Stator Coil Clamping for Laser Welding Without Insulation Damage
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Solution Overview
Problem
The existing method of manufacturing stators using TIG welding requires longer stripped portions, increasing the stator size, and laser welding risks damaging the insulating coating films due to heat transmission.
Innovation Solution
A clamp device that positions and clamps segment coils with specific shafts and grooves to allow for laser welding of shortened stripped portions, dissipating heat away from the coating films using radially extending shafts and circumferentially arranged grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If TIG welding is used to couple stripped portions, then reliable electrical coupling is achieved, but the stripped portions must be longer which increases the stator size
Solution Approach 1:
The patent replaces TIG welding (mechanical/electrical system requiring electrode clamping) with laser welding (optical system). This substitution eliminates the need for long stripped portions to accommodate electrode clamping, while maintaining reliable electrical coupling through precise laser welding of the stripped portions.
Solution Approach 2:
The patent changes the welding method parameter from TIG welding to laser welding. This parameter change allows for shorter stripped portions because laser welding does not require the same clamping length as TIG welding, thereby reducing the overall stator size while maintaining coupling reliability.
2Length of stationary object
If laser welding is used to couple stripped portions, then the stator size is reduced with shorter stripped portions, but heat damage to the insulating coating films may occur
Solution Approach 1:
The patent introduces water as an intermediary cooling medium. Water is supplied to the vicinity of the laser welding position to absorb and dissipate excess heat, preventing heat damage to the insulating coating films while allowing laser welding to proceed with shorter stripped portions.
Solution Approach 2:
The patent applies beforehand cushioning by supplying water cooling in advance and during the laser welding process. This pre-cooling measure protects the insulating coating films from heat damage before the harmful effect can occur, enabling safe use of laser welding with shortened stripped portions.
3Length of stationary object
If the stripped portions are shortened for laser welding, then the stator size is reduced, but heat generated during welding easily transmits to nearby coating films causing damage
Solution Approach 1:
Water acts as a thermal intermediary, absorbing excess heat generated during laser welding and preventing its transmission to the insulating coating films. This allows shorter stripped portions to be used without causing coating film damage from heat.
Solution Approach 2:
The patent converts the harmful heat generated by laser welding into a beneficial cooling effect by using water to absorb and redirect the heat away from the coating films. This transforms the potential harm (heat damage) into a controlled thermal management system that protects the coating while enabling size reduction.
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 clamp device reduces the risk of heat damage to the coating films during welding by directing heat away from the segment coils, enabling efficient electrical coupling without enlarging the stator size.
Implementation Method 1
dissipating heat away from the coating films using radially extending shafts and circumferentially arranged grooves
Implementation Method 2
A clamp device that positions and clamps segment coils with specific shafts and grooves
Data Source
AI summary
The first shaft and the second shaft restrict the positions of the first end portion and the second end portion in the circumferential direction of the stator core with the first end portion and the second end portion interposed therebetween. Each of the first shaft and the second shaft has a groove. The groove is defined by a first side wall, a second side wall, and an end wall connecting the first side wall and the second side wall. A first side wall of the first shaft presses the first curved portion radially outward of the stator core. The second side wall of the second shaft presses the second curved portion radially inward of the stator core. Thereby, the first segment coil and the second segment coil are clamped in a state where the first end portion and the second end portion are brought into contact with each other.