Stator TIG Welding Clamp Layout for Shorter Coil Ends
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Solution Overview
Problem
The existing method for manufacturing stators using TIG welding requires longer coil ends to facilitate electrode contact, making it difficult to reduce the size of the stator.
Innovation Solution
A method and apparatus that utilize welding clamps to hold one coil end and an electrode clamp to hold a different wiring position, allowing TIG welding while minimizing the length of the coil end to be welded, thereby reducing the stator's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil end part is extended to facilitate electrode contact for TIG welding, then the welding process can be performed, but the size of the stator increases
Solution Approach 1:
The patent introduces a clamp as an intermediary device that holds the coil end part, enabling the electrode to contact the coil at a position away from the stator core. This mediator allows welding accessibility without requiring the coil end to extend into the stator, thus resolving the contradiction between welding ease and stator size reduction
Solution Approach 2:
The patent changes the spatial arrangement by holding the coil end part in a direction extending from the stator core and positioning the electrode contact point in a different dimensional space. The clamp extends the coil end in one dimension while the electrode contacts in another dimension, allowing welding without increasing the stator's overall volume
2Volume of moving object
If the coil end part is shortened to reduce stator size, then the stator becomes more compact, but it becomes difficult to bring the electrode into contact with the coil end for welding
Solution Approach 1:
The clamp serves as a mediator that bridges the gap between the shortened coil end and the electrode. It holds the coil end securely and positions it such that the electrode can contact the coil end for welding without requiring the coil end to be long, thus maintaining ease of operation with compact dimensions
Solution Approach 2:
The clamp provides dynamic positioning capability, allowing the coil end to be held at the optimal position for electrode contact. This dynamic adjustment enables the system to maintain ease of operation even with shortened coil ends, as the clamp can adaptively position the coil end where the electrode needs to contact
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 size of the stator by minimizing the metal exposure range and allowing for more flexible clamp design, improving durability and reducing the overall size of the welding apparatus.
Implementation Method 1
holding, by welding clamps, a coil end that is one end of wiring composing each of the coils and another wiring different from that of the coil
Implementation Method 2
holding an energizing position provided in the other wiring by a conductive electrode clamp
Implementation Method 3
joining the coil end and the other wiring clamped by the welding clamps to each other by the TIG welding
Implementation Method 4
joining the coil end and the other wiring clamped by the welding clamps to each other by the TIG welding
Data Source
AI summary
A method for manufacturing a stator in the related art has a problem that the size of a stator cannot be sufficiently reduced. A method for manufacturing a stator according to the present disclosure includes: a welding end holding process of holding, by welding clamps, a coil end that is one end of wiring composing each of the coils and another wiring different from that of the coil; an electrode end holding process of holding an energizing position provided in the other wiring by a conductive electrode clamp; and a welding process of energizing the electrode clamp, and joining the coil end and the other wiring clamped by the welding clamps to each other by the TIG welding.