JP2019118200A - Conductor bonding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To join an end portion of a power line so as not to cause a positional deviation of a terminal of the power line to the end portion of a coil wound around a stator core. SOLUTION: The conductor joining method of joining an end of a coil formed of a conductor coated with an insulating coating and wound around a stator core and an end of a power line connected to a terminal has an insulating coating. After clamping the part where the insulating coating of the coil is not peeled off and the power line so that the end of the peeled coil and the end of the power line are adjacent to each other, the end of the coil and the end of the power line And are clamped and both are welded together. [Selection diagram] FIG. 6

Description

  The present disclosure relates to a conductor joining method of joining a coil wound around a stator core and a power line connected to a terminal.

  DESCRIPTION OF RELATED ART Conventionally, as a welding apparatus which welds the end parts of the electrical conductor inserted in the stator core, the thing containing the jig which supports a stator, a welding torch, and a clamp jig is known (for example, patent document 1) reference). The clamp jig of this welding apparatus clamps the ends of four pairs of electrical conductors collectively from both sides in the circumferential direction of the stator core, and the welding apparatus consists of electrical conductors sandwiched by clamping jigs. Weld the ends in order. Thus, a coil is wound around the stator core, and the end of the power wire connected to the terminal is electrically joined to the end of the coil. And the terminal of a power wire is generally fixed to the terminal block installed in the housing of the motor containing a stator, and is connected to another electric equipment via the said terminal block.

International Publication No. 2017/159865

  However, even when the above-described welding apparatus is used, welding may occur when the end of the power line is inclined with respect to the end of the coil when joining the coil and the power line. In such a case, when the stator is assembled to the housing of the motor, the position of the terminal connected to the power line is shifted with respect to the terminal block to be fixed, and the fixing operation of the terminal to the terminal block is easy It becomes impossible to execute. In addition, if the position of the terminal is forcibly corrected and the terminal is fixed to the terminal block, the strength of the weld between the end of the power line and the end of the coil is adversely affected due to deformation of the power line or the like. There is a fear.

  Then, this indication makes it a main purpose to join the end of the power wire concerned so that position shift of a terminal of a power wire may not be generated at the end of a coil wound around a stator core.

  The conductor joining method of the present disclosure is a conductor joining method for joining an end of a coil formed by a conductor to which an insulating coating is applied and wound around a stator core and an end of a power wire connected to a terminal. And clamping the power line with a portion of the coil where the insulation coating is not peeled off, such that the end of the coil from which the insulation coating is peeled off and the end of the power line are adjacent to each other. And clamping the end of the coil and the end of the power wire to weld them together.

  In this method, the power wire is clamped with the portion of the coil where the insulation coating is not peeled off, before the end of the power wire is welded to the end of the coil where the insulation coating is peeled off. Thus, it is possible to suppress welding at the end of the coil in a state where the end of the power line is inclined to the end of the coil with the end of the insulating coating of the coil as a fulcrum. As a result, it is possible to join the end of the power line to the end of the coil so as not to cause the displacement of the terminal due to the inclination of the power line with respect to the end of the coil.

  Further, when the power line is clamped with the portion of the coil where the insulating coating is not peeled off, the coil may be drawn to the power line side. Thus, since the end of the power line can be joined to the end of the coil based on the positions of the power line and the terminal, the occurrence of positional deviation of the terminal can be better suppressed.

  Furthermore, the clamping force at the time of clamping the end of the coil and the end of the power wire is the clamping force at the time of clamping the power wire and the portion of the coil where the insulating coating is not peeled off. It may be set smaller than that. Thus, when clamping the end of the coil and the end of the power line, it is possible to suppress the power line from being inclined with respect to the end of the coil with the end of the insulating coating of the coil as a fulcrum. It becomes possible.

It is a schematic block diagram which shows the stator for electric motors manufactured using the conductor joining method of this indication. It is a top view which shows the stator for electric motors of FIG. It is explanatory drawing which shows an example of the procedure of joining the end part of the coil wound by the stator core, and the end part of the power wire connected to the terminal. It is a principal part enlarged view for explaining a conductor joining method of this indication. (A) And (b) is a schematic diagram for demonstrating the conductor joining method of this indication. It is a principal part enlarged view for explaining a conductor joining method of this indication. It is explanatory drawing which shows the principal part of the stator for motors manufactured using the conductor joining method of this indication.

  Next, an embodiment of the present disclosure will be described with reference to the drawings.

  FIG. 1 is a schematic configuration view showing a motor stator 1 manufactured using the conductor joining method of the present disclosure, and FIG. 2 is a plan view showing the motor stator 1. The motor stator 1 shown in these drawings constitutes a three-phase alternating current motor used as, for example, a traveling drive source or a generator of an electric car or a hybrid vehicle together with a rotor (not shown). The motor stator 1 according to the present embodiment includes a stator core 2 and a plurality of stator coils 3.

  The stator core 2 is formed, for example, by laminating a plurality of electromagnetic steel plates 21 (see FIG. 2) formed in an annular shape by pressing, and exhibits an annular shape as a whole. The stator core 2 has a plurality of tooth portions (not shown) formed between a plurality of tooth portions (not shown) protruding inward in the radial direction at intervals in the circumferential direction from the annular outer peripheral portion and teeth portions adjacent to each other. And. The stator core 2 may be integrally formed, for example, by pressure-molding and sintering a ferromagnetic powder.

  The plurality of stator coils 3 includes a U-phase coil, a V-phase coil, and a W-phase coil, and each stator coil 3 is formed by electrically joining a plurality of segment coils 4. The segment coil 4 is, for example, an electrical conductor formed by bending a flat wire having an insulating film made of enamel resin or the like having a thickness of about 0.2 to 0.3 mm on its surface into a substantially U shape. And has two tips with the insulation coating removed. The two legs of each segment coil 4 are respectively inserted into the corresponding core slots of the stator core 2, and a portion (not shown) is bent in a portion projecting from one end face (upper end face in FIG. 1) of the stator core 2 of each segment coil 4. Bending is performed using a processing device.

  The tip of each segment coil 4 after bending extends in the axial direction of the stator core 2 and is electrically joined to the corresponding tip of the other segment coil 4 by welding (in the present embodiment, TIG welding) Ru. As a result, the plurality of stator coils 3 are wound around the stator core 2, and each stator coil 3 has two annular coil end portions 3 a and 3 b projecting outward from the end face in the axial direction of the stator core 2. Further, in each core slot of stator core 2, an insulator (insulating paper) not shown is disposed.

  Among the many segment coils 4 inserted into the core slots of the stator core 2, one end of the three segment coils 4u, 4v, 4w is not joined to the other segment coil 4, and FIGS. As shown, while being bent toward the outer periphery of the stator core 2 by a bending device (not shown), it is bent upward in FIG. Hereinafter, one ends of the three segment coils 4u, 4v, 4w drawn out to the outer peripheral side of the stator core 2 in this manner will be referred to as lead wires (first conductors) 40u, 40v, 40w. The lead wire 40u is included in the U-phase coil, the lead wire 40v is included in the V-phase coil, and the lead wire 40w is included in the W-phase coil.

  The tip 41 (first tip: a portion where the insulation coating is peeled off) of the lead wire 40 u extends in the axial direction of the stator core 2 as shown in FIG. 1 and as shown in FIG. By welding (in the present embodiment, TIG welding) to the tip 51 (second tip: a portion where the insulating coating is peeled off, see FIG. 3) of the power wire (second conductor) 50 u electrically joined to 5 u It is electrically joined. Further, the end portion 41 of the lead wire 40v also extends in the axial direction of the stator core 2, and is welded to the end portion 51 of the power line (second conductor) 50v electrically joined to the V phase terminal 5v (this embodiment) In the form, they are electrically joined by TIG welding). The end portion 41 of the lead wire 40 w also extends in the axial direction of the stator core 2 and is welded to the end portion 51 of the power line (second conductor) 50 w electrically joined to the W phase terminal 5 w (in this embodiment) , Electrically connected by TIG welding). The power lines 50u, 50v, 50w are formed of, for example, round wires (electrical conductors) having an insulating film formed on the surface, and are fixed to the holding member 6 made of resin. The terminals 5u-5w are fixed to a terminal block (not shown) installed (fixed) to the housing when the motor stator 1 is assembled to the motor housing (not shown).

  Here, when joining the tip 41 of the lead wire 40u-40w and the tip 51 of the power wire 50u-50w, the tip 51 of the power wire 50u-50w is against the tip 41 of the lead wire 40u-40w. It may be welded in an inclined state. That is, as shown in FIG. 3, the tip portion 41 of the lead wire 40u-40w from which the insulating film 45 is peeled off and the tip portion 51 of the power line 50u-50w are clamped by the clamp 200 functioning as a welding electrode (cathode). When the two are TIG welded together, the end 51 may be slightly inclined with respect to the end 41 with the end 45 e of the insulating coating 45 of the lead wire 40 u-40 w as a fulcrum.

  In such a case, even if the inclination of the distal end portion 51 with respect to the distal end portion 41 is slight, as shown in FIG. 3, of the terminals 5u-5w of the power lines 50u-50w whose inclination is separated from the distal end portion 51. The influence on the position and attitude is not negligible. For this reason, when welding is performed in a state where the end 51 of the power wire 50u-50w is inclined to the end 41 of the lead wire 40u-40w, the position of the terminal 5u-5w is shifted with respect to the terminal block to be fixed. As a result, it becomes impossible to easily perform the fixing operation of the terminals 5u-5w to the terminal block. In addition, when the positional displacement of the terminals 5u-5w occurs, if the positions of the terminals 5u-5w are compulsorily corrected and the terminals 5u-5w are fixed to the terminal block, the tip of the power line 50u-50w is deformed or the like. There is also a possibility that the strength of the weld between the portion 51 and the leading end 41 of the lead wire 40u-40w may be adversely affected.

  Based on this, at the time of manufacturing the motor stator 1, the leading end portion 41 of the lead wire 40u-40w and the leading end portion 51 of the power line 50u-50w are joined by the following procedure. As shown in FIG. 4, for example, when joining the tip end portion 41 of the lead wire 40u and the tip end portion 51 of the power line 50u, first, the portion of the lead wire 40u not peeled off and the insulation coating of the power line 50u The clamp 100 clamps the portion not peeled off. As shown in FIGS. 5A and 5B, the clamp 100 includes a pressing member 101, a pulling member 102 having a claw portion 102a, and a driving device (not shown). The pressing member 101 and the pulling member 102 are formed of a material (for example, iron) having a lower conductivity than a material (for example, copper) forming the clamp 200 that functions as a welding electrode.

  The clamp 100 pulls the lead wire 40u (see FIG. 5A) while pressing the pressing member 101 against one of the lead wire 40u (40v, 40w) and the power wire 50u (50v, 50w) (see FIG. 5A). The other of 40v and 40w) and the power line 50u (50v and 50w) is pulled to one side to clamp both (see FIG. 5 (b)). Then, in the present embodiment, as shown in the drawing, the lead wire 40u (40v, 40w) is drawn to the power line 50u (50v, 50w) side to clamp portions where the both insulating films are not peeled off.

  Then, as shown in FIG. 6, the tip end portion 41 of the lead wire 40u and the tip end portion 51 of the power line 50u-50v are clamped by the clamp 200 functioning as a welding electrode. In the present embodiment, the clamping force of the clamp 200 for clamping the tip portions 41 and 51 is the clamping force (for example, about 200 N) of the clamp 100 for clamping portions of the lead wire 40u and the power wire 50u where the insulation coating is not peeled off. (E.g., about 150 N) smaller than. Then, while an inert gas is sprayed from the welding torch 201 including a tungsten electrode (anode) (not shown) to the tip portions 41 and 51, both are melted and joined by the arc from the welding torch 201.

  Thus, the end 51 of the power line 50u-50v is inclined to the end 41 of the lead 40u-40w with the end 45e of the insulating coating 45 of the lead 40u-40w as a fulcrum, It can control that it is welded. As a result, as shown in FIG. 7, the lead wire 40 u-40 w does not generate positional deviation of the terminals 5 u-5 w due to the inclination of the power wire 50 u-50 v with respect to the tip 41 of the lead wire 40 u-40 w It becomes possible to join the tip 51 of the power line 50u-50v to the tip 41 of the

  Also, when clamping the portion of the lead wire 40u-40w where the insulating film 45 is not peeled off and the power line 50u-50v with the clamp 100, by drawing the lead wire 40u-40w to the power line 50u-50v side, The tip portions 41 and 51 can be joined based on the positions of the power lines 50u-50v and the terminals 5u-5w. Thereby, it becomes possible to control generation of terminal 5u-5w position gap better.

  Furthermore, in the above embodiment, the clamping force of the clamp 200 clamping the tip portions 41 and 51 is set smaller than the clamping force of the clamp 100 clamping portions of the lead wire 40u and the power wire 50u where the insulation coating is not peeled off. Be Thus, when the end portions 41 and 51 are clamped by the clamp 200, the end portion 51 of the power line 50u-50v is the lead wire 40u-40w with the end 45e of the insulating film 45 of the lead wire 40u-40w as a fulcrum. It is possible to suppress the inclination with respect to the tip end portion 41.

  When joining of the lead wires 40u-40w and the power wires 50u-50v is completed, the stator core 2 is formed with the coil end portion 3b in the lower part in the drawing from the coil end part 3a side of each stator coil 3 exposed from the upper end surface in FIG. A resin such as varnish is applied toward the side. Thereby, each segment coil 4 and the insulator which is not shown in figure are fixed to the stator core 2 by the said resin. Furthermore, the exposed portion of the electrical conductor such as the joint between the ends of the segment coil 4 or the joint between the end 41 of the lead wire 40u-40w and the end 51 of the power wire 50u-50w The body is applied.

  As described above, according to the wire bonding method of the present disclosure, the positional deviation of the terminals 5u-5w caused by the inclination of the power lines 50u-50v with respect to the stator coil 3 or the leading end 41 of the leader 40u-40w is generated. It is possible to join the tips 41 and 51 so as not to cause them. Although not shown, the clamps 100 and 200 may be configured to collectively clamp a plurality of sets of lead wires 40u-40w and power lines 50u-50v, or a plurality of sets of tip portions 41 and 51. Good. Further, the tip portions 41 and 51 may be joined by welding other than TIG welding as long as the clamps functioning as welding electrodes are used.

  The invention of the present disclosure is not limited to the above embodiment, and it goes without saying that various modifications can be made within the scope of the present disclosure. Furthermore, the above-described embodiment is merely a specific form of the invention described in the section of the summary of the invention, and does not limit the elements of the invention described in the section of the summary of the invention.

  The invention of the present disclosure can be used in the field of motor manufacturing and the like.

  Reference Signs List 1 motor stator, 2 stator core, 21 electromagnetic steel plate, 3 stator coil, 3a, 3b coil end portion, 4, 4u, 4v, 4w segment coil, 40u, 40v, 40w leader wire, 41 tip portion, 45 insulating film, 45e End part, 5u, 5v, 5w terminal, 50u, 50v, 50w power line, 51 end part, 100 clamp, 101 pressing member, 102 pulling member, 102a claw, 200 clamp, 201 welding torch.

Claims (1)

A conductor joining method for joining an end of a coil formed of a conductor coated with an insulating film and wound around a stator core with an end of a power line connected to a terminal,
The power wire is clamped with a portion of the coil where the insulation coating is not peeled off, such that the end of the coil from which the insulation coating is peeled off and the end of the power wire are adjacent to each other A conductor bonding method for clamping the end of the power line and the end of the power line and welding them together.

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