Stator Clamp Jig for Weld Area Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for welding segment coil ends in stators result in measurement errors due to unintended electricity flow when unwelded coil ends are electrically contacted, as they do not effectively isolate the measurement area.
Innovation Solution
A manufacturing method and clamp jig design that bends coil ends towards opposite sides, using a clamp jig with increased pressing force away from the weld faces and a tapered pressuring structure to isolate the weld area, allowing for precise potential difference measurement post-welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If coil ends are welded without isolation, then welding process is simple, but measurement error occurs due to unintended electricity flow
Solution Approach 1:
The clamp jig is divided into distinct functional segments: isolation pressing members that apply pressing force to isolate the weld area from adjacent coil ends, and support pressing members that provide additional pressing force. This segmentation allows the device to perform multiple functions (isolation and support) simultaneously, improving measurement precision while maintaining reasonable structural complexity
Solution Approach 2:
The clamp jig acts as an intermediary device between the welding process and the measurement process. By introducing this intermediate structure, the patent isolates the weld area from adjacent coil ends during welding, preventing unintended electrical contact. This intermediary structure enables accurate potential difference measurement by ensuring electricity flows only through the welded portion
2Reliability
If pressing force is uniform across coil ends, then clamp jig structure is simple, but oxide film integrity is compromised at weld faces
Solution Approach 1:
The pressuring structure implements local quality by providing different pressing forces at different locations. The isolation pressing members apply higher pressing force to regions away from weld faces to maintain oxide film integrity, while the support pressing members provide appropriate pressing force at the weld faces. This localized differentiation of pressing force ensures oxide film preservation where needed without compromising weld quality
Solution Approach 2:
The patent applies partial pressing action by selectively applying pressing force to specific regions of the coil ends. The isolation pressing members apply pressing force to portions of the coil ends excluding the weld faces, while the support pressing members provide additional pressing force. This partial action approach maintains oxide film integrity at critical areas without excessive pressing that would damage the weld faces
3Measurement precision
If coil ends are isolated during welding, then measurement accuracy improves, but clamping process complexity increases
Solution Approach 1:
The clamp jig merges multiple functions into a single integrated device: isolation of the weld area, application of pressing force to maintain oxide film integrity, and support of the coil ends during welding. By combining these functions in one device, the patent improves measurement precision while avoiding the need for multiple separate operations or devices, thereby maintaining ease of manufacture
Solution Approach 2:
The clamp jig is designed as a multi-functional device that performs isolation, pressing, and support functions simultaneously. The isolation pressing members and support pressing members work together to achieve both weld area isolation and oxide film preservation. This universal design allows a single device to handle multiple requirements, improving measurement precision without significantly increasing manufacturing complexity
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 approach reduces measurement errors by maintaining the oxide film integrity and ensuring accurate potential difference measurements, enhancing the inspection precision of weld quality.
Implementation Method 1
a pressuring structure that increases a pressing force in a direction away from weld faces of the coil ends welded in the welding process
Implementation Method 2
following formation of an oxide film on the end portions of each of the segment coils
Implementation Method 3
the end portions of the segment coils are laser-welded to each other
Implementation Method 4
electric current is applied across the two laser-welded segment coils, and a potential difference is measured
Data Source
AI summary
A manufacturing method of a stator according to the disclosure includes a clamping process of clamping, among coil ends of segment coils assembled into a stator core, a pair of coil ends adjacent to each other in a circumferential direction, by a clamp jig that presses the pair of coil ends in the circumferential direction, and a welding process of welding the coil ends exposed through an opening portion provided in the clamp jig. The clamp jig includes a pressuring structure that increases a pressing force in a direction away from weld faces of the coil ends welded in the welding process, the pressuring structure being provided on at least one of sideward pressing faces that come into contact with side faces of the coil ends that are provided orthogonal to the weld faces.