Sliding Laser Welding Head for Transformer Winding Seams
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Solution Overview
Problem
Current welding technologies for medium and high-voltage transformer windings are inefficient, costly, and pose safety risks due to high heat generation and the need for expensive gases like helium or argon, while existing laser welding technologies are not applicable to machines with a different structure.
Innovation Solution
A laser welding group integrated into a carriage that can slide along the winding machine's structure, allowing for both 'head' and 'butt' welding operations, with clamping and protecting means to ensure uniform weld seams and reduce heat exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding technologies (TIG welding with helium or argon) are used, then weld seams can be produced, but operational costs increase due to expensive gases and heat generation creates safety risks
Solution Approach 1:
The patent replaces traditional TIG welding (which uses gas shielding and generates high heat) with laser welding technology. The laser source creates a concentrated beam that melts and fuses the conductive material to the bar, eliminating the need for helium or argon gases while reducing overall heat generation through precise energy localization.
Solution Approach 2:
The patent changes the fundamental welding parameters by using laser radiation instead of arc discharge. This involves changing the energy source from electrical arc to optical laser beam, altering the welding mechanism from thermal conduction to localized vaporization and melting, thereby eliminating gas consumption and reducing heat-affected zone.
2Reliability
If traditional welding technologies are used, then weld seams can be produced, but operational costs increase due to expensive gases
Solution Approach 1:
The patent replaces the gas-based shielding mechanism of TIG welding with a laser-based melting mechanism. The laser source directly melts the conductive material and bar surface, creating a weld pool that solidifies to form the weld seam, completely eliminating the need for helium or argon gas consumption.
3Object-affected harmful factors
If laser welding technology is used, then heat generation is reduced and safety is enhanced, but the technology is not applicable to machines with different structure
Solution Approach 1:
The patent makes the laser source movable by mounting it on a carriage that can slide along the winding machine's structure. This dynamic positioning system allows the laser welding head to reach different welding locations and adapt to various machine configurations, overcoming the limitation of fixed-structure laser welding systems.
Solution Approach 2:
The patent designs the laser welding group with a movable carriage and adjustable positioning system that can accommodate different winding machine structures. The system performs multiple functions including positioning, welding, and adapting to various machine configurations, making the laser welding technology universally applicable rather than limited to specific machine types.
4Device complexity
If a fixed welding group is used, then the structure is simple, but it cannot adapt to various welding techniques and machine configurations
Solution Approach 1:
The patent transforms the fixed welding group into a dynamic system with a movable carriage along the X-axis and adjustable laser source positioning. This allows the welding group to adapt to different welding techniques (head welding and butt welding) and various machine configurations while maintaining relatively simple structural components.
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 laser welding group provides uniform and efficient weld seams, reduces heat generation, enhances safety, and lowers operational costs by eliminating the need for expensive gases, while being adaptable to various welding techniques and machine configurations.
Implementation Method 1
a laser source (22) integral to said carriage (20)... configured to weld said conductive material (140) to said inlet bar (110)
Implementation Method 2
said carriage (20) being slidingly constrained to said structure (10) of said winding machine... to slidingly move said carriage (20), and hence said laser source (22), from said rest position to said working position along a horizontal (X) axis
Data Source
AI summary
A welding group for winding machines of the type used in the production of windings intended for medium and high voltage electric transformers to be used in the generation, transmission and distribution of electric power. The welding group includes at least one laser welding head and a handling system (20) for the welding head. The welding head includes: a carriage, in the form of a frame having a lower part, an upper part, and at least one right side part or at least one left side part; first retaining means for slidingly constraining the carriage to the structure of the winding machine, the means being placed on the upper part of the carriage; and a first actuator which, in association with the first retaining means, slidingly moves the carriage on at least one axis.