Laser Welding Shaped Conductor End Areas Using Concave Trajectories
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Solution Overview
Problem
Existing methods for welding end portions of shaped conductors in rotary electric machines face challenges in forming stable, conductive joints with low energy input to prevent coating melting.
Innovation Solution
The method involves guiding a laser beam along concave trajectories between the start and end points of the end areas of the shaped conductors, allowing for efficient material utilization and reduced energy input, thereby forming a careful weld seam while preserving the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam is guided along conventional trajectories (e.g., rectangular paths along edges) for welding end areas of shaped conductors, then the weld seam can be formed, but high energy input causes coating melting and material damage
Solution Approach 1:
The patent applies curved concave trajectories instead of straight or rectangular paths for laser beam guidance. The concave curvature allows the laser beam to naturally direct energy toward corner regions and central portions of end areas, distributing heat more effectively and reducing peak energy density that causes coating melting while maintaining reliable weld formation
2Reliability
If sufficient energy is input into the end areas to form stable welded joints, then good electrical conductivity is achieved, but the coating of shaped conductors melts
Solution Approach 1:
The concave trajectory design concentrates laser energy precisely where needed - in corner regions and central portions of end areas - rather than distributing it uniformly along edge paths. This localized energy delivery achieves the necessary thermal conditions for stable welded joints and good electrical conductivity while avoiding excessive energy input that would melt the coating
3Ease of manufacture
If a closed rectangular trajectory is used along the edges of end areas, then the welding process is simple, but corner regions and central portions are not adequately covered
Solution Approach 1:
The concave curved trajectories are designed to naturally sweep across corner regions and central portions of end areas, ensuring complete weld seam coverage. The curvature geometry inherently directs the laser beam through areas that would be missed by rectangular edge paths, achieving comprehensive coverage without significantly complicating the manufacturing 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 approach results in a stable welded joint with good electrical conductivity and lower energy input, effectively addressing the limitations of previous methods by efficiently utilizing material and minimizing coating damage.
Implementation Method 1
welding each pair of the end areas by means of a laser beam which is guided on the end areas of the pair along a first trajectory and a second trajectory
Implementation Method 2
The laser light is guided over several trajectories... welding each pair of the end areas by means of a laser beam
Data Source
AI summary
A method for producing an active part (1) for a rotary electric machine (101), comprising the following steps:providing a core (2) for the active part (1) and shaped conductors (6) inserted into the core;joining together, in each case, two of the end areas (9) so that the two end areas (9) form a pair (10); andwelding each pair (10) of the end areas (9) by means of a laser beam which is guided on the end areas (9) of the pair (10) along a first trajectory (13).