Rotating Electrical Machine Core Welding Productivity
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Solution Overview
Problem
The productivity of manufacturing rotating electrical machine cores is limited by the emission angle and size constraints of laser or electron beams during welding processes, which restrict the axial length and size of through holes in stacked electromagnetic steel plates.
Innovation Solution
A core manufacturing method involving the stacking of electromagnetic steel plates and welding from both sides in the axial direction, with overlapping welding regions to enhance productivity and fixing force, and gradual energy increase during welding to stabilize quality and reduce spatter and blow holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding is performed from one side only, then the emission angle and size constraints of laser or electron beams are satisfied, but productivity is reduced
Solution Approach 1:
The welding process is divided into multiple segments: first welding from one end toward the center, then second welding from the other end toward the center, with the welding regions overlapping in the axial direction. This segmentation allows each welding operation to work within acceptable emission angle and size constraints while collectively achieving complete welding of the through hole.
Solution Approach 2:
The solution transitions from single-direction welding to bidirectional welding along the axial dimension. By adding welding operations from both ends of the stack in the axial direction, the process overcomes the limitations of single-sided welding and improves productivity without violating beam emission constraints.
2Strength
If welding regions overlap in the axial direction, then fixing force is enhanced, but welding complexity increases
Solution Approach 1:
The first and second welding regions are merged in the axial direction with overlapping coverage. This merging of welding zones ensures that the entire inner surface of the through hole is adequately welded, and the overlap provides redundant bonding that enhances the overall fixing force of the electromagnetic steel plates.
3Manufacturing precision
If output energy is gradually increased during welding, then welding quality is stabilized and spatter is reduced, but welding time increases
Solution Approach 1:
The output energy of the welding device is preliminarily increased in a controlled manner before the main welding operation. This preliminary energy increase prepares the material for optimal welding conditions, preventing spatter and blow holes from forming during the subsequent welding process, thereby stabilizing welding quality.
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 method improves productivity and ensures a sufficient fixing force while stabilizing welding quality by overlapping welding regions and controlling energy output, allowing for efficient production of rotating electrical machine cores.
Implementation Method 1
in the case where an inner surface of a through hole formed in the stack of the electromagnetic steel plates is welded by using a process such as laser welding, electron beam welding
Implementation Method 2
in the case where an inner surface of a through hole formed in the stack of the electromagnetic steel plates is welded by using a process such as laser welding, electron beam welding
Data Source
AI summary
A core manufacturing that includes stacking a plurality of electromagnetic steel plates in an axial direction; performing first welding on an inner surface of a through hole formed in a stack of the electromagnetic steel plates and continuous in the axial direction, the first welding being performed toward a first side in the axial direction which is one side in the axial direction; and performing second welding on the inner surface of the through hole, the second welding being performed toward a second side in the axial direction which is the other side in the axial direction.