Electric Machine Winding Bonding With Integrated Joint Insulation
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Solution Overview
Problem
Existing methods for bonding conductor elements in electric machine windings often require additional insulation steps, which can be resource-intensive and complicated, and may lead to short circuits due to inadequate insulation.
Innovation Solution
A method involving a material reservoir arranged on conductor ends before bonding, where the reservoir is melted and distributed over the bonding point to create an insulating structure, thereby simplifying and economizing the insulation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductor ends are bonded by welding to create bonding points, then electrical connection is achieved, but electrical insulation is lost at the bonding points requiring additional insulation steps
Solution Approach 1:
The insulation material is arranged on the conductor ends in advance before the bonding process. This preliminary placement ensures that insulation is already in position before welding occurs, eliminating the need for subsequent insulation steps and reducing process complexity while maintaining reliable electrical connections.
Solution Approach 2:
The bonding process and insulation application are merged into a single integrated process. By combining these two previously separate steps into one operation where insulation material is melted during or after bonding, the overall process complexity is reduced while ensuring both reliable electrical connection and proper insulation.
2Reliability
If additional insulation steps are performed after bonding, then electrical insulation is restored, but resource consumption and process time increase
Solution Approach 1:
The bonding and insulation steps are merged into a single integrated process. The insulation material is positioned beforehand and melted during or immediately after the bonding operation, eliminating the need for separate insulation steps and thereby increasing production efficiency while maintaining insulation reliability.
Solution Approach 2:
The useful action continues seamlessly from bonding to insulation without interruption. The insulation material is already in position and is melted immediately after bonding using the same heat source or a continuous process, eliminating idle time and maintaining continuous productive action throughout the operation.
3Reliability
If the entire winding is heated for insulation in prior art methods, then insulation is achieved, but energy consumption increases
Solution Approach 1:
Instead of heating the entire winding, the insulation process is localized to only the bonding points where insulation is actually needed. The heat is applied locally to melt the insulation material at specific locations, significantly reducing overall energy consumption while maintaining insulation quality at the critical bonding areas.
Solution Approach 2:
The insulation process is extracted from the general winding heating process and applied only where necessary at the bonding points. This selective approach removes the unnecessary energy consumption associated with heating large portions of the winding that do not require insulation, while still achieving reliable insulation at the critical bonding areas.
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 allows for reliable and efficient bonding and insulation of conductor elements in a single process, reducing resource consumption and eliminating the need for separate insulation steps, thus preventing short circuits.
Implementation Method 1
The method proceeds by melting the material reservoir. In particular, the material reservoir is melted after generating the bonding point
Implementation Method 2
distribution occurs such that an insulating structure is provided after cooling (and/or solidification) of the distributed material of the material reservoir
Data Source
AI summary
A method is provided for producing a winding (1) for an electric machine (10). The winding (1) has conductor elements (2) and two conductor ends (3) of different conductor elements (2) are bonded electrically with one another at a bonding point (4). The method includes arranging at least one material reservoir (5) on the conductor ends (3) to be bonded prior to generating the bonding point (4). The method then includes generating the bonding point (4) by joining the conductor ends (3). The method continues by melting the material reservoir (5) and distributing the molten material reservoir (5) at least over the bonding point (4). Thus, an insulating structure (15) is provided after cooling the distributed material of the material reservoir (5). The insulating structure (15) insulates the conductor ends (3) against their surroundings at least at the bonding point (4).