Electric Motor Stator Laser Welding Interconnection
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Solution Overview
Problem
Existing stators for electric motors face challenges in achieving high precision, space efficiency, and flexibility for high-current applications, particularly in terms of adaptable winding connections and wire diameters, while maintaining reliable mechanical and electrical connections.
Innovation Solution
The stator design incorporates a winding wire surrounded by a receptacle material, with an interconnection unit featuring contact plates that are laser-welded to ensure secure mechanical fastening and electrical insulation, allowing for compact and adjustable assembly with a carrier unit, enabling flexible adaptation to different wire diameters and electronics designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical shaping methods are used to create winding-wire receptacles, then the manufacturing process is simpler, but the mechanical fastening reliability and precision are insufficient for high-current applications
Solution Approach 1:
The patent replaces traditional mechanical shaping methods with laser welding technology. The laser beam melts the receptacle material to create precise, high-strength mechanical fastening of winding wires, eliminating the need for complex mechanical shaping while achieving superior reliability for high-current applications.
Solution Approach 2:
The invention changes the manufacturing parameter from mechanical cutting/shaping to thermal processing via laser welding. This parameter change enables the receptacle material to be melted and fused with the winding wire, creating a more reliable mechanical connection that can handle high currents while maintaining manufacturing efficiency.
2Reliability
If paper insulation is used between flat plates of the interconnection unit, then the manufacturing is simpler, but the electrical insulation performance is insufficient for high-current applications
Solution Approach 1:
The patent replaces traditional paper insulation with composite material structures consisting of varnished plates or plates covered with flat insulating materials. This composite approach provides superior electrical insulation performance for high-current applications while maintaining manufacturing feasibility through standardized coating processes.
3Adaptability or versatility
If the stator design uses fixed winding connections, then the manufacturing precision is higher, but the adaptability to different wire diameters and electronics designs is reduced
Solution Approach 1:
The patent implements dynamic adaptability in the stator design by creating winding-wire receptacles that can accommodate different wire diameters. The laser welding process and receptacle geometry are designed to be adjustable, allowing the same basic structure to precisely connect various wire sizes and configurations without sacrificing connection precision.
Solution Approach 2:
The invention creates a universal stator design where the interconnection unit and winding-wire receptacles can serve multiple functions across different applications. The standardized laser welding process and adaptable receptacle structures enable the same basic design to work with different wire diameters, winding connections, and electronics configurations.
4Ease of operation
If the interconnection unit is designed as a single integrated component, then the device complexity is reduced, but the ease of assembly and adjustment is worsened
Solution Approach 1:
The patent segments the interconnection unit into separate functional components that can be independently manufactured and then assembled. This segmentation allows for easier assembly and adjustment while maintaining relatively simple individual component structures, resolving the contradiction between integration and assembly ease.
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 high-quality, space-saving, and adaptable stator assemblies capable of handling high currents with reliable connections, ensuring consistent welding quality and ease of assembly, while maintaining the structural integrity and electrical insulation necessary for efficient motor operation.
Implementation Method 1
the winding wire is surrounded by and connected and welded to on the inside by material of a winding-wire receptacle
Implementation Method 2
the winding-wire receptacle surrounds the winding wire not by mechanical shaping but by a melting process
Data Source
AI summary
A stator of an electric motor having a stator core with a plurality of salient stator poles, an insulating cap, a stator winding consisting of a winding wire, and an interconnection unit with a plurality of winding-wire receptacles having an inside, wherein the winding wire is surrounded by a material constituting the winding-wire receptacle and connected and welded thereto on the inside. The stator is of an electric motor which is of a very high quality and precision so that high-current applications are possible. Without any major adjustments, the stator is combinable with different winding connections and is flexibly adaptable to the rest of the motor and possibly to the electronics design. The manufacturing method is capable of being flexibly adapted to different wire diameters.