Laser Welding of Rectangular Wire Tips Without Trimming
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Solution Overview
Problem
The existing manufacturing process for stators in hybrid vehicles or electric automobiles requires a trimming step to align the tip ends of rectangular wires, which necessitates a large-scale device and results in material wastage due to discarded trimmed ends.
Innovation Solution
A welding method that eliminates the need for a trimming step by using a laser beam to weld the tip ends of rectangular wires with projection shapes, forming fusion zones without the requirement for pre-trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a trimming step is performed to align the tip ends of rectangular wires, then the welding quality is improved, but the manufacturing time increases and material utilization decreases
Solution Approach 1:
The tip ends of the rectangular wires are preliminarily formed with a projection shape (tapered shape) before welding. This preliminary shaping allows the wires to be aligned more easily and reduces the need for extensive trimming, thereby improving manufacturing efficiency while maintaining welding quality
Solution Approach 2:
Instead of trimming the wires to achieve alignment and then welding, the invention inverts the approach by forming projection shapes on the wires first, which naturally facilitate alignment during the welding process. This reverses the conventional sequence of operations
2Manufacturing precision
If a trimming step is performed to align the tip ends of rectangular wires, then the welding quality is improved, but material utilization decreases due to discarded trimmed ends
Solution Approach 1:
The projection shapes formed on the tip ends of the rectangular wires serve multiple functions: they facilitate alignment during welding and also create the necessary geometry for effective laser welding. The wires essentially prepare themselves for welding through the projection formation process, eliminating the need for separate trimming operations that would waste material
3Manufacturing precision
If a large-scale trimming device is used to align the tip ends of rectangular wires, then the welding quality is improved, but the device complexity increases
Solution Approach 1:
The invention replaces the mechanical trimming device with a laser-based system. Instead of using mechanical tools to cut and shape the wire ends, a laser beam is used to form the projection shapes and perform welding. This substitution eliminates the need for complex mechanical trimming equipment while achieving the desired precision
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 reduces manufacturing time by eliminating the need for a trimming device and improves material utilization by avoiding the discard of trimmed ends, while maintaining high-quality welding.
Implementation Method 1
irradiating a position on the tip end of the first member which is close to a butting surface with the laser beam to form a first fusion zone
Implementation Method 2
form a first fusion zone
Implementation Method 3
irradiating a position on the tip end of the second member which is close to a butting surface with the laser beam to form a second fusion zone
Implementation Method 4
form a second fusion zone
Implementation Method 5
welding tip ends of the respective first member and second member by a laser beam with the tip ends facing a laser apparatus
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A welding method of welding tip ends of a first member and a second member with a laser apparatus, the tip ends having a projection shape, the welding method including: arranging the tip ends of the first member and the second member next to each other while facing a butting surface of the first member and a butting surface of the second member and while facing the tip ends towards the laser apparatus; a first step of irradiating a position on the tip end of the first member which is close to the butting surface of the first member with the laser beam to form a first fusion zone; and a second step of irradiating a position on the tip end of the second member which is close to the butting surface of the second member with the laser beam to form a second fusion zone.