Bent Conductor Segment with Preassembled Hard Solder
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Solution Overview
Problem
The existing methods for connecting bent conductor segments in stator windings of electric machines, such as laser welding, are complex and costly, with stringent requirements that can lead to defects and failure if not executed perfectly, while hard soldering methods are time- and cost-intensive due to the need for manual attachment of soldering clips.
Innovation Solution
The implementation of bent conductor segments with preassembled hard solder on one free end, allowing for simplified and cost-effective connections by melting and cooling the solder after bending the segments into place, eliminating the need for manual attachment of soldering clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to connect conductor segments, then connection strength and electrical conductivity are improved, but manufacturing complexity and cost increase due to stringent requirements on welding point precision and material quality
Solution Approach 1:
The patent applies preliminary action by pre-attaching hard solder to the free ends of conductor segments during the winding production process. This preliminary preparation eliminates the need for complex laser welding operations during stator assembly, as the segments are pre-configured for simple hard soldering connection. The solder is applied in advance to ensure proper positioning and reduce assembly complexity.
Solution Approach 2:
The patent replaces the laser welding mechanical/thermal system with a simpler hard soldering process. Instead of using precise laser welding equipment that requires strict control of positioning, temperature, and material quality, the invention uses traditional hard soldering with pre-applied solder, which is less complex and more tolerant of manufacturing variations.
2Reliability
If hard soldering with manual attachment of soldering clips is used, then connection reliability is improved, but production time and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-attaching hard solder to the free ends of conductor segments during the winding production process. This preliminary preparation eliminates the need for manual attachment of soldering clips during stator assembly, significantly reducing production time and labor costs while maintaining the reliability benefits of hard soldering.
Solution Approach 2:
The patent merges the solder attachment operation with the winding production process. Instead of performing solder attachment as a separate manual step during stator assembly, the solder is applied in advance during automated winding production, combining two operations into one efficient process and eliminating redundant manual labor.
3Manufacturing precision
If laser welding is used, then connection precision is improved, but the risk of defects and failure increases due to stringent requirements on component position, gaps, and material quality
Solution Approach 1:
The patent uses hard solder as a disposable sacrificial material that absorbs manufacturing tolerances and imperfections. The soft nature of hard solder allows it to fill gaps and accommodate position variations between conductor segments, preventing the propagation of defects that would occur with rigid laser welding. This approach trades the precision requirement for increased reliability.
Solution Approach 2:
The patent changes the physical parameters of the connection process by using hard soldering instead of laser welding. This changes the temperature profile, pressure requirements, and material interaction characteristics, making the process more tolerant of manufacturing variations and reducing the risk of defects while maintaining adequate connection precision.
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 simplifies the soldering process, reduces production time and costs, and ensures reliable electrical conductivity by preassembling the segments for hard soldering, thereby enhancing the reliability and efficiency of stator winding assembly.
Implementation Method 1
The hard solder is melted locally and subsequently cooled
Implementation Method 2
The hard solder is melted locally and subsequently cooled
Implementation Method 3
the free ends of the conductor segments can be bent over such that a first free end of a first conductor segment is assigned to a second free end of a second adjacent conductor segment. The hard solder is melted locally and subsequently cooled.
Data Source
AI summary
A bent conductor segment (1a, 1b, 1c) for a stator winding of a stator of an electric machine is formed from a bent metal wire and has at least one first straight section (10a, 10b, 10c) with a first free end (11a, 11b, 11c) and a second free end (13a, 13b, 13c). One of the free ends (11a, 11b, 11c, 13a, 13b, 13c) of the conductor segment (1a, 1b, 1c) comprises a hard solder (2a, 2b, 2c) cohesively connected to said free end (11a, 11b, 11c, 13a, 13b, 13c).