Laser Welding of Electric Machine Conductor Ends Without Local Manipulation
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Solution Overview
Problem
Existing methods for welding conductor ends on large electrical machine components, such as stators, require significant effort and time due to the need for local manipulation, like rotation of the component or movement of the laser optics, which limits processing efficiency and increases cycle times.
Innovation Solution
A device and method utilizing a stationary laser and illumination system that allows for simultaneous detection and welding of multiple conductor ends across a large area without moving the component or laser optics, using a scanning device to direct the laser beam and a gas flow to manage smoke and particles, enabling efficient welding of large stators without local manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If local manipulation (rotation of component or movement of laser optics) is used to weld conductor ends on large electrical machine components, then welding coverage is improved, but process time and complexity increase
Solution Approach 1:
Instead of moving the laser optics or rotating the component to achieve welding coverage (conventional approach), the patent inverts the approach by using a stationary laser and moving the workpiece (component) through the laser beam path. This inversion eliminates the need for complex laser positioning systems while maintaining full welding coverage of large electrical machine components.
Solution Approach 2:
The patent replaces the mechanical system of moving laser optics with a simpler mechanical system of moving the workpiece on a rotary table. This substitution reduces system complexity by eliminating精密 laser positioning mechanisms while achieving the same welding coverage through workpiece rotation.
2Area of stationary object
If local manipulation (rotation of component or movement of laser optics) is used to weld conductor ends, then welding coverage is improved, but device complexity increases
Solution Approach 1:
The patent inverts the conventional approach by making the laser stationary and the workpiece movable. This inversion dramatically simplifies the device complexity by eliminating the need for complex laser positioning systems, rotary joints for lasers, and associated control mechanisms, while still achieving complete welding coverage through workpiece rotation.
Solution Approach 2:
The patent substitutes a complex mechanical laser positioning system with a simple workpiece rotation mechanism. The laser remains fixed on the optical bench, and a rotary table moves the component into position, replacing精密 laser manipulation mechanisms with a straightforward rotational positioning system.
3Productivity
If stationary laser with workpiece rotation is used for welding, then process efficiency is improved, but illumination and detection complexity increases
Solution Approach 1:
The patent merges the illumination device and optical detection device into an integrated system that rotates together with the workpiece. This combining of functions into a single rotating assembly simplifies the overall system architecture while maintaining the ability to illuminate and detect conductor ends at all positions during the welding process.
Solution Approach 2:
The patent introduces a camera as an intermediary detection device that captures images of the conductor ends. The camera, positioned on the rotating assembly, optically detects the conductor end positions and transmits this information to a controller, which then directs the laser to the appropriate locations. This intermediary detection system enables precise welding without requiring direct mechanical positioning of the laser.
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 significantly reduces process times and complexity by eliminating the need for local manipulation, allowing for faster and more efficient welding of large electrical machine components with increased output and potential cost savings.
Implementation Method 1
an illumination device for illuminating the conductor end arrangement, an optical detection device for detecting the position of the illuminated conductor ends
Implementation Method 2
a laser device which can direct a laser beam depending on the detected position onto each group of conductor ends to be welded together
Implementation Method 3
a laser device which can direct a laser beam depending on the detected position onto each group of conductor ends to be welded together
Implementation Method 4
a gas flow to manage smoke and particles
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
The invention relates to a device (22.2) and a method for welding conductor ends (24) arranged in a conductor end assembly (42) on a component (26) of an electric machine. To enable the reliable, faster, and significantly more cost-effective processing of larger conductor end assemblies (42), the device (22.2) comprises a lighting device (28.2) for illuminating the conductor end assembly (42), an optical detection device (30.2) for detecting the position of the illuminated conductor ends (24), a laser device (32.2) that can direct a laser beam (5.2) to each group of conductor ends (24) of the entire conductor end assembly (42) to be welded, depending on the detected position, and a holder (34.2) by means of which the component (26) is held stationary relative to the laser device (32.2) during the welding process.