Electric Machine Laser Welding Metal Ring Protection
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Solution Overview
Problem
The combination of a plastic connector component and a metal pole housing and cover in existing electrical machines does not provide reliable heat dissipation and electromagnetic compatibility (EMC) shielding, and the laser welding process poses a risk of damaging sensitive components with high-energy input.
Innovation Solution
A metal ring is strategically placed inside the joint gap between the pole housing and the metal cover to absorb scattered laser beams during welding, ensuring they do not penetrate and damage internal components, while an axial spring element secures the metal ring and connector housing, enhancing EMC shielding and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is used to join the metal cover to the pole housing, then welding efficiency and strength are improved, but scattered laser beams can penetrate the housing and damage sensitive internal components
Solution Approach 1:
A metal ring is introduced as an intermediary component positioned between the laser welding zone and the internal components. This metal ring absorbs scattered laser beams, preventing them from penetrating into the housing and damaging sensitive components while allowing the welding process to proceed efficiently.
Solution Approach 2:
The metal ring is strategically positioned to convert the harmful scattered laser radiation into beneficial heat absorption. By placing the metal ring in the path of scattered laser beams, the harmful radiation is absorbed and dissipated as heat in the metal ring, protecting internal components while maintaining welding efficiency.
2Ease of manufacture
If a plastic connector component is used, then manufacturing flexibility and cost are improved, but heat dissipation and EMC shielding are insufficient
Solution Approach 1:
The housing structure employs a composite design combining plastic and metal materials. The plastic connector component provides manufacturing flexibility and cost benefits, while the integrated metal ring and metal cover provide superior heat dissipation and electromagnetic compatibility shielding, creating a hybrid structure that leverages the advantages of both materials.
Solution Approach 2:
Different regions of the housing structure use different materials optimized for their specific functions. The plastic connector component is used where manufacturing flexibility is needed, while metal components (metal ring and metal cover) are strategically positioned where heat dissipation and EMC shielding are critical, achieving local optimization of material properties.
3Strength
If metal components are welded together, then structural strength is improved, but the risk of laser beams damaging internal components increases
Solution Approach 1:
The metal ring serves as a protective intermediary component positioned between the laser welding zone and internal components. It absorbs scattered laser beams during the welding process, preventing penetration damage to sensitive components while allowing the metal cover to be securely welded to the pole housing for structural strength.
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 configuration effectively protects sensitive components from laser damage, ensures reliable welding, and provides robust electromagnetic shielding, creating a vibration-resistant and efficient heat dissipation system.
Implementation Method 1
laser beams scattered during laser welding are effectively absorbed by the arrangement of a metal ring as radiation protection on the inside of the joint gap between the pole housing and the metal cover
Implementation Method 2
laser beams scattered during laser welding are effectively absorbed by the arrangement of a metal ring as radiation protection
Data Source
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AI summary
The invention relates to an electric machine (10), in particular an electronically commutated (EC) motor, and a method for producing same, comprising a pole housing (15) in which a stator (16) and a rotor (18) are accommodated, and a plug housing (33) made of plastic and having an integrated connection plug (37) is arranged axially on an open side (31) of the pole housing (15), wherein the plug housing (33) is surrounded by a metal cover (81) over its entire perimeter, which is sealingly welded to the open side (31) of the pole housing (15) by means of a peripheral laser weld seam (90), wherein an uninterrupted peripheral metal ring (88) is arranged as a beam protector radially inside the laser weld seam (90), which metal ring is positioned in the beam path of a laser (91) which can penetrate into the internal space of the electric machine (10) through a joining gap between the pole housing (15) and the metal cover (81) during laser welding.