Flat Wire Stator Connections With Partial Stripping for Laser Welding
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Solution Overview
Problem
Existing methods for connecting flat wire ends in stators of electrical machines face challenges in achieving a minimal axial height while meeting electrical specifications, particularly due to thermal damage from laser welding and insufficient clearance and creepage distance.
Innovation Solution
A method for partially stripping insulation on three sides of flat wire ends, leaving one side intact, and connecting them using a laser without filler material, ensuring a precise and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the winding overhang height is reduced to minimize axial length, then the axial installation space is optimized, but thermal damage to insulation material occurs during laser welding
Solution Approach 1:
The insulation material is selectively removed only from specific regions where electrical connection is required, while retaining insulation in other regions. This local differentiation allows laser welding to be performed without thermal damage to insulation, enabling reduced axial length while protecting insulation integrity.
Solution Approach 2:
The insulation material is removed in advance from the regions where laser welding will occur, before the actual connection process. This preliminary preparation allows the laser to weld the conductor ends without inadvertently heating and damaging the insulation material, thus enabling shorter axial dimensions while protecting insulation.
2Productivity
If more insulation material is removed to facilitate laser connection, then connection efficiency is improved, but electrical insulation between adjacent wires deteriorates
Solution Approach 1:
The insulation removal is performed selectively only in the regions where electrical connection is required between adjacent conductors. The insulation is retained in all other regions to maintain electrical insulation. This localized approach enables efficient laser connection while preserving the necessary electrical insulation between adjacent wires.
3Ease of manufacture
If complete stripping of insulation is performed on all sides, then manufacturing simplicity is improved, but time consumption and material loss increase
Solution Approach 1:
Instead of completely stripping insulation from all sides of the conductor ends, the method selectively removes insulation only from the specific regions where electrical connection is required. This localized stripping approach reduces both the time consumption and material loss associated with the stripping process, while still achieving the necessary connection quality.
Solution Approach 2:
The insulation stripping is performed partially rather than completely - only the necessary portions are removed to enable connection. This partial action approach reduces the overall time and material required for stripping while still achieving sufficient connection quality for laser welding.
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 reduces stripping time, improves insulation, and maintains electrical specifications, allowing for a higher fill factor and efficient use of axial space in stators.
Implementation Method 1
connecting them using a laser
Implementation Method 2
connecting them using a laser without filler material
Data Source
Figure 1
Figure 2~5
Figure 6~7
AI summary
The invention relates to a method for connecting free flat wire ends (4, 5) with a substantially rectangular cross section with four sides (41, 42, 43, 44) of a stator of an electrical machine, comprising the steps of: stripping a first flat wire end (4), sheathed with an insulation material, such that partial stripping is carried out at least on three sides (41, 42, 43) and such that the insulation material remains complete on a fourth side (44) of the first flat wire end (4), and electrically connecting the stripped first flat wire end (4) on the completely stripped side (43) to a second flat wire end (5).