Vibration Welding of Thermoplastic Resin Stator Components
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Solution Overview
Problem
Conventional joining methods for rotating electric machine stators with resin components face challenges due to height variations, requiring excessive energy, unstable welding conditions, and increased costs, as well as difficulties in working with complex shapes and high accuracy, leading to residual stress and component breakage.
Innovation Solution
A joining method using a metal joining component with a higher melting point than thermoplastic resin components, inserted through openings in the resin components, and subjected to vibration to form welded parts, ensuring strong fixation even with height variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods are used to join resin components at multiple locations with height variation, then joining strength can be achieved, but excessive energy is required and facility cost increases
Solution Approach 1:
The invention divides the joining process into two stages: first, join selected locations to create an initial connected structure; second, add remaining locations to achieve complete joining. This segmentation allows energy to be distributed across multiple operation cycles rather than concentrated in one high-energy operation, reducing peak energy requirements while achieving the same overall joining strength.
Solution Approach 2:
The invention employs periodic action by performing joining operations in multiple cycles rather than continuously at all locations simultaneously. The joining device operates periodically at different locations, allowing energy consumption to be managed in controlled intervals. This periodic approach reduces the total energy required compared to simultaneous multi-location joining, while still achieving complete joining strength through cumulative bonding.
2Ease of manufacture
If conventional joining methods are used with height variation, then joining can be performed, but welding conditions become unstable
Solution Approach 1:
The invention introduces a height adjustment mechanism that dynamically adapts the joining head position to match the varying heights of different workpiece locations. This dynamic adjustment ensures that the joining tool maintains optimal contact and welding parameters regardless of height variation, thereby stabilizing welding conditions while preserving manufacturing feasibility across diverse geometries.
Solution Approach 2:
The invention implements a feedback control system that detects the actual height or position of each joining location and automatically adjusts the joining parameters or head position accordingly. This feedback mechanism ensures that welding conditions remain stable and optimal even when faced with height variations, maintaining reliable joining quality throughout the manufacturing process.
3Ease of manufacture
If resin components are pressed during sequential welding to handle height variation, then joining can proceed, but residual stress occurs and resin components break
Solution Approach 1:
The invention employs a dynamically adjustable pressing mechanism that applies force adaptively during sequential welding operations. Rather than continuous pressing, the mechanism adjusts the magnitude and timing of pressing forces to match the specific stage of joining and local height conditions. This dynamic force application achieves proper contact for welding while minimizing residual stress accumulation and preventing resin component breakage.
Solution Approach 2:
The invention uses periodic pressing action during sequential welding, where pressing force is applied intermittently at optimized intervals rather than continuously. This periodic pressing allows the resin material to relax between force applications, reducing residual stress buildup. The timing and duration of each pressing cycle are controlled to ensure adequate bonding while maintaining component integrity throughout the sequential joining process.
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
Enables simple and strong joining of resin components with reduced facility costs and stress, stabilizing the welding process despite height variations and complex shapes, while facilitating assembly and reducing manufacturing costs.
Implementation Method 1
applying vibration to the joining component, thereby causing the joining component to form welded parts at locations where the first resin component and the second resin component have contact with the joining component
Implementation Method 2
a welding step of applying vibration to the joining component, thereby causing the joining component to form welded parts
Data Source
AI summary
The present invention is provided with: an insulation holder formed of a thermoplastic resin material and having a first opening; a wire connection ring formed of a thermoplastic resin material and having a second opening; and a joining component inserted astride in the first opening and the second opening, the joining component being formed of a metal material having a higher melting point than those of the thermoplastic resin materials, the joining component having a higher stiffness than those of the insulation holder and the wire connection ring, wherein a welded part is formed by welding in at least a part of an area where each of the insulation holder and the wire connection ring has contact with the joining component.