Stator Weld Joints Using Insulator Removal and Laser Heating
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Solution Overview
Problem
Existing methods for forming weld joints in stators often result in the burning of insulators, leading to electrical shorts and reduced performance due to heat transfer during the welding process.
Innovation Solution
A method involving the removal of insulator portions from magnet wires to create heat affectable zones, where only the distal ends are welded using a diode laser with controlled heat quantities and durations, forming a weld joint that minimizes heat transfer to the insulators and shapes the joint into a hemispherical configuration to maximize conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to join magnet wires, then the weld joint strength is improved, but the insulator is burned due to excessive heat transfer
Solution Approach 1:
The insulator is removed from the distal ends of the magnet wires before welding, creating heat-affectable zones. This preliminary action prevents the insulator from being burned during welding while maintaining adequate electrical insulation along the wire length where insulation is needed.
Solution Approach 2:
The magnet wire structure is modified to have different properties at different locations: the distal ends have exposed cores (heat-affectable zones) for welding, while the remaining portions retain their insulator coating for electrical insulation. This local differentiation allows welding without insulator damage.
2Reliability
If heat quantity during welding is increased to ensure proper weld formation, then the weld joint reliability is improved, but the heat transfer to insulator causes burning and electrical shorts
Solution Approach 1:
By removing the insulator from the distal ends before welding, the patent enables reliable weld formation with adequate heat transfer to the core while eliminating the risk of insulator burning. The preliminary removal creates a heat-affectable zone that safely receives welding heat.
3Reliability
If insulator is preserved during welding to maintain electrical insulation, then electrical safety is improved, but weld joint formation becomes difficult due to heat sensitivity of insulator
Solution Approach 1:
The patent applies local quality by having the insulator present on most of the wire length for electrical insulation, but absent from the distal ends to create heat-affectable zones. This allows welding to proceed easily at the exposed core ends while the insulator remains intact elsewhere to maintain electrical safety.
Solution Approach 2:
The selective removal of insulator from distal ends before welding creates a configuration where welding can be easily performed on exposed cores while the remaining insulator provides continuous electrical insulation along the wire length.
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 prevents insulator burning, enhances electrical conductivity, and allows for a more efficient stacking of magnetic steel laminations, increasing the power output and longevity of electromagnetic machines by avoiding heat-related inefficiencies and shorts.
Implementation Method 1
transferring a first quantity of heat from a diode laser to the weld powder for a first duration of from about 1 second to about 5 seconds
Data Source
AI summary
A method of forming a weld joint includes removing a portion of an insulator from a first core of a first magnet wire and a second core of a second magnet wire so that the first wire has a first heat affectable zone and a first insulator portion adjacent the first zone, and the second wire has a second heat affectable zone and a second insulator portion adjacent the second zone. The first and second insulator portions include the insulator disposed on the first and second cores, respectively. The first and second zones have a first and second distal end spaced apart from the first and second insulator portions, respectively. The method includes welding together only the first end and the second end to form the weld joint, wherein welding does not transfer heat to the first and second insulator portions sufficient to burn the insulator.