor; 76. Laser welding head. Detailed Implementation

[0044] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0045] First embodiment: Please refer to the following: Figures 1-11 In the first embodiment of the present invention, a motor winding welding fixture includes a welding support base plate 1, a welding clamping mechanism 5, a motor winding cover, a welding auxiliary mechanism 6, and a locking welding mechanism 7. A structural support frame 2 is fixedly installed on the upper side of the welding support base plate 1. The welding clamping mechanism 5 includes two sets of symmetrically arranged synchronous electric telescopic rods 51 and a structural support cover 55. An inner arc clamping plate 513 is fixedly connected to the inner side of the structural support cover 55. An electromagnet plate 515 is fixedly installed on the inner side of the inner arc clamping plate 513. Air outlets 518 are symmetrically opened on the side of the structural support cover 55. The motor winding cover is disposed between the two sets of inner arc clamping plates 513. The motor winding cover includes a left clamping sleeve 57 and a right clamping sleeve 58. A tin plate interlayer 59 is provided on the inner side of both the left clamping sleeve 57 and the right clamping sleeve 58. A snap-fit ​​groove 510 is provided at the end of the left clamping sleeve 57. Snap-fit ​​teeth 511 are evenly distributed on the snap-fit ​​groove 510. A docking groove 512 is provided at the end of the right clamping sleeve 58.

[0046] Through the above-described configuration, the welding clamping mechanism 5 achieves automated positioning and pre-closing of the left clamp 57 and the right clamp 58. During operation, the controller 3 instructs two symmetrically arranged synchronous electric telescopic rods 51 to extend synchronously, driving the structural support cover 55 to move closer together. The electromagnet plate 515 is energized to generate magnetic attraction, attracting the left clamp 57 and the right clamp 58 to the inner sides of the inner arc clamping plates 513 on both sides, achieving rapid initial positioning of the clamps without manual connection. As the synchronous electric telescopic rods 51 continue to extend, the locking groove 510 at the end of the left clamp 57 and the docking groove 512 at the end of the right clamp 58 engage with each other. The locking teeth 511 and the locking grooves inside the docking grooves 512 form a mechanical self-locking mechanism, ensuring that the left and right clamps remain closed during subsequent transfer, heating, and secondary closure processes, avoiding problems such as wire harness skewing or uneven distribution caused by unstable closing force.

[0047] Specifically, the synchronous electric telescopic rod 51 is fixedly installed on the inner wall of the structural support frame 2. The output end face of the synchronous electric telescopic rod 51 is screwed with an installation plate 52. The side of the installation plate 52 is fixedly installed with a pressure sensor 53. The pressure sensor 53 is fixedly connected to the structural support cover 55 with a middle support plate 54. The controller 3 and the terminal block 4 are fixedly installed on the outer wall of the structural support frame 2.

[0048] Through the above-described configuration, the synchronous electric telescopic rod 51 provides driving force for the clamp closing and secondary pressing. The mounting plate 52 is screwed to the output end face of the synchronous electric telescopic rod 51, serving as a transitional component for force transmission. The pressure sensor 53 is fixedly installed on the side of the mounting plate 52, monitoring the closing pressure in real time and feeding it back to the controller 3 to ensure precise and controllable closing force, preventing excessive pressure from damaging the wiring harness or insufficient pressure from causing incomplete closing. The intermediate bearing plate 54 connects the pressure sensor 53 to the structural support cover 55, uniformly transmitting the closing force to the inner arc clamping plate 513. The controller 3 is fixedly installed on the outer wall of the structural support frame 2, used for overall logic control and parameter setting. The terminal block 4 is used for connecting external power supplies and signal lines.

[0049] Specifically, several snap-fit ​​grooves are evenly distributed on the inner side of the docking slot 512, a cooling fan 517 is fixedly installed on the side of the structural support cover 55, the air outlet of the cooling fan 517 is connected to the inside of the structural support cover 55, a dustproof net is provided at the air inlet of the cooling fan 517, a dustproof net plate 519 is fixedly installed at the air outlet 518, and the air duct of the air outlet 518 is symmetrically inclined.

[0050] With the above-described configuration, the locking groove on the inner side of the docking slot 512 and the locking tooth 511 cooperate to form a self-locking structure, ensuring that the left and right jackets do not come apart after closing. The cooling fan 517 is fixedly installed on the side of the structural support cover 55, and its air outlet is connected to the inside of the structural support cover 55 to drive airflow for active heat dissipation. The dustproof net installed at the air inlet of the cooling fan 517 prevents external impurities from being sucked in, and the dustproof net plate 519 fixedly installed at the air outlet 518 prevents debris from entering the inside of the cover. The air outlet 518 air duct is symmetrically inclined, so that the air outlet direction blows precisely onto the closing jacket surface located between the inner arc clamps 513 on both sides - this inclination angle ensures that the air outlet accurately covers the outer wall of the jacket, achieving directional heat dissipation.

[0051] Specifically, a heat insulation interlayer 514 is provided between the electromagnet plate 515 and the inner arc clamping plate 513, and several heat dissipation fins 516 are evenly distributed on the back of the electromagnet plate 515. An inspection top cover 56 is screwed onto the top of the structural support cover 55, and an arc-shaped rear extension 520 is fixedly installed on the rear side of the structural support cover 55.

[0052] With the above-described configuration, the heat insulation layer 514 is positioned between the electromagnet plate 515 and the inner arc clamping plate 513, thermally isolating them to prevent the high temperature of the jacket during induction heating from being conducted through the inner arc clamping plate 513 to the electromagnet plate 515, thus preventing magnetic attenuation. The heat dissipation fins 516 are evenly distributed on the back of the electromagnet plate 515, increasing the heat dissipation area. Together with the cooling fan 517, they form an active heat dissipation channel, ensuring that the electromagnet plate 515 maintains a suitable operating temperature during prolonged operation. The inspection top cover 56 is screwed to the top of the structural support cover 55, facilitating internal maintenance and repair. The arc-shaped rear extension 520 is fixedly installed on the rear side of the structural support cover 55, providing a guide channel for the heated closing jacket to exit from the structural cylinder 69, ensuring that the jacket can smoothly slide between the inner arc clamping plates 513 on both sides.

[0053] The aforementioned cooling fan 517 drives airflow into the air inlet of the structural support cover 55. The airflow preferentially flows through the heat dissipation fins 516 on the back of the electromagnet plate 515, carrying away the heat generated by the electromagnet plate 515 itself (purpose 1). Subsequently, the airflow is discharged from the air outlet 518. Since the air outlet 518 is symmetrically inclined, the discharged airflow blows precisely onto the surface of the closing jacket located between the inner arc clamps 513 on both sides. Although the temperature of this airflow has increased, it still has a significant temperature difference compared to the closing jacket, which is about 200~260°C after induction heating. This enables gentle, non-rapid cooling of the jacket and the tin layer inside it (purpose 2): accelerating the solidification of the tin layer to improve production efficiency, while avoiding rapid cooling that could cause coarsening of the tin layer crystals or thermal stress cracks, and simultaneously reducing the surface temperature of the jacket to a suitable range for subsequent laser welding. This cooling system cleverly achieves the dual functions of active cooling of the electromagnet plate and temperature control and cooling of the welded workpiece through the same fan and air duct design.

[0054] Second embodiment: Please refer to the following: Figures 12-15 In this embodiment, the welding auxiliary mechanism 6 includes an electric push rod 62 and a structural cylinder 69. The electric push rod 62 and the structural cylinder 69 are located on both sides of the structural support cover 55. A lower clamping plate 63 is fixedly installed on the output end of the electric push rod 62. An upper clamping plate 65 is provided on the upper side of the lower clamping plate 63. An electromagnetic heating coil 611 is sleeved on the outer wall of the structural cylinder 69. An infrared temperature sensor 614 is provided at the rear axis position of the structural cylinder 69. The outer side of the infrared temperature sensor 614 is coated with a heat-insulating and magnetic-insulating coating.

[0055] Through the above-described configuration, the welding auxiliary mechanism 6 achieves stable clamping, precise transfer, and induction heating of the wire harness. The electric push rod 62 drives the lower clamping plate 63 and upper clamping plate 65 to move to the wire harness position for clamping. The structural cylinder 69 serves as an isolation cavity for induction heating. When the electromagnetic heating coil 611 mounted on its outer wall is energized, it generates an alternating magnetic field, which induction heats the closing jacket entering the structural cylinder 69. The heat is conducted from the jacket body to the tin plate interlayer 59 on its inner wall, causing the tin layer to melt uniformly. The liquid tin, under capillary action, wets and fills the tiny gaps between the multiple wire ends, achieving metallurgical bonding between the copper wires inside the wire harness. This solves the fundamental defect of traditional cold-pressing methods where the wire ends only have mechanical point contact and high contact resistance. An infrared temperature sensor 614, located at the rear shaft center of the structural cylinder 69, collects the jacket temperature in real time and feeds it back to the controller 3, achieving closed-loop precise control of the heating temperature. The heat-insulating and magnetic-insulating coating on the outside of the infrared temperature sensor 614 effectively isolates high-temperature radiation and alternating magnetic field interference, ensuring accurate temperature acquisition.

[0056] Specifically, the bottom of the electric push rod 62 is fixedly connected to a support folding plate 61, which is screwed onto the upper side of the welded support base plate 1. The bottom of the lower clamping plate 63 is fixedly installed with an electric lifting rod 64. The output end of the electric lifting rod 64 slides through the lower clamping plate 63 and extends to its upper side. A tension sensor is fixedly connected between the output end of the electric lifting rod 64 and the upper clamping plate 65. Rubber pads 66 are fixedly adhered to the inner sides of both the lower clamping plate 63 and the upper clamping plate 65.

[0057] With the above-described configuration, the supporting plate 61 securely mounts the electric push rod 62 to the upper side of the welded supporting base plate 1, ensuring the stability of the electric push rod 62's position during operation. The lower clamping plate 63 and upper clamping plate 65, fixedly mounted at the output end of the electric push rod 62, constitute the clamping execution end. An electric lifting rod 64, fixedly mounted at the bottom of the lower clamping plate 63, slides its output end through the lower clamping plate 63 and extends to its upper side, pushing the upper clamping plate 65 towards the lower clamping plate 63 to achieve the clamping action. A tension sensor fixedly connected between the output end of the electric lifting rod 64 and the upper clamping plate 65 monitors the clamping force in real time and feeds it back to the controller 3, achieving closed-loop precise control of the clamping force. This prevents excessive clamping force from damaging the surface of the de-coated wire end or insufficient clamping force from causing the wire harness to slip during transport. Rubber pads 66, fixedly bonded to the inner surfaces of the lower clamping plate 63 and the upper clamping plate 65, provide cushioning protection, further preventing damage to the wire end surface.

[0058] Specifically, the structural cylinder 69 has symmetrically arranged flared arc mouths 610 at both ends. The structural cylinder 69 is made of high-strength ceramic material. Several support rods 68 are fixedly connected to the bottom of the structural cylinder 69. A base 67 is fixedly installed at the bottom of the support rods 68. The base 67 is screwed onto the upper side of the welded support base plate 1. A bent rod 612 is fixedly connected to the rear end of the structural cylinder 69. An end seat 613 is fixedly connected to the end of the bent rod 612. An infrared temperature sensor 614 is fixedly installed on the end seat 613.

[0059] Through the above-described configuration, the symmetrically arranged flared arches 610 at both ends of the structural cylinder 69 provide a smooth guide cone surface. When the electric push rod 62 moves the wire harness and the closing sleeve backward, the closing sleeve will sag slightly on the wire harness due to its non-rigid nature. The guiding effect of the cone surface of the flared arches 610 ensures that the closing sleeve can smoothly slide into the structural cylinder 69 without jamming. The structural cylinder 69 is made of high-strength ceramic material, and its non-magnetic and non-conductive properties prevent it from heating up in an alternating magnetic field, thus avoiding interference with the induction heating process. The bottom of the structural cylinder 69 is fixedly installed on the base 67 via a support rod 68. The base 67 is screwed to the upper side of the welded support base plate 1 to ensure the stability of the structural cylinder 69. The bent rod 612 and end seat 613 fixedly connected to the rear end of the structural cylinder 69 stably install the infrared temperature sensor 614 at the axial position of the structural cylinder 69, ensuring the accuracy and consistency of temperature detection.

[0060] It should be noted that the structural cylinder 69 is made of high-strength ceramic material. The purpose of this is that when the electromagnetic heating coil 611 is energized to generate an alternating magnetic field, if the structural cylinder 69 is made of metal, it will heat up due to the eddy current effect, which will not only divert the electromagnetic energy and reduce the heating efficiency of the closed jacket, but may also damage the structural cylinder 69 due to overheating. The ceramic material is non-magnetic and non-conductive, and does not heat up in the alternating magnetic field, ensuring that all the electromagnetic energy is used to heat the closed jacket that enters the interior of the structural cylinder 69, namely the whole after the left jacket 57 and the right jacket 58 are closed.

[0061] Third embodiment: Please refer to the following: Figure 16 In this embodiment, the locking welding mechanism 7 includes a structural ring 71, structural folding seats 72 are symmetrically fixedly installed on the upper and lower sides of the structural ring 71, a shaft seat 73 is fixedly installed on the inner side of the structural folding seat 72, a rotating block 74 is rotatably installed on the inner side of the shaft seat 73, and a laser welding head 76 is fixedly installed on the rotating block 74.

[0062] Through the above-described configuration, the locking welding mechanism 7 achieves precise alignment and rapid laser sealing of the butt joint of the closing jackets. The structural ring 71 is fixedly sleeved on the outer wall of the output end of the synchronous electric telescopic rod 51, moving synchronously with the telescopic rod. This ensures that the emitting end of the laser welding head 76, fixedly mounted on the structural ring 71, remains precisely aligned with the butt joint formed after the left and right jackets 57 and 58 are closed, eliminating the need for an additional alignment adjustment mechanism. The structural folding seat 72 is symmetrically fixedly mounted on the upper and lower sides of the structural ring 71. A rotating block 74 is rotatably mounted within a bearing seat 73 fixedly mounted on its inner side, and the laser welding head 76 is fixedly mounted on the rotating block 74. An electric motor 75 is fixedly mounted on the outer wall of the bearing seat 73, its output end being fixedly connected to the rotating shaft of the rotating block 74. This drives the rotating block 74 to reciprocate on the bearing seat 73, causing the laser welding head 76 to rapidly scan and weld along the butt joint trajectory of the closing jackets, fusing the two half-jackets together into a permanent integral collar.

[0063] Specifically, the structural ring 71 is fixedly sleeved on the outer wall of the output end of the synchronous electric telescopic rod 51, and the electric motor 75 is fixedly installed on the outer wall of the shaft seat 73. The output end of the electric motor 75 is fixedly connected to the rotating shaft of the rotating block 74. The emitting end of the laser welding head 76 is aligned with the butt joint formed after the left jacket 57 and the right jacket 58 are closed, and is used to perform laser welding on the closed butt joint.

[0064] With the above-described configuration, the structural ring 71 serves as the mounting base for the locking welding mechanism 7. Its placement on the outer wall of the output end of the synchronous electric telescopic rod 51 ensures a fixed relative position between the laser welding head 76 and the butt joint of the closing jacket. The electric motor 75 provides the oscillating power, driving the rotating block 74 to reciprocate within the bearing 73, thus enabling the laser welding head 76 to scan along the butt joint trajectory. The emitting end of the laser welding head 76 is aligned with the butt joint formed after the left and right jackets 57 and 58 are closed, and is used for laser welding of the closed butt joint. This laser sealing step fuses the two half-jackets into a closed, rigid, integral ring, providing permanent structural locking. Its mechanical clamping capacity far exceeds the interface pressure maintained by the elastic deformation of metal in traditional cold-pressed terminals. It does not experience stress relaxation under high-frequency vibration and repeated thermal cycling conditions, significantly improving the long-term reliability of the joint.

[0065] The present invention provides a method for welding motor windings as follows:

[0066] S1. Clip adsorption positioning: Place the left clip 57 and the right clip 58 inside the two sets of inner arc clamping plates 513 respectively. The controller 3 starts the electromagnet plate 515 to generate magnetic attraction, which adsorbs the left clip 57 and the right clip 58 onto the inner arc clamping plates 513 on both sides, thereby realizing the rapid positioning of the clips.

[0067] S2. Jacket Closure and Self-Locking: The controller 3 drives two sets of symmetrically arranged synchronous electric telescopic rods 51 to extend synchronously, causing the structural support cover 55 to move closer to each other, so that the snap-fit ​​groove 510 at the end of the left jacket 57 and the docking groove 512 at the end of the right jacket 58 dock together. The snap-fit ​​teeth 511 and the snap-fit ​​grooves on the inner side of the docking groove 512 engage to form a mechanical self-locking, realizing the pre-closure of the jacket. During the closure process, the pressure sensor 53 monitors the closure pressure in real time and feeds it back to the controller 3 to ensure that the closure force is accurate and controllable.

[0068] S3. Wire harness insertion: Pass the multi-strand wire ends, after the paint removal treatment, through the lower clamping plate 63 and the upper clamping plate 65, and feed them forward into the closed left clamping sleeve 57 and right clamping sleeve 58, so that the wire ends protrude from the front end of the clamping sleeve by an appropriate length. This protruding section is uniformly and neatly cut in subsequent processes.

[0069] S4. Wire Harness Pre-compression: Controller 3 restarts the synchronous electric telescopic rod 51, continuing to close it according to the preset pre-compression force. This applies radial pre-pressure to the inner walls of the left and right sleeves 57 and 58 on the internal multi-strand wire ends. This pre-compression force causes the wire ends to move closer together and be initially shaped within the sleeve cavity, eliminating large gaps between the wire harnesses. Simultaneously, it ensures that the wire ends are evenly distributed within the sleeve cavity, preventing relative movement or skewness of the wire ends during subsequent transport. After pre-compression is completed... The controller 3 activates the electric lifting rod 64 to push the upper clamping plate 65 towards the lower clamping plate 63, and works with the tension sensor to achieve closed-loop control of the clamping force, so that the rubber clamping pad 66 clamps the wire harness. Subsequently, the controller 3 controls the electromagnet plate 515 to be de-energized and drives the synchronous electric telescopic rod 51 to retract slightly, so that the inner arc clamping plate 513 slightly opens, releasing the clamping and adsorption of the inner arc clamping plate 513 on the closing sleeve, so that the electric push rod 62 can send the closing sleeve backward from between the inner arc clamping plates 513.

[0070] S5. Induction Heating and Solder Immersion: The electric push rod 62 extends, moving the wire harness and the closing sleeve backward as a whole. During the movement, since the wire harness is a non-rigid body, the closing sleeve will sag or deflect slightly on the wire harness. At this time, the symmetrically arranged flared arc 610 at the front end of the structural cylinder 69 provides a smooth guide cone surface, guiding the closing sleeve to slide smoothly into the interior of the structural cylinder 69 without jamming. The electromagnetic heating coil 611 is energized to generate an alternating magnetic field, which induction heats the closing sleeve. The heat is conducted from the sleeve body to the solder plate interlayer 59 on its inner wall, so that the solder layer is heated to 200~260°C. The liquid tin melts uniformly within the 0℃ range, and under capillary action, it wettes and fills the interior of the wire bundle along the tiny gaps between the multiple wire ends. Because the wire ends have been pre-compressed in step S4 to bring them closer together, distribute them evenly, and eliminate large gaps, the liquid tin can penetrate into the capillary gaps between the wire ends evenly and stably, without causing turbulence or local accumulation of molten tin due to irregular large gaps between the wire ends. The infrared temperature sensor 614 collects the jacket temperature in real time and feeds it back to the controller 3 to achieve closed-loop control of the heating temperature, avoiding overheating and oxidation of the tin layer or insufficient wetting due to insufficient heating.

[0071] S6. Secondary Pressing and Laser Sealing: After heating, the electric push rod 62 retracts, pushing the wire harness and closing sleeve out of the structural cylinder 69. The arc-shaped rear extension 520 fixedly installed on the rear side of the structural support cover 55 guides the closing sleeve to slide between the inner arc clamps 513 on both sides. The synchronous electric telescopic rod 51 closes again according to the preset secondary closing pressure, and performs secondary compaction on the wire harness under the dynamic condition that the molten solder has not completely solidified. This secondary closing pressure is greater than the pre-compression force in step S4, and applies pressure to the wire harness through the inner walls of the left clamp 57 and the right clamp 58. Higher radial pressure is applied to squeeze liquid tin into all the tiny gaps inside the wire harness, while squeezing out residual air bubbles and excess tin between the wires, creating a dense, pore-free contact interface between the wire ends and between the wire ends and the inner wall of the jacket. Subsequently, the electric motor 75 drives the rotating block 74 to oscillate back and forth on the shaft seat 73, driving the laser welding head 76 to perform rapid scanning welding along the butt joint trajectory of the closing jacket, welding the closing joint of the left jacket 57 and the right jacket 58 into a permanent integral collar, so that the closing jacket obtains permanent structural locking.

[0072] In the above method, the cooling fan 517 operates continuously during the operation of the electromagnet plate 515, driving the airflow to preferentially flow through the heat dissipation fins 516 on the back of the electromagnet plate 515, actively dissipating heat from the electromagnet plate 515 to prevent magnetic force attenuation. Simultaneously, the airflow is discharged through the air outlet 518 and blown onto the surface of the closing jacket, achieving gentle heat dissipation from the heated jacket and internal tin layer, accelerating tin layer solidification and reducing the jacket surface temperature to a suitable range for laser welding. Throughout the welding process, the copper material of the wire harness does not undergo high-temperature melting and recrystallization, thus maintaining its grain structure and mechanical properties. Through the coordinated four-step process of "pre-compression shaping, induction heating solder wetting, dynamic secondary compaction, and laser sealing and solidification," tight consolidation within the multi-strand wire bundle and long-term reliability of the joint are achieved.

[0073] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An electrical machine winding welding tool, characterized in that, include: Welded support base plate (1), and a structural support frame (2) is installed on the upper side of the welded support base plate (1); The welding clamping mechanism (5) includes two sets of symmetrically arranged synchronous electric telescopic rods (51) and a structural support cover (55). An inner arc clamping plate (513) is installed on the inner side of the structural support cover (55), and an electromagnet plate (515) is installed on the inner side of the inner arc clamping plate (513). Air outlets (518) are symmetrically opened on the side of the structural support cover (55). A motor winding sleeve is disposed between two sets of inner arc clamps (513). The motor winding sleeve includes a left clamp (57) and a right clamp (58). A tin plate interlayer (59) is provided on the inner side of both the left clamp (57) and the right clamp (58). A snap-fit ​​groove (510) is provided at the end of the left clamp (57). Snap-fit ​​teeth (511) are evenly distributed on the snap-fit ​​groove (510). A mating snap-fit ​​groove (512) is provided at the end of the right clamp (58). Welding auxiliary mechanism (6); Locking welding mechanism (7).

2. The motor winding welding tool of claim 1, wherein, The welding auxiliary mechanism (6) includes an electric push rod (62) and a structural cylinder (69). The electric push rod (62) and the structural cylinder (69) are located on both sides of the structural support cover (55). A lower clamping plate (63) is installed on the output end of the electric push rod (62). An upper clamping plate (65) is provided on the upper side of the lower clamping plate (63). An electromagnetic heating coil (611) is sleeved on the outer wall of the structural cylinder (69). An infrared temperature sensor (614) is provided at the rear axis position of the structural cylinder (69). The outer side of the infrared temperature sensor (614) is coated with a heat-insulating and magnetic-insulating coating.

3. The motor winding welding tool of claim 1, wherein, The locking welding mechanism (7) includes a structural ring (71), on which structural folding seats (72) are symmetrically installed on the upper and lower sides. A bearing seat (73) is installed on the inner side of the structural folding seat (72). A rotating block (74) is rotatably installed on the inner side of the bearing seat (73). A laser welding head (76) is installed on the rotating block (74).

4. The motor winding welding tool of claim 1, wherein, The synchronous electric telescopic rod (51) is installed on the inner wall of the structural support frame (2). An installation plate (52) is installed on the output end face of the synchronous electric telescopic rod (51). A pressure sensor (53) is installed on the side of the installation plate (52). A middle support plate (54) is connected between the pressure sensor (53) and the structural support cover (55). A controller (3) and a terminal block (4) are installed on the outer wall of the structural support frame (2).

5. The motor winding welding tool of claim 1, wherein, The inner side of the docking slot (512) is provided with several snap-fit ​​grooves. The side of the structural support cover (55) is equipped with a heat dissipation fan (517). The air outlet of the heat dissipation fan (517) is connected to the inside of the structural support cover (55). A dustproof net is provided at the air inlet of the heat dissipation fan (517). A dustproof net plate (519) is installed at the air outlet (518). The air duct of the air outlet (518) is symmetrically inclined.

6. The motor winding welding tool of claim 1, wherein, A heat insulation interlayer (514) is provided between the electromagnet plate (515) and the inner arc clamp (513). A number of heat dissipation fins (516) are evenly distributed on the back of the electromagnet plate (515). An inspection top cover (56) is screwed onto the top of the structural support cover (55). An arc-shaped rear extension (520) is fixedly installed on the rear side of the structural support cover (55).

7. The motor winding welding tool of claim 2, wherein, The electric push rod (62) is provided with a support folding plate (61) at the bottom. The support folding plate (61) is installed on the upper side of the welded support base plate (1). An electric lifting rod (64) is installed at the bottom of the lower clamping plate (63). The output end of the electric lifting rod (64) slides through the lower clamping plate (63) and extends to its upper side. A tension sensor is installed between the output end of the electric lifting rod (64) and the upper clamping plate (65). Rubber pads (66) are fixedly bonded to the inner sides of the lower clamping plate (63) and the upper clamping plate (65).

8. The motor winding welding tool of claim 2, wherein, The structural cylinder (69) has symmetrically arranged horn-shaped openings (610) at both ends. Several support rods (68) are fixedly connected to the bottom of the structural cylinder (69). A base (67) is installed at the bottom of the support rod (68). The base (67) is installed on the upper side of the welding support base plate (1). A bent rod (612) is connected to the rear end of the structural cylinder (69). An end seat (613) is installed at the end of the bent rod (612). The infrared temperature sensor (614) is installed on the end seat (613).

9. The motor winding welding tool of claim 3, wherein, The structural ring (71) is sleeved and installed on the outer wall of the output end of the synchronous electric telescopic rod (51). An electric motor (75) is installed on the outer wall of the bearing seat (73). The output end of the electric motor (75) is connected to the rotating shaft of the rotating block (74). The emitting end of the laser welding head (76) is aligned with the butt joint formed after the left jacket (57) and the right jacket (58) are closed, and is used to perform laser welding on the closed butt joint.

10. A method of motor winding welding, based on the motor winding welding tooling of any of claims 1-9, characterized in that, Includes the following steps: S1: Place the left sleeve (57) and the right sleeve (58) inside the two sets of inner arc plates (513) respectively. The controller (3) starts the electromagnet plate (515) to generate magnetic attraction, and the left sleeve (57) and the right sleeve (58) are attracted to the inner sides of the inner arc plates (513) on both sides respectively. S2: The controller (3) drives two sets of symmetrically arranged synchronous electric telescopic rods (51) to extend synchronously, causing the structural support cover (55) to move closer to each other, so that the snap-fit ​​groove (510) at the end of the left sleeve (57) and the docking groove (512) at the end of the right sleeve (58) dock together, and the snap-fit ​​teeth (511) and the snap-fit ​​groove inside the docking groove (512) bite together to form a mechanical self-locking; during the closing process, the pressure sensor (53) monitors the closing pressure in real time and feeds it back to the controller (3). S3: Pass the multi-strand wire end that has been de-coated through the lower clamp (63) and the upper clamp (65), and feed it forward into the closed left clamp (57) and right clamp (58) so that the wire end protrudes from the front end of the clamp. S4: The controller (3) restarts the synchronous electric telescopic rod (51) and continues to close it according to the preset pre-tightening force, so that the inner walls of the left sleeve (57) and the right sleeve (58) apply radial pre-pressure to the internal multi-strand wire ends; after the pre-tightening is completed, the controller (3) starts the electric lifting rod (64) to push the upper clamping plate (65) to move towards the lower clamping plate (63), so that the rubber clamping pad (66) clamps the wire harness; then, the controller (3) controls the electromagnet plate (515) to de-energize and drive the synchronous electric telescopic rod (51) to shrink slightly, so that the inner arc clamping plate (513) opens slightly; S5: The electric push rod (62) extends and moves the wire harness and the closing sleeve backward as a whole. The horn-shaped arc (610) guides the closing sleeve to slide into the structure cylinder (69). The electromagnetic heating coil (611) is energized to generate an alternating magnetic field, which induction heats the closing sleeve. The heat is conducted from the sleeve body to the tin plate interlayer (59) on its inner wall, causing the tin layer to melt. The liquid tin wets and fills the tiny gaps between the multi-strand wire ends under capillary action. The infrared temperature sensor (614) collects the sleeve temperature in real time and feeds it back to the controller (3). S6: After heating is completed, the electric push rod (62) retracts, pushing the wire harness and closing sleeve out of the structural cylinder (69). The arc-shaped rear extension (520) guides the closing sleeve to slide between the inner arc plates (513) on both sides. The synchronous electric telescopic rod (51) closes again according to the preset secondary closing pressure, and the wire harness is compacted twice under the dynamic condition that the molten solder has not completely solidified. Subsequently, the electric motor (75) drives the rotating block (74) to swing back and forth on the bearing seat (73), driving the laser welding head (76) to scan and weld along the butt joint trajectory of the closing sleeve, and weld the closing joint of the left sleeve (57) and the right sleeve (58) into an integral collar.

Images