Clamping Device for Laser Welding Stator Coil Ends
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Solution Overview
Problem
Existing stator manufacturing methods face challenges with coating damage due to welding heat during the joining of coil segments, particularly when using laser welding, as the short stripped portions are prone to heat conduction from the coating, and the need for longer stripped portions for TIG welding enlarges the stator undesirably.
Innovation Solution
A clamping device with radial shafts positioned to sandwich and hold the ends of coil segments in place, allowing for laser welding without direct contact with the coating, thereby isolating the heat from the coating and maintaining the stator's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If TIG welding is performed to join the stripped portions, then reliable electrical connections are achieved, but the stripped portions need to be long enough to allow for clamping by electrodes which enlarges the stator
Solution Approach 1:
The patent replaces TIG welding (mechanical/electrical system requiring electrode clamping) with laser welding (optical system). The laser beam directly melts and fuses the stripped portions without requiring mechanical clamping fixtures, thereby eliminating the need for long stripped portions and reducing stator size while maintaining connection reliability.
Solution Approach 2:
The patent introduces a clamping device as an intermediary mechanism that holds the coil segments in position during laser welding. This mediator enables precise positioning and stable welding of short stripped portions without requiring the strips to be long enough for electrode clamping, thus solving the contradiction between connection reliability and stator size.
2Length of stationary object
If laser welding is performed with short stripped portions, then the stator size is maintained, but the heat produced by laser welding is easily conducted to the coating near the stripped portions causing damage to the coating
Solution Approach 1:
The clamping device acts as a thermal intermediary or heat sink between the laser welding zone and the coating. By clamping the coil segments, it provides a heat dissipation path that protects the coating from excessive heat conduction, enabling safe laser welding of short stripped portions.
Solution Approach 2:
The clamping device is positioned and activated before laser welding begins. This preliminary action establishes thermal protection for the coating by creating heat dissipation pathways through the clamped coil segments, preventing heat damage before it can occur during the welding process.
3Ease of manufacture
If the stripped portions are made long to accommodate TIG welding electrodes, then reliable welding is achieved, but the stator dimensions are enlarged which is not desirable
Solution Approach 1:
The patent substitutes TIG welding with laser welding, fundamentally changing the manufacturing process. Laser welding requires minimal preparation and can effectively join short stripped portions without the need for long strips to accommodate electrode clamping, thereby maintaining ease of manufacture while reducing stator dimensions.
Solution Approach 2:
The patent changes the welding process parameters by switching from TIG welding (requiring long strips for electrode attachment) to laser welding (effective with short strips). This parameter change enables manufacturing feasibility with reduced stator dimensions.
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 clamping device effectively prevents coating damage from welding heat while enabling efficient laser welding of shorter stripped portions, maintaining the stator's dimensions and ensuring reliable electrical connections.
Implementation Method 1
a first shaft and a second shaft arranged to extend in a radial direction of the stator core and spaced apart from each other in a circumferential direction of the stator core so that in a state in which the first shaft is pressed against the second coil segment and the second shaft is pressed against the first coil segment, the first shaft and the second shaft sandwich the first end and the second end
Implementation Method 2
performing laser welding and joining a first stripped portion, where the coating is absent from a first end of the first coil segment, and a second stripped portion, where the coating is absent from a second end of the second coil segment
Implementation Method 3
the heat produced by laser welding will easily be conducted to the coating near the stripped portions. This will raise the temperature of the coating thereby causing damage to the coating
Data Source
AI summary
A clamping device performs a clamping action when performing laser welding to join a first stripped portion, where a coating is absent from a first end, and a second stripped portion, where a coating is absent from a second end. A second claw extends in a radial direction of a second shaft. In a state in which a first shaft and the second shaft are moved toward a stator core such that the first end and the second end are sandwiched between the first shaft and the second shaft, and the first shaft is pressed against a second curved portion and the second shaft is pressed against a first curved portion, the clamping device performs the clamping action by rotating the second shaft about a center axis of the second shaft until the second claw comes into contact with the second end.