Electric Machine Frame Laser Welding Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing electric machine frames, such as casting, are costly and inefficient for small batches, often requiring complex welding processes that lead to measurement errors and increased machining needs, as well as complicating maintenance due to structural stiffness and accessibility issues.
Innovation Solution
A method involving the use of laser welding to form sheet metal parts around a stator, with a cooling element and flanges, allowing for the manufacture of electric machine frames without casting molds, enabling easier adjustment and reduced machining, and facilitating easier maintenance by allowing bearing replacement from within the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting methods are used to manufacture frame parts, then manufacturing cost is reduced for large batches, but mould storage and logistics costs considerably increase total costs
Solution Approach 1:
The patent replaces expensive, reusable casting moulds with disposable sheet metal parts that are laser-cut and welded. This eliminates the need for costly mould storage and logistics infrastructure while maintaining cost-effectiveness for small production batches. The sheet metal components can be easily stored and transported without specialized facilities.
Solution Approach 2:
The invention changes the manufacturing approach from bulk casting to individual sheet metal assembly. This parameter change allows production to be scaled down to small batches without requiring expensive mould infrastructure, as each frame can be assembled from pre-cut sheet metal components using automated laser cutting and welding.
2Ease of manufacture
If traditional welding methods are used to form metal parts, then frames can be manufactured without casting, but measuring errors and tension increase requiring extra machining
Solution Approach 1:
The patent replaces traditional mechanical welding processes with laser welding technology. This substitution eliminates the measuring errors and tension problems associated with conventional welding methods. The laser welding process provides precise, controlled heating that minimizes thermal distortion and eliminates the need for subsequent machining operations to correct welding defects.
Solution Approach 2:
The sheet metal parts are pre-cut and pre-bent to their final dimensions using laser technology before assembly. This preliminary precision work ensures that when the parts are welded together, minimal additional machining is required. The pre-forming process accounts for thermal expansion and contraction, ensuring final dimensions are accurate.
3Device complexity
If head plates are fixed to the inner cylindrical jacket, then structure is formed, but the structure may not be stiff enough requiring additional stiffening members
Solution Approach 1:
The patent merges the stiffening function directly into the sheet metal frame structure itself. The laser-cut and welded sheet metal components are designed with inherent geometric stiffness and structural optimization, eliminating the need for separate stiffening members. The frame structure is integrated to provide both support and rigidity simultaneously.
Solution Approach 2:
The invention uses composite construction combining sheet metal layers welded together to create a structure with high stiffness-to-weight ratio. The multi-layer sheet metal assembly provides structural rigidity without requiring additional stiffening members, as the layered composite structure itself delivers the necessary mechanical properties.
4Strength
If complex welding and machining processes are used, then frames can be manufactured with good structural integrity, but production costs increase and small batches become less affordable
Solution Approach 1:
The patent replaces complex mechanical welding and machining processes with automated laser technology. Laser cutting and welding provide consistent, high-quality joints with minimal post-processing required. This automation reduces labor costs and increases production efficiency, making small batch manufacturing economically viable while maintaining structural integrity.
Solution Approach 2:
The invention adopts a make-to-order production approach where frames are manufactured only when needed rather than producing large batches in advance. This eliminates the need for expensive tooling amortization over large production volumes. The sheet metal components can be quickly produced and assembled, allowing economical small batch production while maintaining high structural quality through consistent laser processing.
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 reduces production costs, simplifies the manufacturing process, and enhances maintenance accessibility by eliminating the need for intermediate storage and additional stiffening members, enabling cost-effective production of small batches with improved structural integrity and ease of maintenance.
Implementation Method 1
a first sheath of sheet metal is formed around the stator which sheath is attached to the stator by laser welding, as well as a cooling element which is attached to the first sheath by laser welding
Data Source
Figure 1~3
Figure 4~5
Figure 6~9
AI summary
A method for manufacturing the frame (1) of an electric machine (9) in which method a stator (8) is formed. In addition, in the method the first sheath (91) of sheet metal is formed around the stator (8) which sheath is attached to the stator by laser welding, as well as a cooling element (93) is formed which element is attached to the first sheath by laser welding. The electric machine (1), in turn, comprises at least a frame (9), a stator (8) attached to the frame, an axis (6), a rotor (7) attached to the axis and the front flange (3) to which a bearing casing (11) has been fitted in order to fit the bearing (10) used to support the axis. Bearing casing (11) has been fitted into the front flange (3) in such a manner that the bearing (10) can be placed into the bearing casing from inside the frame (9). In addition, the invention relates to the frame of an electric machine.