Stator Coil End Welding Insulation and Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding methods for coil ends of stator windings in electric rotating machines often result in electrical discharge due to insufficient insulation distance, and zigzag alignment complicates electrode insertion during TIG welding.
Innovation Solution
The method involves arranging coil end pairs in a zigzag pattern to increase the distance between them, using diagonal arrays with electrodes inserted from both outside and inside the stator core to facilitate efficient welding while maintaining electrical insulation, and employing multiple discrete electrodes to ensure direct contact and effective welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil end pairs are arranged in radial arrays for TIG welding, then welding efficiency is improved, but electrical insulation distance is insufficient causing electrical discharge
Solution Approach 1:
The patent applies asymmetry by changing from radial array alignment to zigzag alignment of coil end pairs. This asymmetric arrangement increases the electrical insulation distance between adjacent coil end pairs in the radial direction while maintaining welding accessibility, thereby preventing electrical discharge during the welding process
2Reliability
If zigzag alignment of coil end pairs is used to increase insulation distance, then electrical discharge is reduced, but electrode insertion becomes obstructed
Solution Approach 1:
The patent applies segmentation by dividing the welding operation into multiple steps with different electrode insertion directions. Instead of requiring single-direction insertion, the method allows electrodes to be inserted from different directions (radial and axial) to access coil end pairs at different positions, thereby maintaining ease of operation while achieving proper zigzag alignment for electrical insulation
3Ease of manufacture
If multiple discrete electrodes are used to ensure direct contact, then welding effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent applies dynamics by making the electrode configuration adaptable and flexible rather than fixed. The welding system can dynamically adjust electrode insertion directions and positions based on the zigzag arrangement of coil end pairs, allowing multiple discrete electrodes to effectively contact different pairs while managing complexity through controlled flexibility in the welding process
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 allows for efficient welding of coil ends with increased insulation distance, reducing electrical discharge and simplifying the welding process by ensuring proper electrode placement and contact.
Implementation Method 1
bringing a second electrode close to one of the adjacent two of the diagonal arrays to weld the pairs of the coil ends
Implementation Method 2
The coil ends 16b of each pair 16c may be joined by, for example, TIG (Tungsten Inert Gas) welding
Data Source
AI summary
A method of welding a plurality of conductors to form a winding extending through an annular stator core. The conductors are inserted into slots formed in the stator core to have coil ends extending outside an end surface of the stator core. A plurality of pairs of the coil ends are arranged in diagonal arrays extending diagonally with respect to a radial direction of the stator core. The method inserts a first electrode into a gap between adjacent two of the diagonal arrays and then brings a second electrode close to one of the adjacent two of the diagonal arrays to arc-weld the pairs of the coil ends. This welding method enables the welding of the coil ends arrayed in the above layout efficiently while keeping the electrical insulation between the pairs of the coil ends.