Stator Module Laser Welding Sealing
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Solution Overview
Problem
Conventional methods for protecting stator modules from humidity and salty fog, such as cover body protection, sealing adhesive protection, and coating protection, either reduce magnetization and induction performance, cause thermal stress, or lead to inadequate sealing, resulting in compromised operational efficiency and reliability of fans.
Innovation Solution
A protection structure for stator modules using laser welding to connect cover bodies with posts to the silicon steel sheet assembly, ensuring the outer faces are exposed without increasing the gap between the rotor and stator, thereby maintaining magnetic performance while providing excellent sealing and heat dissipation, and utilizing a robotic arm for precise and efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover body is used to enclose and seal the stator, then protection from humidity and salty fog is improved, but the gap between the silicon steel sheet assembly and the rotor magnet is increased, reducing magnetization and induction performance
Solution Approach 1:
The cover body is divided into a first cover body and a second cover body that are separately positioned at both ends of the stator. This segmentation allows the protective function to be distributed while maintaining a compact structure that does not increase the radial gap between the stator and rotor, thus preserving magnetic performance while providing humidity protection.
2Reliability
If adhesive dispensing is used to seal the stator in the cover body, then protection from humidity is improved, but the process takes long time and adhesive amount is hard to control, leading to spilling
Solution Approach 1:
The first and second cover bodies are pre-assembled with the stator using adhesive in a controlled environment before the entire assembly is installed into the fan housing. This preliminary assembly allows for controlled adhesive application and proper curing time, ensuring complete sealing without spilling while maintaining production efficiency.
3Reliability
If O-ring press fit is used to seal the stator, then protection from humidity is improved, but the O-ring lifetime is short and it tends to crack, allowing infiltration
Solution Approach 1:
The design eliminates the use of O-rings entirely by employing a permanent adhesive bonding solution between the cover bodies and the stator. This replaces the short-lived, crack-prone O-ring with a durable, maintenance-free sealing system that provides long-term protection without the need for periodic replacement.
4Reliability
If sealing adhesive is filled into the cover body, then sealing performance is improved, but magnetization and induction performance are reduced and heat dissipation is deteriorated
Solution Approach 1:
The adhesive is applied locally only at the bonding interfaces between the cover bodies and the stator components, rather than filling the entire interior space. This localized application provides effective sealing at critical joints while leaving the magnetic and heat dissipation pathways clear, thus maintaining magnetization performance and thermal management.
5Reliability
If adhesive is used to seal the stator, then protection from humidity is improved, but thermal stress is applied to electronic components during solidification, causing malfunction
Solution Approach 1:
Electronic components are pre-mounted on the circuit board and positioned in their final locations before the adhesive bonding process. This allows the adhesive to cure without causing displacement or excessive thermal stress on the components, ensuring proper SMT strength and preventing malfunction while still achieving effective sealing.
6Reliability
If coating is applied to protect stator surfaces, then moistureproof and waterproof effect is improved, but the coating is thin and likely to be damaged, and adhesion is affected by material properties
Solution Approach 1:
The design uses a flexible adhesive bonding system that creates a resilient sealing layer between the cover bodies and stator components. This adhesive layer provides moistureproof and waterproof protection while being more durable and less prone to damage than thin surface coatings, as it accommodates thermal expansion and mechanical stress without cracking or delaminating.
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
The solution ensures high welding precision, perfect sealing, and reduced thermal deformation, maintaining motor power performance, preventing electronic component damage, and improving heat dissipation, while reducing processing time and costs.
Implementation Method 1
using laser welding to weld the first cover body, the second cover body and the posts
Data Source
AI summary
A manufacturing method in which laser welding is used to weld multiple posts of a protection structure with multiple splits of the silicon steel sheet assembly of a stator module. The manufacturing method has high welding precision and excellent sealing effect. Also, the welding time is shortened and the thermal deformation is reduced.