EP4162595A1 - Procédé de remise en état d'un joint soudé défectueux d'un enroulement en épingle à cheveux - Google Patents

Procédé de remise en état d'un joint soudé défectueux d'un enroulement en épingle à cheveux

Info

Publication number
EP4162595A1
EP4162595A1 EP21726375.5A EP21726375A EP4162595A1 EP 4162595 A1 EP4162595 A1 EP 4162595A1 EP 21726375 A EP21726375 A EP 21726375A EP 4162595 A1 EP4162595 A1 EP 4162595A1
Authority
EP
European Patent Office
Prior art keywords
welded
welding
conductor
connection
winding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21726375.5A
Other languages
German (de)
English (en)
Inventor
Patrick Herrmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Audi AG
Original Assignee
Audi AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Audi AG filed Critical Audi AG
Publication of EP4162595A1 publication Critical patent/EP4162595A1/fr
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/35—Form-wound windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/50—Disassembling, repairing or modifying dynamo-electric machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00 relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas

Definitions

  • the invention relates to a method for reworking a defective welded connection of a hairpin winding for a rotor or stator of an electrical machine.
  • a stator with attached coils is typically used to drive a rotor by energizing the coils that vary over time or to convert a magnetic field that changes over time into an induction current.
  • a cylinder-shaped winding carrier can be used which has a large number of grooves running in the axial direction through which a conductor forming the coils is guided. In principle, it is possible to wind separate windings around each of the coil teeth delimiting the slots. However, it can be advantageous to meander a connected conductor through several grooves.
  • a so-called hairpin design is now often used in order to produce such turns meandering through grooves.
  • a profile wire usually a rectangular wire
  • the legs of this hairpin are then arranged in a circular shape and inserted into the grooves of a laminated stator core.
  • the free ends of the respective hairpins are concentrated in the next step. Rotated by a defined angle relative to the stator axis or to the axis of rotation of the electrical machine.
  • the invention is therefore based on the object of specifying a comparatively improved solution for reworking faulty welded connections of a hairpin winding.
  • the object is achieved according to the invention by a method for reworking a faulty welded connection of a hairpin winding for a rotor or stator of an electrical machine, which comprises the following steps:
  • the hairpin winding having at least one conductor formed from several conductor sections, the conductor sections of the respective conductor being welded in pairs to a respective welded connection by a first welding process, with at least one of the welded connections being a faulty welded connection is, separating the defective welded connection, and connecting the previously connected by the defective welded connection, to be welded conductor sections by a connection method different from the first welding method, in particular by a second welding method.
  • the defective welded connection is first separated, in particular by severing the area having the welded connection. In this way, a defined geometry of the ends of the conductor sections to be connected can be provided, so that the problems explained at the beginning with regard to an undefined initial geometry for post-processing can be avoided.
  • the reworked welded connection would have a significantly different shape, in particular a significantly different length in the axial direction of the rotor or stator, than for non-reworked welded connections, which can be disadvantageous for subsequent steps, for example for the insulation of the welded connections.
  • connection method in particular a second welding method, is used in order to reconnect the previously separated conductor sections.
  • a different connection method in particular a second welding method, is used in order to reconnect the previously separated conductor sections.
  • the conductor sections can in particular be clip-shaped, so z. B. by two slot segments guided through a respective slot in the winding support cuts and a connecting portion connecting these be formed.
  • Corresponding clip-shaped conductor sections also called hairpins, are common and known in hairpin windings.
  • differently shaped conductor sections for example linear conductor sections, also called I-pins, can also be used.
  • Welded joints can be defective for a number of reasons. For example, voids or pores, that is, air pockets, can occur. With these defects, the copper cross-section is reduced at the welding point, which can reduce the service life of the rotor or stator, as higher thermal loads occur locally. In addition, due to the resulting smaller connection cross-section, mechanical loads can lead to a break in the connection during operation of the rotor or stator. If too much energy is used during welding, the insulation of the respective conductor section can be damaged, which in turn can lead to a reduction in the life of the rotor or stator.
  • connection method a connection method that applies additional material to the conductor sections to be welded can be used.
  • connection processes that apply additional material can be carried out at lower temperatures or introduce less energy into the conductor ends of the conductor sections than beam welding processes. with increasing material input from an insulation of the respective Porterab cut away.
  • connection methods that apply additional material is that they typically require longer process times. However, this is less relevant in the context of a rework solution, so that these connection methods are nevertheless well suited for rework.
  • the first welding process can be a beam welding process.
  • laser welding or electron beam welding can be used.
  • the first welding process in particular, only material of the conductor sections is used that is melted in order to connect them.
  • the short process times that can be achieved are an advantage of beam welding processes. This is particularly relevant since a large number of welded connections are to be made in the production of the hairpin winding.
  • gas shielded metal welding can be used as the joining method.
  • the shielding gas used can transfer heat to the conductor sections. It can therefore be advantageous to prevent the gas from flowing down the conductor into the insulated areas of the respective conductor section by means of a tool which grips around the ends of the conductor sections to be welded, for example in the manner of a sleeve.
  • CMT welding or metal inert gas welding or metal active gas welding can be used as the joining method.
  • Metal inert gas welding and metal active gas welding are well known welding processes in which the electrode is partially melted off and forms part of the weld. In summary, these welding processes are also sometimes referred to as Mig / Mag welding.
  • CMT welding is also a gas metal arc welding process.
  • the term CMT welding is derived from the English expression "cold metal transfer”.
  • This welding process is a further development of Mig / Mag welding, in which the welding wire is moved back and forth at a high frequency.
  • the droplet detachment from the electrode is improved and a lower temperature entry can be achieved in the conductor sections to be welded.
  • a stripped length of the conductor ends of 5 to 6 mm can be sufficient to remove the conductor ends without damaging the insulation. lation to weld.
  • Usual laser welding processes require an isolated length of approx. 10 mm.
  • the defective welded connection can be separated by separating an area comprising the defective welded connection from the conductor sections to be connected. This is also referred to as cutting to length and can be implemented, for example, by cutting off the conductor ends of the conductor sections. This provides a defined surface for the connection method.
  • a volume of the additional material which is between 50% and 200% or between 80% and 120% of the volume of the separated area can be applied by the second connection method.
  • the reworked welded joint can have a similar shape to that of the unreworked welded joints, which can be advantageous for subsequent processing steps, for example insulation processes.
  • At least the welded connections of the winding can be immersed in a bath of insulating agent after connecting the conductor sections to be connected in the axial direction of the rotor or of the stator.
  • it can be immersed in resin or powder coating.
  • the conductor ends of the conductor sections or the welded connections protrude approximately the same distance beyond the winding support. This can be achieved by applying additional material with approximately the same volume as the separated area, as explained above.
  • the provision of the hairpin winding applied to a winding carrier can comprise the following steps:
  • the steps known per se for producing a hairpin winding of a rotor or stator can also be part of the method according to the invention, so that the method according to the invention can include faulty production of the hairpin winding and the subsequent reworking.
  • Fig. 1 is a sectional detailed view of a hairpin winding for egg NEN rotor or stator of an electrical machine
  • FIG. 2 shows the state of a welded connection to be reworked in different steps of an embodiment of the method according to the invention.
  • stator 1 shows a detailed view of a stator 1 of an electrical machine.
  • the stator 1 comprises a winding carrier 2 with several slots 15, which carries several continuous conductors 3, 4 of a hairpin winding.
  • the conductors 3, 4 can, for example, form windings for different phases or be windings of one phase connected in parallel. For reasons of clarity, only two such conductors 3, 4 are shown in FIG. 1, with real ones electrical machines one or more conductors 3, 4 are used for typically three phases.
  • the turns formed by the conductors 3, 4 are made by a method in which the winding support 2 and a plurality of bracket-shaped conductor sections 5 are provided, after which thenatiab sections are arranged in a basket and are pushed axially into the winding support 2 that two groove sections 6, 7 of each conductor section 5 run in a respective groove 15 of the winding support, the groove sections 6, 7 being connected by a connecting section 8.
  • the free ends 9 to 12 of the groove sections 6, 7 or the Lei ter sections 5 are bent in the manner shown in Fig. 1, so that two free ends 10, 11 and 9, 12 come to lie immediately adjacent to each other. This is also known as twisting.
  • the free ends 10, 11 and 9, 12 are then welded by a first welding process, for example laser welding or another beam welding process, in order to produce respective welded connections 13, 14.
  • a large number of welded connections 13, 14 are made between different conductor sections 5, for example over 200 welded connections, so that even with a relatively low error rate of the welding process of 0.1%, for example, a relatively high proportion of defective stators results , in which at least one of the welded connections 13, 14 is faulty.
  • Defective welds 13, 14 can be recognized, for example, by a manual or automatic inspection. In the following it is assumed that the welded connection 13 is faulty. For the welded connection 13, a method for reworking this welded connection 13 is then carried out, which is explained in more detail below with reference to FIG. 2.
  • step S1 the hairpin winding applied to the winding carrier 2 is first made available, as has been explained above.
  • step S2 an area 15 comprising the defective weld connection 13 is separated from the conductor sections 5 to be connected or from the free ends 10, 11, for example by a cutting process.
  • the stripped length 16 of the Leinicden to a shorter stripped length 17 is reduced. If a beam welding process were again used to reconnect the conductor sections 5 or the free ends 10, 11, this would on the one hand potentially result in a large amount of heat input in the area of the insulation, which can damage it.
  • the weld connection 13 would be considerably shorter after such reworking than the welded connections 14 that have not been reworked, which would be disadvantageous, for example, if the welded connections 13, 14 are immersed in an insulating bath after connection, since in this case the welded connections 13 under Not reliably isolated under certain circumstances.
  • step S3 a different connection method from the first welding method, ie in particular no beam welding method, is used to reconnect the conductor sections 5 or their free ends 10, 11.
  • a connection method is used here which applies additional material 18 to the conductor sections 5 to be welded or their free ends 10, 11.
  • Gas-shielded metal welding can be used as the connection method, in which the welding electrode is partially melted and forms part of the welded connection.
  • CMT welding can be used particularly advantageously, since in this case there is particularly little heat input and damage to the insulation of the conductor sections 5 can thus be avoided in a particularly reliable manner.
  • a volume of additional chemical material 18 is applied in the connection method, which essentially corresponds to the volume of the separated area 15, so that, as can be seen in FIG. 2 from a comparison of the state in step S1 and the state after step S3 results, a total of at least a similar shape of the welded joint 13 results, as before the post-processing.
  • the stripped length 16 or the length with which the welded joint 13 protrudes beyond the winding support 2, after such post-processing essentially correspond to the corresponding lengths for other welded joints 14 for which no post-processing has taken place.
  • interconnection bridges can be placed and / or the welded connections 13, 14 can be isolated, for example by dipping the welded connections in the axial direction of the rotor or stator into an insulating bath in order to manufacture the rotor or stator complete.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Quality & Reliability (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un procédé de remise en état d'un joint soudé défectueux (13, 14) d'un enroulement en épingle à cheveux pour un rotor ou un stator (1) d'une machine électrique, comprenant les étapes suivantes : - fournir l'enroulement en épingle à cheveux, qui est monté sur un support d'enroulement (2), l'enroulement en épingle à cheveux ayant au moins un conducteur (3, 4) formé à partir d'une pluralité de sections conductrices (5), les sections conductrices (5) du conducteur respectif (3, 4) étant soudées par paires au niveau d'un joint soudé respectif (13, 14) au moyen d'un premier procédé de soudage, au moins un des joints soudés (13, 14) étant un joint soudé défectueux (13), - séparer le joint soudé défectueux (13), et - relier les sections conductrices (5) connectées précédemment au joint soudé défectueux (13) et qui doivent être soudées, au moyen d'un procédé de connexion qui diffère du premier procédé de soudage, plus particulièrement au moyen d'un deuxième procédé de soudage.
EP21726375.5A 2020-06-08 2021-05-12 Procédé de remise en état d'un joint soudé défectueux d'un enroulement en épingle à cheveux Pending EP4162595A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102020115124.1A DE102020115124B4 (de) 2020-06-08 2020-06-08 Verfahren zur Nachbearbeitung einer fehlerhaften Schweißverbindung einer Hairpin-Wicklung
PCT/EP2021/062566 WO2021249713A1 (fr) 2020-06-08 2021-05-12 Procédé de remise en état d'un joint soudé défectueux d'un enroulement en épingle à cheveux

Publications (1)

Publication Number Publication Date
EP4162595A1 true EP4162595A1 (fr) 2023-04-12

Family

ID=75977755

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21726375.5A Pending EP4162595A1 (fr) 2020-06-08 2021-05-12 Procédé de remise en état d'un joint soudé défectueux d'un enroulement en épingle à cheveux

Country Status (5)

Country Link
US (1) US12456906B2 (fr)
EP (1) EP4162595A1 (fr)
CN (1) CN115699542B (fr)
DE (1) DE102020115124B4 (fr)
WO (1) WO2021249713A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116511905B (zh) * 2023-05-15 2024-01-23 跃科智能制造(无锡)有限公司 一种扁线电机定子切平焊接设备
DE102023004177B4 (de) * 2023-10-16 2025-12-04 Grob-Werke Gmbh & Co. Kg Verfahren zum Nachbearbeiten einer fehlerhaften Schweißverbindung einer Hairpin-Wicklung für einen Stator einer elektrischen Maschine
GB2639192A (en) * 2024-03-07 2025-09-17 Jaguar Land Rover Ltd Laser welding method

Citations (4)

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JP2002292468A (ja) * 2001-03-30 2002-10-08 Kobe Steel Ltd 溶接ロボット装置の自動運転方法
EP1700663A2 (fr) * 2005-03-08 2006-09-13 Central Motor Wheel Co., Ltd. Méthode et appareil de soudage
US8110774B2 (en) * 2004-07-08 2012-02-07 Trumpf Laser Gmbh + Co. Kg Laser welding method and apparatus
JP2014238387A (ja) * 2013-05-07 2014-12-18 トヨタ自動車株式会社 溶接品質検査装置

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SE510950C2 (sv) 1997-11-25 1999-07-12 Asea Brown Boveri Högspänningsledning, metod att skarva en ledare ingående i sådan högspänningslindning och elektrisk maskin innefattande sådan högspänningsledning med skarvad ledare
SE9704382L (sv) * 1997-11-27 1999-05-28 Asea Brown Boveri Förfarande vid elektrisk maskin
JP3964116B2 (ja) * 2000-09-12 2007-08-22 三菱電機株式会社 回転電機の固定子
JP4910572B2 (ja) * 2006-08-30 2012-04-04 株式会社デンソー 車両用回転電機
US20130075371A1 (en) 2011-09-22 2013-03-28 GM Global Technology Operations LLC Non-destructive evaluation of welded joints of bar wound stator utilizing infrared and thermal methods
JP5866673B2 (ja) * 2014-01-22 2016-02-17 トヨタ自動車株式会社 溶接部の画像検査装置及び画像検査方法
EP3051669B1 (fr) 2015-01-27 2018-08-22 Brusa Elektronik AG Bobine pour un stator, machine électrique, et procédé de fabrication de la bobine pour un stator
CN105215623A (zh) 2015-10-16 2016-01-06 安徽欣创节能环保科技股份有限公司 一种笼形转子笼条断裂修复方法
JP6642123B2 (ja) * 2016-03-04 2020-02-05 株式会社デンソー 回転電機
DE102016218431A1 (de) 2016-09-26 2018-03-29 Ford Global Technologies, Llc Verfahren zum Reparieren fehlerhafter Verbindungen
DE102016222385A1 (de) * 2016-11-15 2018-05-17 Robert Bosch Gmbh Laserschweißverfahren für Stator
JP7009986B2 (ja) * 2017-12-27 2022-01-26 トヨタ自動車株式会社 回転電機のステータ、および、ステータコイルの製造方法
DE102018200035A1 (de) 2018-01-03 2019-07-04 Volkswagen Aktiengesellschaft Verfahren zum elektrischen Verbinden von Hairpin-Enden bei der Herstellung eines Rotors oder Stators mit Hairpin-Wicklung
JP6606202B2 (ja) * 2018-01-10 2019-11-13 本田技研工業株式会社 溶接部検査装置
EP3950210A4 (fr) * 2019-03-29 2023-01-04 IHI Corporation Procédé de réparation de fissures pour structure en acier existante
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JP2002292468A (ja) * 2001-03-30 2002-10-08 Kobe Steel Ltd 溶接ロボット装置の自動運転方法
US8110774B2 (en) * 2004-07-08 2012-02-07 Trumpf Laser Gmbh + Co. Kg Laser welding method and apparatus
EP1700663A2 (fr) * 2005-03-08 2006-09-13 Central Motor Wheel Co., Ltd. Méthode et appareil de soudage
JP2014238387A (ja) * 2013-05-07 2014-12-18 トヨタ自動車株式会社 溶接品質検査装置

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Title
See also references of WO2021249713A1 *

Also Published As

Publication number Publication date
WO2021249713A1 (fr) 2021-12-16
CN115699542A (zh) 2023-02-03
CN115699542B (zh) 2025-08-26
DE102020115124B4 (de) 2025-11-20
US20230198351A1 (en) 2023-06-22
DE102020115124A1 (de) 2021-12-09
US12456906B2 (en) 2025-10-28

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