Segment Coil Laser Welding Using End-Part Imaging Feedback
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Solution Overview
Problem
Existing coil welding methods for segment coils face challenges in achieving high accuracy due to the need for precise alignment and contact of end parts, which results in poor workability and difficulty in eliminating non-uniformities in end part positions.
Innovation Solution
A coil welding device and method that acquire end part information from images of the coils, set welding conditions based on this information, and use laser irradiation to integrate the end parts, allowing for accurate welding even with position displacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the end parts of segment coils are arranged in contact with each other for laser welding, then welding can be achieved using a simple irradiation path, but the workability deteriorates due to the difficulty of precise alignment and constant contact positioning
Solution Approach 1:
The patent applies preliminary action by acquiring end part information (position, shape, size) through imaging before welding begins. This pre-acquisition of data allows the system to prepare welding conditions in advance, eliminating the need for precise manual alignment during the welding process itself. The coils can be positioned more loosely beforehand, and the precise welding parameters are determined automatically from the captured images.
Solution Approach 2:
The patent implements feedback by using the acquired end part information to automatically adjust and set welding conditions. The imaging system provides real-time feedback about the actual positions and shapes of the coil end parts, and this information is used to modify the welding path and parameters dynamically, ensuring accurate welding without requiring perfect initial positioning.
2Ease of operation
If the end parts of segment coils are separated from each other to improve workability, then alignment becomes easier, but welding cannot be achieved using conventional irradiation paths
Solution Approach 1:
The patent applies dynamics by making the welding system adaptable to varying coil positions and separations. Instead of requiring fixed, contact-aligned positions, the system dynamically adjusts the laser irradiation path and welding conditions based on the actual separated positions of the coil end parts. This dynamic adaptation allows welding of separated parts while maintaining welding quality.
Solution Approach 2:
The patent changes parameters by modifying the welding conditions (irradiation path, power, speed) based on the acquired end part information. When coils are separated, the system automatically adjusts these parameters to account for the gap and positioning variations, enabling successful welding of separated parts that would fail with conventional fixed-path welding.
3Device complexity
If laser irradiation is applied along a fixed predetermined path, then the welding process is simple to control, but welding accuracy deteriorates when coil positions vary due to non-uniformity in end part locations
Solution Approach 1:
The system performs preliminary imaging and measurement of the coil end parts before welding. This pre-action captures the actual positions and dimensions, allowing the welding path to be customized for each specific configuration rather than using a single fixed path for all cases.
Solution Approach 2:
The patent dynamically changes welding parameters including the irradiation path, laser power, and scanning speed based on the measured end part characteristics. This parameter adaptation maintains welding accuracy across varying coil positions while keeping the overall process automated and controlled, rather than requiring complex manual intervention.
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 solution enables high-accuracy welding of coil end parts with reduced need for precise initial alignment, improving workability and allowing for more reliable integration of segment coils.
Implementation Method 1
the end parts of the segment coils 55a and 55b are welded together by laser welding
Implementation Method 2
the end parts of the segment coils 55a and 55b are melted in substantially the same way and to be integrated
Data Source
AI summary
A control unit 5 functions as an end part information acquisition means that acquires, from an end part image obtained of a coil, various kinds of end part information for each end part to be welded of each portion. That is, the control unit 5 is able to acquire end part information from an image of the end parts of a pair of segment coils to be welded. The control unit 5 functions as a welding condition setting means that sets a welding condition on the basis of the end part information obtained. The control unit 5, with respect to each end part pair, controls the operation and the like of a laser irradiation unit 11 on the basis of the welding condition set, so that the end parts of the pair of segment coils to be welded are irradiated with laser and integrated by welding.