Stator Coil Insulation Removal by Continuous Laser Processing
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Solution Overview
Problem
Existing conductor wire insulating film separating methods require individual conveyance of coil pieces to a laser separator, leading to reduced productivity.
Innovation Solution
A method for efficiently removing the insulating film from coil piece extremities using a coating removing laser, allowing simultaneous processing of multiple coil pieces and reducing the need for individual conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical means (files, sandpaper, abrasives) are used to remove insulation, then insulation can be removed, but the conductor surface becomes damaged and rough
Solution Approach 1:
The patent replaces mechanical removal methods (files, sandpaper, abrasives) with a chemical etching process using ferric chloride solution. This substitution eliminates mechanical contact with the conductor surface, preventing damage and roughness while effectively removing insulation and oxidation layers through chemical reaction.
2Manufacturing precision
If chemical etching is used to remove insulation, then conductor surface is not damaged, but iron particles contaminate the conductor
Solution Approach 1:
The patent extracts and removes iron particles generated during etching through multiple rinsing steps with clean water or alcohol, and uses a brush to physically remove particles from the conductor surface. This separation process eliminates the harmful contamination while preserving the benefits of chemical etching.
Solution Approach 2:
The patent introduces intermediary substances (clean water, alcohol, flux) to mediate between the etching process and the conductor. These intermediaries facilitate the removal of iron particles and prevent direct contamination, allowing the conductor to achieve a clean, oxidation-free surface.
3Ease of operation
If flux is applied before soldering, then soldering is facilitated, but the flux becomes dry and must be removed requiring additional steps
Solution Approach 1:
The patent applies flux immediately before soldering in a continuous process, ensuring the flux remains moist and effective. By timing the flux application right before the soldering operation, the need for removal steps is eliminated as the flux performs its function and can be cleaned during normal washing procedures.
4Ease of operation
If insulation is removed leaving conductor exposed, then conductor can be connected, but conductor oxidizes quickly
Solution Approach 1:
The patent performs preliminary etching and oxidation removal before the conductor is exposed to air during connection. By preparing the conductor surface in a controlled environment and immediately proceeding with connection or applying protective coating, oxidation is prevented before it can occur.
Solution Approach 2:
The patent uses flux as an intermediary substance that protects the exposed conductor surface during the connection process. The flux creates a protective layer that prevents direct contact between oxygen and the conductor, eliminating oxidation until the connection is complete.
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
Enhances productivity by enabling efficient and simultaneous removal of insulating films from coil piece extremities, improving the efficiency of the conductor wire insulating film separating process.
Implementation Method 1
The etching process involves applying a ferric chloride solution to the conductor surface
Implementation Method 2
rinsing with hot water or alcohol to remove any remaining etching residues or iron particles
Implementation Method 3
rinsing with hot water or alcohol to remove any remaining etching residues or iron particles
Data Source
Figure 1
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AI summary
A conductor wire insulating film separating method disclosed includes: a preparing step involving preparing rectangular cross-section coil pieces each of which is a conductor wire coated with an insulating film and used to provide a stator coil of a rotary electric machine; a delivering-in step involving, after the preparing step, delivering the coil pieces into a laser separator, with the coil pieces aligned such that extremities thereof are adjacent to each other; an applying step involving, after the delivering-in step, continuously applying film removing laser to the extremities of the aligned coil pieces such that the laser is applied to one extremity and then to another extremity, thus removing at least portions of the insulating film from the extremities of the coil pieces; and a delivering-out step involving delivering the coil pieces, from which the at least portions of the insulating film have been removed by the applying step, out of the laser separator.