Stator Bar Conductor Welding With Rotating Masked Support
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Solution Overview
Problem
The production of stators with welded bar conductors for electric machines is complex and inefficient, particularly due to limitations in coil winding processes and contamination issues during the welding of rod conductors.
Innovation Solution
A welding machine with a rotatable support structure and an openable/closable welding mask, equipped with a laser welding device and a leveling device for cutting rod conductors to length, ensures precise alignment and protection from contamination, allowing for efficient welding and handling of stators with rod conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser welding device is used to weld rod conductors, then welding precision and speed are improved, but contamination from weld spatter and complexity of handling the stator worsen
Solution Approach 1:
The support structure serves multiple functions: it holds the stator during welding, provides rotational movement between welding and loading positions, and supports the welding mask. This multi-functionality reduces the need for additional separate devices while maintaining precision and managing contamination.
Solution Approach 2:
The welding mask is positioned and secured on the support structure before welding begins. The support structure is pre-configured with the mask in the correct position, so that when welding starts, the protective barrier is already in place to prevent spatter contamination.
2Stability of the object's composition
If the stator is held in a holding device during transport between machines, then positioning stability is improved, but handling complexity and time consumption worsen
Solution Approach 1:
The holding device is merged with the support structure, combining the functions of holding the stator and providing rotational movement into a single integrated unit. This eliminates the need for separate holding devices at each workstation, reducing handling complexity while maintaining stability.
Solution Approach 2:
The support structure with the integrated holding device can rotate between different positions (welding position and loading position), providing dynamic adaptability. This rotational capability allows the same device to serve multiple functions at different stages of the process, reducing overall system complexity.
3Manufacturing precision
If rod conductors are cut to length before welding, then alignment precision for welding is improved, but the number of processing steps and time consumption worsen
Solution Approach 1:
The rod conductors are cut to length and pre-positioned on the support structure before the welding process begins. This preliminary preparation ensures that when welding starts, the conductors are already at the correct length and position, eliminating the need for adjustment during welding and reducing overall time consumption.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: cutting rod conductors to length, positioning them on the support structure, and then welding. By separating these operations and preparing components in advance, the actual welding process is accelerated while maintaining precision.
4Object-affected harmful factors
If the welding mask is openable and closeable, then protection from weld spatter is improved, but device complexity and operation time worsen
Solution Approach 1:
The welding mask is integrated into the support structure, combining the protective function with the holding and positioning functions of the support structure. This integration reduces the need for separate protective devices while maintaining effective spatter protection.
Solution Approach 2:
The welding mask is designed to be openable and closeable, providing dynamic adaptability. It can be closed during welding to protect from spatter and opened when needed for loading or inspection. This dynamic capability allows the same structure to serve multiple functions without requiring separate fixed protective barriers.
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 solution enables reliable and efficient production of stators with high conductor filling, minimizing contamination and handling complexities, and is particularly suitable for electric motor stators in motor vehicles.
Implementation Method 1
a welding device, in particular a laser welding device
Data Source
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AI summary
The invention relates to a welding machine (10) for welding free ends of rod conductors of a stator (16) of an electric machine, in particular an electric motor, comprising: - a support structure (18) for directly or indirectly attaching the stator (16), with an openable and closeable welding mask (30); - a welding device (20), wherein the welding device (20) is arranged above the support structure (18), and wherein the support structure (18) is rotatable between a welding position and a loading position, wherein a first side of the welding mask (30) is oriented towards the welding device (20) in the welding position and is oriented downwards in the loading position, characterized in that the welding machine (10) further comprises a leveling device (48) for cutting the rod conductors (40) to length at the free ends (42) when the support structure (18) is in the loading position.The welding machine enables reliable and efficient production of stators with welded rod conductors.