Two-Step Welding for Electrical Conductor Joining
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Solution Overview
Problem
Existing methods for joining electrical conductors, particularly those at the middle portion in a radial direction, face challenges such as dislocation during welding due to inadequate clamping and difficulty in correcting positional errors, leading to potential joining defects.
Innovation Solution
A method involving a two-step welding process where electrical conductors are pressed from both sides in the radial direction, with the first step welding a group of conductors arranged in a column and the second step welding a cross-group configuration to prevent dislocation and ensure accurate positioning, using a clamp tool and pressing device to maintain alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrical conductors are welded while moved close to each other, then welding efficiency is improved, but electrical conductors at the middle portion may dislocate from appropriate joining position
Solution Approach 1:
The clamp tool is positioned and adjusted before the welding operation begins, establishing proper clamping points for all electrical conductors including those at the middle portion. This preliminary positioning ensures that conductors are securely held in place before welding forces are applied, preventing dislocation during the welding process.
Solution Approach 2:
The clamp tool acts as an intermediary device between the welding operation and the electrical conductors. It provides a mechanical means to secure the conductors at appropriate joining positions, mediating the interaction between the welding process and the conductors to prevent unwanted movement or dislocation.
2Manufacturing precision
If strong force is applied to correct positions of electrical conductors, then positioning accuracy is improved, but damage to electrical conductors may occur
Solution Approach 1:
The clamp tool is positioned and adjusted before the welding operation begins, establishing proper clamping points for all electrical conductors including those at the middle portion. This preliminary positioning ensures that conductors are securely held in place before welding forces are applied, preventing dislocation during the welding process.
Solution Approach 2:
The clamping force parameters are optimized to provide sufficient holding power to prevent conductor dislocation during welding, while remaining below the threshold that would cause damage to the conductors. This parameter optimization allows effective positioning without harmful effects.
3Stability of the object's composition
If clamp tool is used to secure electrical conductors, then positioning stability is improved, but contact friction may cause damage to electrical conductors
Solution Approach 1:
The clamping force parameters are optimized to provide sufficient holding power to prevent conductor dislocation during welding, while remaining below the threshold that would cause damage to the conductors. This parameter optimization allows effective positioning without harmful effects.
Solution Approach 2:
The patent specifies selecting clamp tool contact surfaces with appropriate surface properties (analogous to color selection in the principle) to minimize friction damage. The contact surfaces are chosen or treated to have low friction characteristics that prevent damage while maintaining stable positioning.
4Manufacturing precision
If pressing force is applied from both sides in radial direction, then positioning accuracy is improved, but force transfer to middle portion conductors is insufficient
Solution Approach 1:
The clamp tool acts as an intermediary device between the welding operation and the electrical conductors. It provides a mechanical means to secure the conductors at appropriate joining positions, mediating the interaction between the welding process and the conductors to prevent unwanted movement or dislocation.
Solution Approach 2:
Instead of relying solely on radial pressing force, the clamp tool introduces a circumferential dimension of control by clamping the conductors from the sides. This dimensional change in the applying force direction enables effective positioning of middle portion conductors that cannot be adequately controlled by radial pressing alone.
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 method effectively prevents dislocation of conductors at the middle portion, reducing the risk of joining defects by securely maintaining their position during the welding process, even when positional corrections are difficult from outside.
Implementation Method 1
Two of the electrical conductors, whose ends are adjacent to each other in a radial direction of the core and which extend in a circumferential direction of the core from two of the slots different from each other, are joined as a pair of electrical conductors by welding
Data Source
AI summary
A method for joining segments (electrical conductors) includes first and second joining steps. The first joining step includes welding a group of the segments including ends, such that the first group is welded to pairs of electrical conductors. The second joining step includes welding a second group of the segments including ends, which are composed of the segments whose ends are arranged in a column in the radial direction, such that the second group is welded to pairs of electrical conductors. The first group includes a segment as a first electrical conductor including the end which is located at the middle portion of a group of the segments including the ends in the radial direction. The second group includes a segment as a second electrical conductor including the end which crosses the first electrical conductor on the opposite sides with respect to the middle portion in the radial direction.