Stator Distal End Parts Twisting for Welding Bead Control

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Solution Overview

Problem

The existing stator manufacturing techniques face challenges in preventing beads from protruding and contacting adjacent distal end parts during TIG welding, requiring precise control and increasing manufacturing costs.

Innovation Solution

The stator design involves twisting and shaping distal end parts in opposite directions to create appropriate gaps in both the circumferential and radial directions, ensuring that even large beads are less likely to contact adjacent parts, thereby eliminating the need for precise bead size control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If TIG welding is used to join distal end parts, then the distal end parts are securely connected, but beads may protrude and contact adjacent distal end parts requiring precise control

Engineering Contradiction:

Improvewelding connection strengthVSAvoidbead size control precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies preliminary anti-action by pre-shaping the distal end parts of the wires before welding. Specifically, the distal end parts are bent at predetermined angles (e.g., 90 degrees) and positioned at specific locations to ensure that even if large beads form during welding, they will not contact adjacent distal end parts. This preventive positioning eliminates the need for precise bead size control while maintaining secure welding connections.

Inventive Principle:

Principle #9Preliminary anti-action

2Reliability

If additional control measures are implemented to prevent bead contact, then reliability is improved, but manufacturing costs increase

Engineering Contradiction:

Improveprevention of bead contact with adjacent partsVSAvoidmanufacturing facility cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent implements preliminary action by performing wire shaping and positioning operations before the welding process. The distal end parts are bent and positioned in advance to predetermined locations, ensuring proper spacing and orientation. This preliminary preparation ensures reliable prevention of bead contact without requiring complex control systems or expensive manufacturing facilities during the welding process itself.

Inventive Principle:

Principle #10Preliminary action

3Volume of moving object

If distal end parts are arranged closely to reduce gaps, then space utilization is improved, but bead contact risk increases

Engineering Contradiction:

Improvespace utilization in statorVSAvoidbead contact with adjacent distal end parts

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating different spatial configurations for different parts of the wire assembly. The distal end parts are given special localized shaping (bending at specific angles) and positioning at specific locations, while the main body of the wires maintains close arrangement for space utilization. This localized differentiation allows close packing overall while preventing bead contact at the critical welding locations.

Inventive Principle:

Principle #3Local quality

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 configuration reduces the likelihood of bead contact with adjacent parts, leading to cost savings by eliminating the need for precise bead size control and ensuring uniform gaps around the welded areas.

Implementation Method 1

the distal end parts located in odd-numbered positions from an outer or inner circumferential side in a radial direction are twisted in one direction and the distal end parts located in even-numbered positions are twisted in an opposite direction to the one direction

Methodology Applied

Scientific EffectTwisting:

Implementation Method 2

the distal end parts twisted in the one direction and the distal end parts twisted in the opposite direction are joined to each other by welding

Methodology Applied

Scientific EffectTIG welding: Welding

Data Source

PatentUS10333373B2Method of manufacturing a stator operatively associated with inner and outer circumferential jigs

Publication Date: 2019.06.25 TOYOTA JIDOSHA KK

AI summary

A method for manufacturing a stator operatively associated with an inner and outer circumferential jigs including sequentially ordered steps of inserting segment coils, each constituting of a pair of straight portions connected with a connecting portion in a U-like shape, in slots of a stator core, rotating a twisting ring while distal end parts of the pairs of straight portions protruding on an opposite side to the connecting portions are engaged with ring grooves of the twisting ring to twist and shape in one direction the distal end parts located in odd-numbered positions from an outer circumferential side or an inner circumferential side in a radial direction and twist and shape the distal end parts located in even-numbered positions in an opposite direction to the one direction, and welding the distal end parts twisted in the one direction and the distal end parts twisted in the opposite direction.