Inductive Winding Cable-End Welding with Wettability Grooves
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Solution Overview
Problem
Existing methods for coupling ends of electrical cables in inductive windings often result in incomplete removal of dielectric layers, leading to weak and aesthetically flawed welds, with CO2 lasers being inefficient and fiber lasers being costly, while also risking damage to the conducting material.
Innovation Solution
A coupling method involving surface texturing with longitudinal and transverse grooves on the cable ends to enhance wettability, allowing for efficient removal of dielectric layers and ensuring strong, defect-free welds through controlled melting and flow of molten metal during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CO2 laser is used to remove dielectric layer, then cost is reduced, but removal quality is poor and residues remain
Solution Approach 1:
The method applies preliminary mechanical abrasion to remove the bulk of the dielectric layer before welding, creating initial surface grooves that enhance subsequent laser ablation effectiveness and ensure complete residue elimination without requiring expensive fiber lasers
Solution Approach 2:
The invention replaces expensive fiber laser ablation with a combination of mechanical abrasion and CO2 laser treatment, using mechanical means to prepare the surface and then applying thermal energy to complete the dielectric removal and create the desired surface texture for welding
2Reliability
If fiber laser is used to remove dielectric layer, then complete removal is achieved, but cost increases and conducting material is damaged
Solution Approach 1:
Mechanical abrasion is performed first to remove the majority of the dielectric layer and create surface grooves, so that subsequent CO2 laser treatment only needs to address residual dielectric material, preventing overheating and damage to the conducting core
Solution Approach 2:
The method creates localized surface grooves through mechanical abrasion that concentrate the CO2 laser energy precisely where dielectric material remains, ensuring complete removal in those specific areas while avoiding exposure of the conducting material to excessive thermal energy
3Manufacturing precision
If surface grooves are created to enhance wettability, then weld quality improves, but additional processing steps are required
Solution Approach 1:
The invention combines mechanical abrasion and CO2 laser treatment into a single integrated process that simultaneously creates surface grooves for enhanced wettability and removes dielectric residues, eliminating the need for separate processing steps
Solution Approach 2:
The CO2 laser replaces dedicated mechanical grooving equipment by creating the same surface texture and grooves through thermal ablation, simplifying the overall process while achieving the same weld quality enhancement
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
The method achieves a strong, stable, and aesthetically superior coupling of cable ends with complete removal of dielectric residues, ensuring high-quality welds and mechanical strength, while being cost-effective and potentially automated.
Implementation Method 1
by laser ablation (using CO2 lasers or fiber lasers). It should be noted that CO2 lasers are adapted to remove dielectric material
Implementation Method 2
Fiber lasers, which cost more, carry out a removal of material that also includes the surface layers of the electrical conductor, and therefore they ensure the complete elimination of the dielectric layer
Implementation Method 3
which are inserted into the specific recesses present in the ferromagnetic cores of the machine under construction. These pieces are known as 'hairpins' in the jargon and they require, before their insertion into the respective recesses, preparatory operations to remove the layer of surface insulation dielectric material from their end surfaces (which can subsequently be coupled, generally using welding methods)
Data Source
AI summary
A coupling method for ends of electrical cables of an inductive winding. The cables are constituted by an electrically conducting core covered by a layer of dielectric material. The method comprises a first step of juxtaposing side faces of distinct ends that are arranged substantially parallel, and a second step of welding the ends that have the faces juxtaposed. The method consists of providing, before the first step, at least one engraved groove on the surface of at least one side face. The at least one groove will determine an asymmetry in the respective wettability on the face, consisting of a greater wettability in the longitudinal direction than in the transverse direction.