Stator Hairpin Clamping and Masking for Reliable Welding Alignment
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Solution Overview
Problem
Existing methods for aligning and masking hairpin arrangements in stators during welding are complex, labor-intensive, costly, and limited by cross-sectional geometries, number of hairpin pairs, and welding rings, making the process inefficient and prone to failure.
Innovation Solution
A device with a positioning unit, masking unit, and actuation unit that allows simultaneous masking and clamping of multiple hairpin arrangements by moving them along concentric circular paths, using coupling units to adjust in both radial and circumferential directions, enabling flexible alignment and compensation for geometric deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual stator segments are clamped and masked one after the other within a welding ring, then the welding process can be performed, but the process is complex, labor-intensive, and time-consuming
Solution Approach 1:
The patent combines multiple clamping devices and masking devices into a single integrated device that can simultaneously clamp and mask multiple hairpin arrangements across different stator segments. This merging of functions reduces device complexity and operational steps while maintaining welding capability.
Solution Approach 2:
The device is designed to process stator segments individually through a modular approach, where each segment can be clamped and masked in sequence within the same device framework. This segmentation allows efficient processing without requiring complete disassembly or complex reconfiguration between segments.
2Manufacturing precision
If full clamping and full masking are performed using cover plates with through holes, then alignment is achieved, but the risk of metal particles blocking the twisting mechanism increases
Solution Approach 1:
The patent extracts the masking function from the clamping mechanism by using separate masking devices that can be independently positioned and removed. This separation prevents metal particles generated during welding from blocking the clamping mechanism, while still achieving precise alignment through the masking device's positioning capability.
3Adaptability or versatility
If sheet metal strips with holes are used for clamping and masking, then radial alignment is achieved, but the process is limited regarding cross-sectional geometries and number of hairpin pairs
Solution Approach 1:
The patent designs the clamping and masking devices with universal features that can accommodate various cross-sectional geometries of hairpins (round, rectangular, etc.) and different numbers of hairpin pairs. The devices include adjustable elements and standardized interfaces that allow the same basic mechanism to handle diverse configurations without requiring complete redesign.
Data Source
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AI summary
The invention relates to a device (1) for simultaneously masking and clamping several hairpin assemblies (14) of a stator (10) to be welded together. The invention further relates to a method for joining an upper section (22) of hairpin assemblies (10) of a stator (10) by means of a welding process. The invention also relates to a system comprising a stator (10) and such a device (1).