Motor Stator Welding Hood for One-Step Lead Wire Joining
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Solution Overview
Problem
The manual alignment and welding of lead-out wires in motor stators is challenging, leading to inefficiencies and inconsistencies, and existing methods are not suitable for automated production, with issues such as broken or loosened wires and inconsistent welding heights.
Innovation Solution
A protective hood and a hot pressing head are used to guide and weld lead-out wires to welding points on a substrate, allowing all coil windings to be welded in one movement while protecting the motor stator from splattered solder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual alignment and welding of lead-out wires is performed, then welding can be completed, but the process is time-consuming and cannot be done on an automated mass-production line
Solution Approach 1:
The patent replaces manual mechanical alignment and welding operations with an automated welding machine that uses a positioning fixture. The fixture includes positioning grooves that automatically align the lead-out wires with welding points, eliminating the need for manual positioning and enabling automated welding processes.
Solution Approach 2:
The patent introduces a positioning fixture as an intermediary device between the lead-out wires and the welding machine. This fixture with its positioning grooves serves as a mediator that automatically guides and aligns the wires, enabling the welding machine to perform automated welding without manual intervention.
2Manufacturing precision
If manual welding is performed, then welding can be completed, but welding heights are inconsistent and may interfere with other components
Solution Approach 1:
The patent replaces manual welding operations with an automated welding machine controlled by a computer. The welding machine executes pre-programmed welding paths and parameters, ensuring consistent welding heights and eliminating variations caused by manual operation. The system automatically adjusts welding parameters and maintains precise control over the welding process.
3Productivity
If lead-out wires are manually pulled through multiple grooves and tied to segments, then electrical connection is achieved, but the process is complicated and time-consuming
Solution Approach 1:
The patent extracts and eliminates the complex manual procedure of pulling wires through multiple grooves and tying them to segments. Instead, the positioning fixture with its integrated positioning grooves directly guides the lead-out wires to the correct welding points in a single operation, simplifying the connection process while maintaining electrical connectivity.
Solution Approach 2:
The patent merges the alignment and positioning functions into a single positioning fixture structure. The positioning grooves are integrated into the fixture body, combining multiple alignment steps into one unified positioning mechanism that guides all lead-out wires to their respective welding points simultaneously.
4Object-affected harmful factors
If manual welding is performed, then welding can be completed, but solder splatter may damage the motor stator
Solution Approach 1:
The patent introduces a positioning fixture as an intermediary structure that serves multiple functions: it positions the lead-out wires for welding and simultaneously acts as a protective barrier against solder splatter. The fixture structure intercepts and contains solder splatter, preventing it from reaching and damaging the motor stator components.
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 enables consistent and efficient welding of motor stators, preventing solder splatter and ensuring precise alignment, suitable for automated production.
Implementation Method 1
the hot pressing end heats and welds the lead-out wires and the welding points together
Implementation Method 2
the hot pressing end heats and welds the lead-out wires and the welding points together
Data Source
AI summary
Equipment for welding a motor stator to a substrate includes a protective hood and a hot pressing head. The protective hood covers the motor stator and the substrate to protect the motor stator from undesired displacing and possible damage, and is provided with a plurality of wire slots, via which lead-out wires of coil windings of the motor stator can be pulled out to expose from the protective hood. The hot pressing head has a hot pressing end corresponding to welding points on the substrate and is movable to cover an outer side of the protective hood while the hot pressing end heats and welds the lead-out wires and the welding points together. With the equipment, all the coil windings of the motor stator can be welded to the substrate in one single movement while the motor stator is protected against splattered solders during the welding operation.