Stator Winding Laser Stripping and Welding in One Station

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Solution Overview

Problem

Current methods for producing stator arrangements face challenges in efficiently stripping insulation from winding elements and welding them together, leading to reliability issues and contamination risks, especially when dealing with complex geometries and multiple working stations.

Innovation Solution

A method utilizing a first laser arrangement to strip insulation from specific regions of winding element end portions, followed by a second laser arrangement for welding, with a positioning device to manage the end portions and a suction/blower system for particle removal, allowing for efficient insulation removal and welding in a single working station with optimized laser angles and beam paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single working station is used for both insulation stripping and welding, then productivity is improved by eliminating transport between stations, but device complexity increases due to integrating multiple functions

Engineering Contradiction:

Improveproduction efficiencyVSAvoidworking station complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the insulation stripping function and welding function into a single working station. The laser arrangement is configured to perform both insulation removal and welding operations at the same location, eliminating the need to transport the stator arrangement between separate stations and thereby improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The laser arrangement is designed with multi-functionality to perform both insulation stripping and welding operations. By using a single laser system that can execute multiple functions, the patent reduces device complexity compared to having separate specialized stations for each operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If laser beam is used for insulation stripping, then manufacturing precision is improved by achieving clean insulation removal, but object-generated harmful factors increase due to particle contamination

Engineering Contradiction:

Improveinsulation stripping precisionVSAvoidparticle contamination

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful laser-induced particles into a beneficial situation by introducing a suction device that actively removes particles from the working area. The harmful byproduct of laser insulation stripping is captured and eliminated, preventing contamination of the welding area and maintaining manufacturing precision.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If winding element end portions are positioned close together for welding, then productivity is improved by reducing positioning steps, but manufacturing precision decreases due to difficulty in accessing both ends

Engineering Contradiction:

Improvewelding process efficiencyVSAvoidlaser beam accessibility

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent positions the laser arrangement above the stator arrangement, utilizing the vertical dimension to access both winding element end portions simultaneously. This overhead positioning allows the laser beam to reach both ends without requiring complex lateral positioning, maintaining manufacturing precision while improving productivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 method enhances the reliability of the welding process, reduces contamination risks, and streamlines the production by allowing simultaneous insulation stripping and welding in a single station, improving efficiency and accessibility of the stator arrangement.

Implementation Method 1

using a first laser arrangement (91A, 91B) for removing the insulation layer (82) at least in certain regions on a first winding element end portion (41) of a first winding element (40) and a second winding element end portion (42) of a second winding element (40)

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

using a second laser arrangement (92) for welding the first and second winding element end portions (41, 42) to one another

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

The transporting device may comprise a suction removal device

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS12027924B2Method for producing a stator arrangement

Publication Date: 2024.07.02 DR ING H C F PORSCHE AG

AI summary

A method is provided for producing a stator arrangement that has a stator core and a winding arrangement. The stator core has stator slots. The winding arrangement has winding elements with a conductor and an insulation layer. Each winding element has two interconnected winding element legs with two winding element end portions on each winding element leg. The method includes positioning the winding elements on the stator core so that the winding element legs extend through one of the stator slots with winding element end portions protruding on a first side of the stator core. The method then includes using a first laser arrangement to remove the insulation layer from regions of the winding element end portions. The method then includes pressing the first and second winding element end portions against one another and using a second laser arrangement to carry out welding.