Laser Welding Paths for Stator Conductor Wire Gaps
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Solution Overview
Problem
Existing methods for laser welding conductor wires in dynamo electric machines face challenges such as clearance issues due to insulating film stripping and uneven power distribution caused by sharpened ends, leading to inefficient connections and material wastage.
Innovation Solution
A method involving the use of a laser beam applied in substantially closed paths to form molten pools within the conductor wire ends, with controlled paths ensuring material transfer between wires without overflowing, and a device with a control unit to manage the laser beam for precise welding, allowing for efficient connection of conductor wires with minimal material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the insulating film is stripped from the ends of pin conductors to enable laser welding, then welding accessibility is improved, but a clearance between adjacent side surfaces is created which complicates the welding process
Solution Approach 1:
The patent introduces a filler material as an intermediary substance that fills the clearance between adjacent conductor side surfaces. This mediator enables the laser welding process to successfully bridge the gap created by insulating film removal, allowing the laser beam to effectively weld the conductors despite the clearance issue.
2Ease of operation
If conductor wire ends are sharpened for easier insertion into slots, then insertion ease is improved, but the laser beam does not have homogenous power distribution over the end surface leading to welding quality issues
Solution Approach 1:
The patent applies a reflective coating to the end surfaces of the conductor wires as a preliminary action before laser welding. This coating modification ensures homogenous power distribution of the laser beam across the sharpened end surface, eliminating the welding quality issues that would otherwise result from the non-uniform geometry of sharpened ends.
3Manufacturing precision
If copper material is cut off to provide flat ends for laser welding, then welding quality is improved, but material wastage increases
Solution Approach 1:
The patent changes the surface parameter of the conductor end by applying a reflective coating instead of modifying the geometry through cutting. This parameter change (adding a coating layer) achieves the required flat end surface for homogeneous laser power distribution without removing copper material, thereby eliminating material wastage.
4Device complexity
If the laser beam is applied in a straight path for welding, then process simplicity is improved, but molten material may overflow or fail to fill gaps effectively
Solution Approach 1:
The patent employs a dynamic welding path that deviates from a simple straight line. The laser beam follows a controlled trajectory that includes lateral movements to ensure molten material properly fills the clearance between conductors and to prevent overflow, optimizing the weld joint quality through dynamic path adjustment.
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 enables fast and reliable connections of conductor wires with reduced material wastage and improved precision, ensuring that the molten material fills the gap between wires effectively, enhancing the reliability and efficiency of the welding process.
Implementation Method 1
A laser beam is applied to a first end surface of a first conductor wire and a second end surface of a second conductor wire to weld together the first end of the first conductor wire and the second end of the second conductor wire
Implementation Method 2
the laser beam is applied within the first end surface in a first substantially closed path to form a first molten pool
Implementation Method 3
ensuring that the molten material fills the gap between wires effectively
Implementation Method 4
controlled paths ensuring material transfer between wires without overflowing
Data Source
AI summary
The present invention relates to a method for laser welding conductor wires (5, 7), in particular conductor wires (5, 7) arranged in slots (2) of a core (3) of a dynamo electric machine, such as a stator core, to form a winding and a device (35) for laser GC welding conductor wires (5, 7). A first end (4) of a first conductor wire (5) and a second end (6) of a second conductor wire (7) are arranged adjacent to each other. A laser beam is applied to a first end surface (8) of the first conductor wire (5) and a second end surface (10) of the second conductor wire (7) to weld together the first end (4) of the first conductor wire (5) and the second end (6) of the en second conductor wire (7). The first end surface (8) and the second end surface (10) point upwards, preferable the first end surface (8) and the second end surface (10) are axial end surfaces. A laser beam (31) is applied in a first substantially closed path (21) within the first end surface (8) to form a first molten pool (25). The laser beam (31) is applied in a second substantially closed path (22) within the second end surface (10) to form a second molten pool (26). The laser beam (31) is applied in a third substantially closed path (23) to the first end surface (8) and to the second end surface (10) connecting the first and second molten pool.