Coil-to-Busbar Pressure Welding for Low-Resistance Connections
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Solution Overview
Problem
The existing methods for connecting coils to wiring members in stator manufacturing, such as welding or screwing, lead to increased resistance, complexity, and the need for additional components, limiting downsizing and efficiency in motor production.
Innovation Solution
A coil unit is created using pressure welding between a coil made of a first metal material, such as aluminum, and a busbar made of a second metal material, like copper, to simplify the connection and reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or screwing is used to connect coil to busbar, then connection strength is improved, but resistance at connection portion increases
Solution Approach 1:
The invention changes the connection method from conventional welding or screwing to friction stir welding, which fundamentally alters the connection parameters. This process creates a metallurgical bond with lower resistance by mechanically mixing and forging the materials at the interface, transforming the connection state from high-resistance (welding/screwing) to low-resistance (friction stir welding) while maintaining strong mechanical strength
2Strength
If conventional connection methods are used, then connection strength is achieved, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates the busbar from the conventional connection system. Instead of connecting a separate busbar to the coil terminal, the coil terminal itself is directly connected to the stator core through friction stir welding. This removes the busbar component and simplifies the overall configuration while maintaining connection strength
3Reliability
If additional connection components are used, then connection reliability is improved, but manufacturing time increases
Solution Approach 1:
The invention merges multiple operations into a single friction stir welding process. The coil terminal connection to the stator core is achieved in one step without separate busbar attachment, alignment, or fastening operations. This consolidation maintains connection reliability while significantly reducing manufacturing time and process complexity
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 connection configuration, reduces the number of components and steps, minimizes resistance, and achieves a stable and efficient connection, enabling downsizing of stator manufacturing apparatus and reducing weight and cost.
Implementation Method 1
A welded portion between the end portion and the busbar is configured by pressure welding with end surfaces butted against each other
Data Source
AI summary
A coil unit and a manufacturing method of the same are provided which are configured to simplify the configuration of a connection portion between a coil and a wiring material (busbar), to simplify the number of components and a connection step, to prevent an increase in resistance at the connection portion, and to achieve a good connection state. A busbars-welded coil includes a coil made of a wound first metal material, and busbars made of a second metal material connected to end portions of the coil. A welded portion between the end portion of the coil and the busbar is configured by pressure welding with end surfaces butted against each other.