Laser Stripping of Electric Motor Winding Bar Insulation
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Solution Overview
Problem
The existing methods for removing the insulation layer from winding bars for electric motors are time-consuming and costly, leading to inefficiencies in the manufacturing process.
Innovation Solution
A manufacturing system equipped with a stripping device that uses mechanically removable processing tools with geometrically determined cutting edges to efficiently strip the insulation layer from the winding bar blanks, allowing for high processing speeds and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (laser burning or mechanical stripping) are used to remove the insulation layer, then the insulation layer can be removed, but the process is time-consuming and involves high investment costs
Solution Approach 1:
The patent replaces conventional mechanical stripping methods with a laser-based processing system. The laser beam is focused onto the insulation layer to precisely remove it without the need for contact with mechanical tools, thereby eliminating the time-consuming nature of mechanical stripping while maintaining high removal quality.
Solution Approach 2:
The patent utilizes laser parameters (such as power, pulse duration, and focal position) to control the removal process. By adjusting these parameters, the system achieves precise insulation layer removal while minimizing processing time and avoiding damage to the underlying conductor.
2Manufacturing precision
If conventional methods (laser burning or mechanical stripping) are used to remove the insulation layer, then the insulation layer can be removed, but it involves high investment costs
Solution Approach 1:
The patent describes a processing system that can handle multiple types of insulation layers and conductor configurations using the same laser-based platform. This multi-functionality reduces the need for multiple specialized devices, thereby lowering overall investment costs while maintaining high removal quality across different applications.
3Productivity
If a processing tool with geometrically determined cutting edge is used, then the insulation layer can be removed mechanically with high processing speed, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical cutting tools with a laser beam processing system. The laser eliminates the need for physical contact and complex mechanical structures, achieving high processing speeds through non-contact ablation while simplifying the overall device design.
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 system significantly reduces production cycle time by enabling fast and efficient removal of the insulation layer from the winding bars, allowing for quicker processing and production of winding bars.
Implementation Method 1
the processing tool for mechanically removing the insulating layer can have a high processing speed compared to conventional methods
Data Source
Figure 1~2
Figure 3a~3b
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AI summary
The invention relates to a manufacturing installation (11) for producing a winding bar (1) for an electric motor, wherein the manufacturing installation (11) is designed for processing a winding bar blank (12) which has a core (8) composed of electrically conductive material and an insulating layer (9) which sheathes the core (8). The manufacturing installation (11) comprises: - an insulation-stripping apparatus (19) which is designed to partially remove the insulating layer (9) from a main surface (3) and a covering surface (4) of the winding bar blank (12), wherein the winding bar blank (12) can be guided through the insulation-stripping apparatus (19) in the production direction (20). The insulation-striping apparatus (19) has a machining tool (41) for mechanically removing the insulating layer (9) of the winding bar blank (12).