Winding Support End-Segment Welding With Circular Clamping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for positioning and welding end portions of electric motor windings lack precision, leading to inconsistent connections in high-power electric motor applications.
Innovation Solution
A method and device utilizing a processing unit with actuator elements that move along a circular path to precisely bring together and clamp end portions of winding rods for precise welding, employing laser welding and active cooling to ensure accurate alignment and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning methods are used for end portions, then the device complexity is low, but the manufacturing precision is insufficient
Solution Approach 1:
The processing unit is divided into multiple actuator elements (first actuator element, second actuator element) that independently control different end portions. This segmentation allows precise individual positioning of each end portion while maintaining a modular device structure that doesn't excessively increase complexity.
Solution Approach 2:
The patent replaces conventional mechanical positioning systems with a controlled actuator mechanism that uses circular path movement and coordinated actuation. This substitution enables higher positioning precision through controlled motion rather than relying on mechanical fixtures alone.
2Manufacturing precision
If individual processing of end portion pairs is implemented, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The processing unit continuously moves along the circular path and processes end portion pairs in sequence without interruption. The actuator elements remain engaged with the end portions throughout the circular motion, maintaining continuous useful action that balances precision with efficient throughput.
Solution Approach 2:
The processing follows a periodic cycle where the processing unit completes circular paths and returns to process the next end portion pair. This periodic action allows systematic individual processing while maintaining predictable production rhythm and overall productivity.
3Measurement precision
If a processing unit moves on a circular path is used, then the positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The processing unit moves along a circular path instead of linear trajectories, utilizing curved motion to achieve precise positioning. The circular guide device provides inherent geometric constraints that simplify alignment while the curvature enables accurate positioning through rotational symmetry.
Solution Approach 2:
The circular guide device serves multiple functions: it guides the processing unit, provides positioning references, and enables access to multiple end portion pairs in sequence. This multi-functionality reduces the need for separate positioning mechanisms for each end portion, thereby limiting the increase in device complexity.
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 achieves precise welding of end portions, enhancing the quality and reliability of electric motor windings by ensuring accurate alignment and efficient processing, thereby improving the precision and reliability of electric motor connections.
Implementation Method 1
at least one clamping force caused by the bringing together of the first actuator element and the second actuator element brings together the first end portion and the second end portion into a welding position
Implementation Method 2
a processing unit (6), which can be moved on a circular path (K) along a guide device (5)
Implementation Method 3
The bringing together of the first end portion and second in portion preferably takes place individually, so that on each bringing together, only one first end portion and one second end portion are brought together
Data Source
AI summary
A method (100) for processing conductor segments (2) of a winding support (3) of an electric motor, wherein at least two conductor segments (2) are arranged on the winding support (3), wherein the conductor segments (2) protrude out of the end side of the winding support (3) by way of end sections (4). The method (100) ensuring sufficient precision when positioning the end sections joined for a welding operation using at least the following steps: advancing (200) a processing unit (6), which can be moved on a circular path (K) along a guide device (5) and having at least one first actuator element (7a) and at least one second actuator element (7b) to at least one first end section pair (4a, 4b) having a first end section (4a) and a second end section (4b) or the first end section (4a) and the second end section (4b) to the processing unit (6), joining (300) the first actuator element (7a) and the second actuator element (7b) so that, in a clamping region (9), a clamping force joins the first end section (4a) and the second end section (4b) into a welding position, welding (400) the first end section (4a) and the second end section (4b).