Inductor Coil Welding Sequence for Alignment and Joint Strength
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Solution Overview
Problem
Existing inductor coil production methods face challenges such as welding defects, metal deformation, high equipment costs, and alignment accuracy issues, particularly with small pin diameters, in both solid-state and laser welding technologies.
Innovation Solution
A combined inductor coil welding equipment and process that integrates solid-state and laser welding, utilizing a feeding system, solid-state welding device, and laser welding device to ensure precise alignment and stable connection, with mechanisms for clamping, pressing, and visual inspection to enhance welding quality and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solid-state welding is used for inductor coil production, then welding speed and efficiency are improved, but welding quality and joint strength deteriorate due to excessive heat generation and metal deformation
Solution Approach 1:
The welding process is divided into two distinct stages: solid-state welding for initial connection and laser welding for quality enhancement. This segmentation allows each welding method to perform its optimal function - solid-state welding provides fast initial bonding while laser welding ensures high-quality joint strength without excessive heat generation.
Solution Approach 2:
Solid-state welding is performed first to establish a preliminary connection between the inductor coil and conductive plate. This preliminary action secures the components in position, enabling subsequent laser welding to focus on quality enhancement without worrying about component misalignment.
2Manufacturing precision
If laser welding is used for inductor coil production, then welding quality and precision are improved, but equipment cost and technical barriers increase
Solution Approach 1:
Laser welding is applied selectively only to enhance the quality of the welding joint after solid-state welding has established the initial connection. This partial action approach allows the system to benefit from high-quality laser welding where needed while avoiding the cost of using laser welding for the entire process.
Solution Approach 2:
The system merges solid-state welding and laser welding into a single integrated equipment platform. This combination allows the system to leverage the advantages of both welding methods - the cost-effectiveness and speed of solid-state welding combined with the precision and quality of laser welding - while sharing common infrastructure such as the feeding system, positioning mechanisms, and control systems.
3Volume of moving object
If small pin diameter is used for inductor coil, then product miniaturization is achieved, but alignment accuracy requirements increase significantly
Solution Approach 1:
The system replaces manual alignment and positioning with automated mechanical feeding and positioning mechanisms. The feeding system automatically delivers inductor coils and conductive plates to precise positions, eliminating human error and ensuring consistent alignment accuracy even for small pin diameters.
Solution Approach 2:
The system incorporates visual inspection mechanisms that detect the position and alignment of inductor coils and conductive plates. This feedback allows the system to identify and correct alignment deviations before welding, ensuring high precision even when working with small pin diameters for miniaturized products.
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
The integrated system achieves high-quality, reliable welding of inductor coils with improved alignment accuracy, reduced defects, and increased production efficiency by ensuring stable connection and precise positioning, leveraging the advantages of both welding methods.
Implementation Method 1
the solid-state welding mechanism uses resistance heating to pre-weld and fix two pins of the inductor coil to corresponding positions on the conductive plate
Implementation Method 2
The laser welding is used for performing enhancement welding at a welding joint between the inductor coil and the conductive plate
Data Source
AI summary
An inductor coil welding equipment includes a feeding system, a solid-state welding device, and a laser welding device. The laser welding device is installed behind the solid-state welding device, and the feeding system is used to sequentially send the inductor coil and the conductive plates to the solid-state welding device and the laser welding device. The solid-state welding device is used to pre-weld and fix the inductor coil to the conductive plates, forming a welded inductance conductive plate. Laser welding is used for performing enhancement welding at a welding joint between the inductor coil and the conductive plate.