Motor Stator Welding With Protective Hood and Single-Press Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual alignment and welding of lead-out wires in motor stators to substrate welding points is challenging, leading to inefficiencies and inconsistencies, and existing methods are not suitable for automated production.
Innovation Solution
A method involving a protective hood and a hot pressing head is used to align and weld lead-out wires of a motor stator to substrate welding points in a single movement, utilizing a protective hood with wire slots and a hot pressing head that moves through three strokes to ensure consistent welding without solder splattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and welding of lead-out wires is performed, then welding can be completed, but the process consumes excessive time and cannot be automated
Solution Approach 1:
The lead-out wires are pre-aligned with the welding points before the welding process begins. The motor stator is positioned such that the lead-out wires already correspond to the welding points on the circuit board, eliminating the need for manual alignment during welding and enabling automated mass production
Solution Approach 2:
The manual mechanical alignment process is replaced by a fixed positioning system where the motor stator and circuit board are pre-positioned relative to each other. This mechanical substitution allows the welding process to be automated without requiring manual intervention for wire alignment
2Ease of manufacture
If lead-out wire is manually pulled through multiple grooves and segments, then electrical connection is achieved, but the procedure is complex and time-consuming
Solution Approach 1:
The complex multi-step process of pulling wires through multiple grooves and segments is extracted and replaced by a single-step alignment process. The lead-out wires are directly aligned with welding points through pre-positioning, removing unnecessary intermediate steps and significantly reducing connection time
Solution Approach 2:
Instead of manually guiding the wire through a complex path of grooves and segments, the invention inverts the approach by pre-positioning the motor stator such that the wires naturally align with the welding points. This reverses the traditional sequence of operations and simplifies the manufacturing process
3Manufacturing precision
If manual welding with soldering iron is performed, then welding can be completed, but consistent dimensions and welding heights cannot be achieved
Solution Approach 1:
The manual soldering iron process is replaced by an automated reflow soldering system. The circuit board with the motor stator is placed on a heating stage, and the solder is melted and re-solidified automatically through controlled heating cycles, ensuring consistent welding dimensions and heights without manual intervention
Solution Approach 2:
The welding process parameters such as heating temperature, heating time, and cooling rate are precisely controlled and standardized. By changing and controlling these parameters automatically, the system achieves consistent welding quality and dimensions that cannot be obtained through manual soldering
4Productivity
If manual welding is performed, then welding can be completed, but the process is inefficient and slow
Solution Approach 1:
The manual welding operation is completely replaced by an automated reflow soldering system. The entire welding process is performed automatically through controlled heating and cooling cycles, dramatically improving welding efficiency and enabling mass production without increasing manufacturing complexity
Solution Approach 2:
The welding process is made continuous through the reflow soldering method. The circuit board remains on the heating stage throughout the entire welding process, and multiple welding points are soldered simultaneously in one continuous heating cycle, eliminating the need for sequential manual welding operations
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 method allows for efficient, automated welding of all coil windings in one movement, preventing solder splattering and ensuring consistent dimensions, thus improving operational efficiency and suitability for mass production.
Implementation Method 1
a hot pressing head (40) having a hot pressing end (42) corresponding to welding points (22) on the substrate and movable to cover an outer side of the protective hood (30) while the hot pressing end (42) heats and welds the lead-out wires (12) and the welding points (22) together
Data Source
AI summary
A method for welding a motor stator to a substrate includes steps of: providing a motor stator and a substrate; preliminarily fixing the motor stator to the substrate; pulling out lead-out wires of coil windings wound on the motor stator to align with solders of welding points on the substrate; covering a protective hood on the motor stator; covering the hot pressing head around the protective hood while the hot pressing end is located corresponding to the welding points; heating and compressing the welding points to melt the solders; and waiting the molten solders on the welding points to cool and cure to weld the coil windings of the motor stator to the welding points. With the present invention, all the coil windings of the motor stator can be welded to the substrate in one single movement while the motor stator is protected against splattered solders during the welding operation.