Adaptive Welding Energy Control for Conductor End Groups
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Solution Overview
Problem
Existing methods for welding conductor ends in electrical machine components, such as stators, face challenges in ensuring high weld seam quality due to variability in pin positions and boundary conditions, leading to inconsistent energy input and potential for defective connections, which can result in entire stators being rejected even if only one connection is faulty.
Innovation Solution
A method and device that detect the relative position and size parameters of conductor ends using optical measurement techniques like optical coherence tomography, allowing for real-time adjustment of welding energy input to achieve consistent weld bead dimensions and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed welding energy input is used, then welding process is simple, but weld seam quality becomes inconsistent due to position variability
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the welding energy input based on the detected relative position of conductor ends. The control device modifies welding parameters (energy input) in response to position variations, ensuring consistent weld seam quality despite position variability. This resolves the contradiction by making the welding parameter adaptive rather than fixed.
Solution Approach 2:
The patent implements feedback control by detecting the relative position of conductor ends and using this information to control the welding energy input. The measurement device provides real-time position data to the control device, which adjusts welding parameters accordingly. This closed-loop feedback system ensures consistent weld quality while managing process complexity through automated control.
2Strength
If welding energy input is increased to compensate for unfavorable positions, then connection strength improves, but risk of defects increases due to excessive energy
Solution Approach 1:
The patent uses parameter changes to precisely control welding energy input based on detected conductor end positions. Rather than using fixed high energy to compensate for all position variations, the system dynamically adjusts energy levels to match actual position conditions. This ensures sufficient connection strength while avoiding excessive energy that causes defects.
Solution Approach 2:
The patent applies local quality by tailoring the welding energy input to the specific local condition of each conductor end pair's relative position. Each welding operation receives customized energy input based on its detected position, ensuring optimal connection strength for that specific location without subjecting it to unnecessary excessive energy that could cause defects.
3Manufacturing precision
If real-time position detection and energy adjustment is implemented, then weld quality consistency improves, but device complexity and measurement requirements increase
Solution Approach 1:
The patent implements feedback control where the measurement device detects conductor end positions and the control device uses this information to adjust welding energy input in real-time. This closed-loop system ensures consistent weld quality by continuously monitoring position and adapting welding parameters, resolving the contradiction through automated feedback-based control.
Solution Approach 2:
The patent replaces manual or fixed mechanical welding control with an automated optical measurement and electronic control system. The measurement device (optical system) detects positions and the control device (electronic system) adjusts welding parameters, substituting complex mechanical adjustment mechanisms with automated sensing and control, thereby achieving precision while managing complexity through automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures consistent weld seam quality by adapting energy input based on real-time measurements, reducing the risk of defective connections and minimizing scrap rates by maintaining a constant connection cross-section, even under unfavorable conditions.
Implementation Method 1
detecting a relative position of a first conductor end and a second conductor end of the conductor end group
Implementation Method 2
welding device for applying welding energy to a conductor end group
Data Source
Figure 1~2b
Figure 2c~3
Figure 4a~5d
AI summary
To improve quality and reduce rejects in the mass production of components (12) of an electric machine equipped with coil windings, the invention provides a welding method for welding conductor ends (16, 16a, 16b) of a component (12) for an electric machine, grouped into conductor end groups (18), comprising: a) detecting the relative position of a first conductor end (16a) and a second conductor end (16b) of a conductor end group (18) and b) controlling the input of welding energy to the conductor ends (16, 16a, 16b) to be welded, depending on the detected relative position. A welding device (14) for carrying out the welding method is also proposed.