Stator Coil Laser Welding Positioning for Thickness Variation
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Solution Overview
Problem
In existing methods for manufacturing stators for rotary electric machines, accurately determining the laser radiation position for joining coil pieces is challenging due to individual variations in coil piece thicknesses, leading to inaccurate laser irradiation.
Innovation Solution
A method involving the installation of coil pieces in a stator core, followed by image recognition of non-contact surfaces continuous with the contact surfaces, allowing for precise determination of the laser radiation position for laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image recognition is performed on clamping surfaces of the clamp jig, then the laser radiation position can be determined, but accurate irradiation of contact surfaces becomes difficult due to individual variations in coil piece thicknesses
Solution Approach 1:
The patent uses image recognition to create a digital representation (copy) of the actual contact surfaces and their positions. By capturing images of the coil pieces and clamp jig, the system creates a visual model that can be processed to determine the precise location of contact surfaces, compensating for thickness variations without requiring direct physical measurement
Solution Approach 2:
The patent introduces the clamp jig as an intermediary element that provides reference features (clamping surfaces) for image recognition. These clamping surfaces serve as mediators between the variable coil piece dimensions and the laser positioning system, allowing indirect determination of contact surface locations through geometric relationships
2Extent of automation
If laser welding is performed based on image recognition of clamping surfaces, then joining can be automated, but joining accuracy deteriorates due to thickness variations in coil pieces
Solution Approach 1:
The patent implements a feedback mechanism where images of the coil pieces and clamp jig are captured, processed through image recognition, and used to dynamically adjust the laser radiation position. This closed-loop approach allows the automated system to adapt to actual component variations in real-time, maintaining joining accuracy despite thickness variations
Solution Approach 2:
The patent changes the parameter used for positioning from direct clamping surface coordinates to derived contact surface locations. By calculating the relationship between clamping surfaces and contact surfaces, and adjusting the laser position parameters accordingly, the system compensates for thickness variations while maintaining automation
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 enables accurate laser radiation positioning, ensuring reliable and precise joining of coil pieces despite variations in thickness, enhancing the quality and reliability of the stator assembly.
Implementation Method 1
a radiation step of radiating the laser beam to the welding target portion
Implementation Method 2
laser welding after the installation step
Data Source
AI summary
A method for manufacturing a stator for a rotary electric machine includes an installation step of installing coil pieces for a stator coil in a stator core, and a joining step of joining ends of the coil pieces or the end of the coil piece and an end of a busbar by laser welding after the installation step. The joining step includes a setting step of bringing two ends to be joined into contact with each other, an image recognition step of detecting, after the setting step, image features related to non-contact surfaces continuous with contact surfaces of the two ends in an image obtained by imaging the two ends, and a determination step of determining, after the image recognition step, a laser radiation position based on the image features related to the non-contact surfaces subjected to image recognition.