Segment Coil Laser Welding with Image-Based Alignment Compensation
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Solution Overview
Problem
Existing coil welding methods for segment coils face challenges in achieving high accuracy due to the need for precise alignment and contact of end parts, which results in poor workability and difficulty in eliminating non-uniformities in end part positions.
Innovation Solution
A coil welding device and method that acquire end part information from images, set appropriate welding conditions based on this information, and use laser irradiation to integrate the end parts, allowing for accurate welding even with positional displacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the end parts of segment coils are arranged in contact with each other for laser welding, then welding can be achieved, but workability deteriorates due to the difficulty of alignment and positioning
Solution Approach 1:
The patent applies preliminary action by capturing images of the coil end parts before welding to measure their actual positions and dimensions. This pre-measurement allows the system to compensate for positioning variations and set appropriate welding parameters in advance, eliminating the need for precise manual alignment while ensuring reliable welding results.
Solution Approach 2:
The patent changes welding parameters (such as laser power, scanning speed, and scanning pattern) based on the measured end part dimensions and positions. By dynamically adjusting these parameters according to actual measurements, the system maintains high welding quality even when coil positions vary, thereby improving workability without sacrificing reliability.
2Ease of operation
If the end parts of segment coils are separated from each other to improve workability, then alignment becomes easier, but welding accuracy deteriorates due to difficulty in achieving proper laser irradiation
Solution Approach 1:
The patent introduces image capture and measurement as an intermediate dimension between the physical coil positioning and the welding process. By measuring end part positions and dimensions through imaging, the system can calculate and adjust welding parameters to compensate for separations, thereby maintaining welding accuracy even when coils are positioned with greater ease rather than forced contact.
Solution Approach 2:
The patent implements feedback by using captured images to measure actual end part positions and dimensions, then using this measurement information to adjust welding parameters. This closed-loop approach ensures that welding accuracy is maintained despite variations in coil positioning, allowing improved workability without sacrificing precision.
3Device complexity
If laser irradiation is applied along a fixed path to weld segment coils, then the process is simple, but welding quality deteriorates when end part positions vary
Solution Approach 1:
The patent transforms the static fixed laser path into a dynamic adaptive path. By measuring end part positions and dimensions through imaging, the system dynamically adjusts the laser scanning path and parameters to match the actual coil configurations. This dynamic adaptation maintains reliable welding quality while preserving relative process simplicity through automated parameter 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
The solution enables high-accuracy welding of coil end parts with reduced need for precise initial alignment, improving workability and allowing for more reliable integration of segment coils.
Implementation Method 1
a welding means that irradiates end parts of a pair of segment coils to be welded with laser to integrate the end parts
Implementation Method 2
irradiating the end parts with laser to melt and integrate them
Data Source
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AI summary
A control unit 5 functions as an end part information acquisition means that acquires, from an end part image obtained of a coil, various kinds of end part information for each end part to be welded of each portion. That is, the control unit 5 is able to acquire end part information from an image of the end parts of a pair of segment coils to be welded. The control unit 5 functions as a welding condition setting means that sets a welding condition on the basis of the end part information obtained. The control unit 5, with respect to each end part pair, controls the operation and the like of a laser irradiation unit 11 on the basis of the welding condition set, so that the end parts of the pair of segment coils to be welded are irradiated with laser and integrated by welding.