Enamel-Insulated Conductor Joining via Ultrasonic Compaction and Laser Welding
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Solution Overview
Problem
Existing methods for producing coil windings for electric motors and transformers require additional connecting elements and large space for ultrasonic welding, leading to increased manufacturing costs and reduced node density.
Innovation Solution
A method involving ultrasonic compacting to remove insulating lacquer followed by laser welding to connect conductor ends without additional elements, allowing for high node density and efficient production of coil windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic welding is used to join conductor ends, then reliable electrical connections are achieved, but large installation space is required
Solution Approach 1:
The patent divides the joining process into two distinct stages: ultrasonic compaction (performed before winding) and ultrasonic welding (performed after winding). This segmentation allows each process to be optimized independently - compaction creates initial contact in a spacious environment, while welding creates the final reliable connection in the constrained winding space, thus resolving the contradiction between connection reliability and space requirements.
Solution Approach 2:
The patent applies ultrasonic compaction as a preliminary action before the conductor ends are inserted into the winding. This pre-compaction creates initial mechanical and electrical contact between conductor ends in advance, when sufficient space is available. The subsequent welding then only needs to strengthen this pre-established connection, requiring minimal space and ensuring reliable electrical connections in the final product.
2Reliability
If additional connecting elements such as sleeves or end lugs are used, then mechanical and electrical connections are achieved, but production effort and manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the need for additional connecting elements (sleeves, end lugs, ferrules) from the traditional joining process. By applying ultrasonic compaction and welding directly to the conductor ends themselves, the method achieves reliable mechanical and electrical connections without any intermediate components, thereby simplifying manufacturing and reducing costs while maintaining connection reliability.
Solution Approach 2:
The conductor ends perform the joining function themselves through ultrasonic compaction and welding, without requiring external connecting elements. The process utilizes the conductor material's own properties to create the mechanical and electrical connection, making the system self-sufficient and eliminating the need for additional components that would increase manufacturing complexity.
3Use of energy by stationary object
If conductor ends are deformed before joining, then welding temperature is reduced, but additional process steps are required
Solution Approach 1:
The patent applies ultrasonic compaction as a preliminary action that pre-heats and pre-compresses the conductor ends before the actual welding process. This preliminary action reduces the energy required during the subsequent welding step by preparing the material in advance, creating optimal conditions for low-temperature welding while maintaining a streamlined two-stage process.
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 enables the production of coil windings with high node density and copper fill factor, reducing manufacturing costs and space requirements while ensuring reliable electrical connections.
Implementation Method 1
the lacquered conductor ends and/or lacquered stranded wire ends to be joined are ultrasonically compacted to remove insulating lacquer
Implementation Method 2
a metallurgical bond is created between the conductor ends and/or stranded wire ends to be joined by means of laser welding
Data Source
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AI summary
In order to allow for as high a density of connecting nodes as possible in as small an amount of space as possible, the invention proposes that ultrasonic compacting of the conductor end pieces to be connected is first performed in order to remove insulation enamel and, in a subsequent step, a cohesive connection is made by means of laser welding between the conductor end pieces to be connected.