Stator Winding Overhang Welding With Push-Bent Conductors
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Solution Overview
Problem
Conventional winding overhangs in electric vehicle motors have a large overall size and can cause damage to the insulation layer due to the use of drag forces during the machining process, limiting their reliability and application scope.
Innovation Solution
A method involving cutting off corners of conductors to form angled welding surfaces, exerting a pushing force to create a bend in the base portion, and connecting the conductors via laser welding, eliminating the need for drag areas and preventing insulation layer damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tip twisting process with drag force is used to machine the winding overhang, then the conductor can be bent and connected, but the overall size of the winding overhang becomes large and the insulation layer may be damaged
Solution Approach 1:
The patent inverts the conventional approach by applying pushing force from the base portion toward the tip portion, rather than applying drag force from the tip portion. This reversal eliminates the need for a long drag end, significantly reducing the winding overhang height while achieving the same bending and connection效果
Solution Approach 2:
The patent extracts and removes the drag end portion of the conductor that causes the increased height. By cutting off the corner of the tip portion to create a welding surface and using pushing force instead of drag force, the unnecessary drag end is eliminated, reducing material waste and overall size
2Ease of manufacture
If drag force is exerted on the conductor during machining, then the conductor can be bent, but the insulation layer may flake and defects occur
Solution Approach 1:
The patent reverses the direction of force application from dragging (tip to base) to pushing (base to tip). This inversion prevents the insulation layer from being subjected to tensile stress and flaking, while still achieving the necessary conductor bending for connection
Solution Approach 2:
The patent applies preliminary anti-action by using pushing force that prevents insulation layer damage before it can occur. The force is applied in a direction that avoids tensile stress on the insulation layer, preventing flaking and defects proactively
3Ease of manufacture
If the winding overhang is machined with conventional methods, then the conductor can be connected, but material is wasted and the overall outer size increases
Solution Approach 1:
The patent extracts and eliminates the unnecessary drag end portion of the conductor. By using pushing force and cutting the tip portion at an angle to create a welding surface, the excessive material that would otherwise be wasted is removed, achieving both connection and material efficiency
Solution Approach 2:
The patent discards the corner portion of the tip portion to create a welding surface, and recovers the remaining conductor material by using it efficiently in the bending and connection process, minimizing overall material waste
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 approach reduces the height and overall size of the winding overhang, enhances reliability by avoiding insulation layer damage, and improves the compactness and fault tolerance of the winding design.
Implementation Method 1
connecting the two conductors together by performing laser welding on the welding surfaces
Data Source
AI summary
A winding overhang machining method includes: cutting off corners of tip portions of conductors to form welding surfaces which are angled with respect to axes of the respective conductors; exerting a pushing force on each of the conductors, which have been inserted through an iron core so as to protrude out of the iron core, to form a bend in a base portion of the conductor so that the welding surfaces of two of the bent conductors to be connected together become contiguous and form a welding line; and connecting the two conductors together by performing laser welding on the welding surfaces. With this arrangement, a winding overhang structure can be obtained by processing the tip portions of the conductors with pushing forces but not drag forces.