Variable Cross-Section Conductor Segment Rolling
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Solution Overview
Problem
The existing methods for producing conductor segments with varying cross sections or shapes are not compatible with standard processes, particularly for non-rectangular cross sections, leading to inefficiencies and material loss, especially with copper, which is costly and requires manual handling.
Innovation Solution
A method using at least four rolls, with two work rolls and two backup rolls, allowing for continuous adjustment of curvature, thickness, and shape, utilizing inductive heating to control material properties, enabling the production of conductor segments with variable dimensions and shapes without significant material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard rolling processes are used for producing conductor segments with varying cross sections, then production efficiency is maintained, but material loss increases and manufacturing precision deteriorates
Solution Approach 1:
The patent applies dynamics by making the rolling gap continuously variable along the length of the conductor segment. Instead of using fixed rolling gaps for uniform cross-sections, the rolling gap is dynamically adjusted to produce varying thickness profiles. This allows the production of conductor segments with optimized cross-sections that match the actual current density distribution, reducing material usage while maintaining production efficiency through continuous rolling processes.
2Shape
If conductor segments with non-rectangular cross sections are produced using existing methods, then shape requirements are met, but compatibility with standard processes is lost and device complexity increases
Solution Approach 1:
The patent transitions from two-dimensional rolling (constant thickness) to three-dimensional rolling by introducing a longitudinal dimension to the rolling gap variation. The rolling gap becomes a function of both transverse position and longitudinal position along the conductor segment. This dimensional extension enables the production of complex varying cross-sections including non-rectangular shapes while maintaining compatibility with standard rolling mill infrastructure through programmable control of the rolling gap profile.
3Adaptability or versatility
If manual handling and production methods are used for conductor segments, then manufacturing flexibility is maintained, but productivity decreases and labor intensity increases
Solution Approach 1:
The patent replaces manual handling and mechanical production methods with an automated rolling system controlled by computer programs. The rolling gap profile is programmably adjusted along the length of the conductor segment, enabling automatic production of various cross-section shapes without manual intervention. This substitution maintains manufacturing flexibility through software control while dramatically increasing productivity and eliminating manual labor requirements.
4Manufacturing precision
If inductive heating is applied to control material properties during rolling, then manufacturing precision improves, but energy consumption increases
Solution Approach 1:
The patent utilizes parameter changes by applying inductive heating to temporarily alter the physical properties of the copper material during the rolling process. By heating the copper to specific temperatures, the material becomes more ductile and easier to form, allowing for precise dimensional control and complex cross-section shapes. The heating is applied locally and temporarily, and the material returns to its original state after rolling, minimizing overall energy consumption while achieving superior manufacturing 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
Enables efficient, automatic production of conductor segments with varying dimensions and shapes within a short cycle time, improving compatibility with electric machine production and reducing material waste, while allowing for precise control over curvature and thickness.
Implementation Method 1
An inductive heater (15) heats the copper bar, before it passes through the work rolls (11, 12), to a working temperature that is above its recrystallization temperature of approximately 200° C., but under its melting point of approximately 1085° C.
Data Source
AI summary
A method for producing a conductor segment includes: passing a copper bar in a predetermined direction of movement through a rotating first work roll and a second work roll rotating in the opposite direction to the first work roll; rotating a first backup roll in the opposite direction to the first work roll to brace the first work roll against the copper bar with an adjustable first force directed perpendicularly to the direction of movement; rotating at least one second backup roll in the opposite direction to the second work roll to brace the second work roll against the copper bar with an adjustable second force directed counter to the first force; and adjusting the first and second forces such that the work rolls give the conductor bar a thickness that varies along its length. Also described is a corresponding device and a corresponding method for producing an electric machine.