JP2022134033A - Electrical equipment and method for manufacturing electrical equipment - Google Patents

Abstract

An object of the present invention is to provide an electric device having a simple structure for connecting a lead wire and a coil wire, and a method for manufacturing the electric device. An electric wire having a coil formed by winding an aluminum coil wire covered with an insulator around an iron core, a lead wire, and a joint connecting a part of the coil and the lead wire. In the device, the lead wire and the coil wire are joined by a method that does not pull out the coil wire. For this purpose, the insulation at the joint of the coil is stripped, the end of the lead wire is brought into contact with the joint where the insulation has been stripped under a predetermined pressure, and heat joining is performed in this state. Molten matter generated during bonding is removed by air. After joining, the joint and the end of the lead wire are insulated with an insulator. [Selection drawing] Fig. 1

Description

TECHNICAL FIELD The present invention relates to an electric device having a coil and a method for manufacturing the electric device.

Japanese Patent Application Laid-Open No. 2014-44887 (Patent Document 1) discloses an electrical connection device that uses a coil in which an aluminum wire is wound around an iron core and connects the aluminum wire and a copper electrical terminal.
The technology described in Patent Document 1 includes a winding coil in which an aluminum wire is wound around an iron iron core, a copper electrical terminal having a generally planar welding portion at one end and a pressure contact portion at the other end, and a power source. A winding coil and a copper wire are provided in which the aluminum core wire of the aluminum wire is press-contacted to the press-contact portion and the copper wire is welded to the welding portion of the electric terminal. The press contact portion of the electrical terminal is divided into a first press contact portion and a second press contact portion, and the first press contact portion and the second press contact portion are configured to have different press contact heights when the aluminum core wire is pressed into contact with the first press contact portion and the second press contact portion. The welding part and the press-contact part are integrally molded so as to be covered with resin.

JP 2014-44887 A

In the technique of Patent Document 1, when obtaining a plurality of terminal voltages, it is necessary to pull out the coil wire from the coil, and furthermore, the pulled-out coil wire is connected to the coil wire by a copper electrical terminal having a pressure contact portion at one end. , and the other end of the electrical terminal is welded to the lead wire, which complicates the structure of the connecting device. There is also a need for an electrical terminal with an insulation displacement portion. In addition, the pressure contact requires complicated adjustment work such as changing the height of the pressure contact between the first pressure contact portion and the second pressure contact portion.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide an electric device and a method for manufacturing the electric device which have a simple connection structure between the lead wire and the coil wire and which improves the workability during manufacture.

In order to achieve the above object, the present invention provides, for example, a coil formed by winding a coil wire covered with an insulator around an iron core, a lead wire, the coil wire and the coil wire. and a connecting portion connected to a lead wire, wherein the connecting portion has the insulating material peeled off from the joint portion joined to the lead wire, and the insulating material is peeled from the end portion of the lead wire. In the electric device, the coil is joined while being in contact with the joint portion, and the joint portion and the end portion of the lead wire are insulated with an insulator after the joint.

In another example of the present invention, a coil formed by winding a coil wire covered with an insulator around an iron core, a lead wire, and a part of the coil and the lead wire are connected. In the method of manufacturing an electric device, the insulation of the coil wire at the joint connected to the lead wire is stripped, and the end of the lead wire is pressed against the joint where the insulator is stripped. In addition, they are brought into contact with each other, and in the state of contact, the joining portion and the end portion of the lead wire are joined, and after the joining is completed, the joining portion and the end portion of the lead wire are insulated with an insulator. It is a method of manufacturing an electrical device that

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the electric equipment which made the connection of a lead wire and a coil wire the simple structure can be implement|achieved.

FIG. 4 is a structural diagram showing connection between coil wires and lead wires in Example 1 of the present invention. It is a figure which shows the joining method of the joining part in Example 1 of this invention. FIG. 4 is an external view of insulating paper attached after joining the coil wire and the lead wire; FIG. 4 is an external view of a configuration in which insulating paper is attached after the coil wire and the lead wire are joined; It is a figure which shows the joining method of the joining part which concerns on Example 2 of this invention.

Hereinafter, the present invention will be described in detail based on specific examples. It should be noted that the present invention is not limited to the examples described below. Further, in each drawing, the same reference numerals (numbers) are used for the same parts and devices, and duplicate descriptions of the parts and functions that have already been described may be omitted.

First, in order to facilitate understanding of the present invention, a conventional common method of connecting lead wires and coil wires will be described.

With the conventional connection method, it was difficult to connect the coil wire and the lead wire to a location inside the coil during coil winding. For example, as shown in Patent Literature 1, a coil wire made of an aluminum material is once pulled out to the outside of the coil, and after the coil is finished winding, the lead wire and the pulled out coil wire are combined by a method such as welding and crimping. was connected.

By the way, in order to obtain a plurality of terminal voltages (tap voltages) from the secondary side of the transformer, it is necessary to connect a part of the coil wire obtained by winding the coil a predetermined number of times and a lead wire. Specifically, in order to connect the coil wire and the lead wire, once the winding of the coil wire reaches the predetermined number of turns required to obtain the terminal voltage, the coil wire is once connected to the outside of the coil. Pull out for connection. The coil wire (lead wire) that has been pulled out by the length required for connection needs to be folded back as it is and returned to the original winding position of the coil so that winding can be restarted. At this time, the lead wire and the folded wire (folded wire) are connected to one lead wire corresponding to the terminal voltage. That is, two coil wires extending to the outside of the coil are connected to one lead wire each for one prescribed number of turns.

After that, the coil wire is wound from above two wires, the lead wire and the return wire, and laminated. Repeat the folding process. After the winding of the coil is completed, the two wires of each lead wire and return wire are connected to their respective lead wires. It should be noted that the lead wire and the folded wire may be connected without cutting the folded portion, or may be connected to the lead wire after being cut in advance so as to facilitate the work. Finally, the lead wire, the lead wire and the folded wire should be connected. Insulating paper is wrapped around the lead wires and folded wires that are drawn out of the coil when connecting to lead wires. or welding.

Originally, the current flowing through the coil should be closed inside the coil for better efficiency and less waste. That is, the length for connecting the coil wire to the lead wire from the point where the coil wire is pulled out to the outside of the coil 1 and the length for returning to the original position of the coil by folding are unnecessary parts for the function of the coil. is. However, in the conventional connection method, a lead wire and a folded wire are required to connect the lead wire and the coil wire. work is also required. Furthermore, a connection work is required to connect the lead wires and the return wires to the lead wires. As described above, the conventional connection method is complicated and has a problem of poor workability.

<<Example 1>>
Next, Embodiment 1 of the present invention will be described with reference to FIGS. 1 and 2. FIG. FIG. 1 is a diagram showing the configuration of Embodiment 1 of the present invention when the present invention is applied to a transformer. In FIG. 1, the right side shows the schematic structure of a transformer in which a coil is wound around an iron core, and the left side shows an enlarged view of a portion related to the structure of a connection between a lead wire and a coil. Moreover, FIG. 2 shows a diagram for explaining a method of connecting the coil and the lead wire in the first embodiment of the present invention.

First, in FIG. 1, the coil 1 is composed of a winding frame 7, a low-voltage coil 1L and a high-voltage coil 1H. In the first embodiment, the coil 1 uses a wire made of an aluminum material (aluminum wire) as the coil wire 2 of at least one of the high-voltage coil 1H and the low-voltage coil 1L. This is because aluminum wires are superior to copper wires in terms of weight reduction and cost reduction. The coil wire 2 is insulated in advance with an insulator (insulating material). A coil 1 is manufactured by winding an insulated coil wire. In this embodiment, the coil wire 2 insulated with the insulating paper 5 is used, but the coil wire can be insulated with various insulators. The coil 1 is formed by spirally winding a coil wire 2 preliminarily wound with insulating paper 5 around the axis of a winding frame 7 and laminating a plurality of layers in the radial direction of the coil.

The lead wire 3 (using a good conductor such as copper or aluminum) connects one end of the lead wire 3 to the coil wire 2 with the specified number of turns of the high voltage coil 1H, and the subsequent coil wire 2 is connected to the lead wire 3. The coil wire 2 and the lead wire 3 are connected to each other inside the coil 1 .

The enlarged view shown on the left side of FIG. 1 shows an enlarged appearance of the periphery of the joint portion of the coil wire being wound. A lower layer of coil wire 2b (preliminarily wound insulating paper 5 in the figure) is wound around this enlarged portion, and a coil wire 2a (preliminarily wound insulating paper 5 in the figure) is laminated on the coil wire 2b. It shows a wound state. In addition, in the center of the enlarged portion, a joint 2an between the coil wire and the lead wire (a connection portion of the aluminum wire with the lead wire and its vicinity) is shown.

At this joint portion 2an, first, the insulating paper of the joint portion 2an of the upper coil wire 2a is peeled off, and the end of the lead wire 3 is brought into contact with the joint portion 2an of the coil wire from which the insulating paper has been removed by applying a predetermined pressure. (pressure contact). Predetermined pressure means a pressure that is suitable for the joining operation. In this state, the joints of the coil wire and the lead wire are joined by a method such as heat joining. After this joining, using insulating paper 15 separately prepared, both the joining portion 2an where the surface of the aluminum material is exposed and the end portion of the lead wire 3 are insulated by the insulating paper 15 (by wrapping the insulating paper). It is configured as

In the configuration of the transformer shown in Example 1 of FIG. 1, the lead wire 3 is connected inside the coil 1 without drawing out or folding back the coil wire. The structure of the connection portion of the coil with the lead wire is such that the insulating paper wrapped around the joint portion 2an that is joined to the lead wire is peeled off, and the end of the lead wire is directly connected to the joint portion 2an of the coil from which the insulating paper has been removed. In order to join, the joining portion 2an and the ends of the lead wires 3 are insulated by winding insulating paper 15 prepared separately. Although an example of insulating paper is shown here, it goes without saying that a known insulating material other than insulating paper can be used for insulation. By adopting such a configuration, it is possible to realize a transformer in which the connection structure between arbitrary joints of the coil and the lead wires is simple and workability is improved.

Next, with reference to FIG. 2, a method of joining (connecting) the lead wire and the joining portion of the coil in Example 1 shown in FIG. 1 will be described in detail.

In FIG. 2, 40 is a box (box body) used for joining the coil wire 2 and the lead wire 3 . The box 40 includes a heater 43 for heating and joining the joint and the lead wire, and a nozzle (air 41 in this example) for ejecting gas (in this example, air 41) for removing the melt 9 generated during joining. In this example, an air nozzle 42) and a suction device 44 for sucking the melt 9 removed by the air 41 are attached.

For joining the lead wire 3 and the coil wire 2 at the joining portion 2an, first, the insulating paper 5 at the joining portion 2an is peeled off. After peeling off the insulating paper 5 from the joint 2an, the coil wire 2 with the specified number of turns is lifted on the surface of the winding coil 1 (not shown) so as not to interfere with the surface of the coil 1, and the coil is Attach the joint 2an of the wire 2 so as to be inside the box 40 . The lead wire 3 is wound on a bobbin (not shown) and waits around the coil being wound. It is assumed here that the lead wire 3 wound around the bobbin is not wrapped with insulating paper and is wound as is. Although the lead wire 3 may be insulated with an insulator, it is necessary to peel off the insulator from the end on the joining side and leave the lead wire 3 in a state of raw material. The exposed lead wire 3 is unwound from the bobbin by a predetermined length in order to be attached to the box 40 . The end of the lead wire 3 is aligned with the connection point 8 so that the axis of the lead wire 3 forms a certain angle (for example, a substantially vertical direction) with respect to the axial direction of the joint 2an of the coil wire 2, and in that state, as shown in the figure. Next, the end of the lead wire 3 is joined to the joining portion 2an. That is, they are arranged in a T shape.

The cross-sectional shape of the coil wire 2 used for joining in this example is a rectangular wire of 4 mm×7 mm, and the cross-sectional shape of the lead wire 3 is a rectangular wire of 4 mm×7 mm. In the present invention, the cross-sectional dimensions of the coil wire 2 and the lead wire 3 are not particularly defined. Also, the cross-sectional dimensions of the coil wire 2 and the lead wire 3 used for joining may be different, and the cross-sectional shape may be circular, polygonal, or elliptical. In the drawing, the end of the lead wire 3 is butted against the connection point 8 on the side of the joint 2an of the coil wire 2, but the connection structure in which the coil wire 2 and the lead wire 3 are overlapped is also possible.

The end of the lead wire 3 and the joint portion 2an are joined by pressing the end portion of the lead wire against the joint portion 8 of the joint portion 2an with a predetermined pressure suitable for joining. That is, they are brought into pressure contact. In this state, the heater 43 is operated to heat. In addition to the method of heating the heater tube with electricity as shown here, the method of heating the connection part includes high-frequency induction heating, microwave dielectric heating, electric resistance heating, laser heating, arc discharge heating, and other metal heating methods. A known method for heating can be used. During heating, the pressure contact state is continued until the bonding is completed so that the end of the lead wire 3 and the connection portion 8 (connecting surface) of the bonding portion 2an of the coil wire 2 are not separated.

When connecting the joint 2an of the coil wire 2 and the lead wire 3, the molten material 9 may appear as a protrusion in the out-of-plane direction of the connection portion 8 due to the heating of the connection portion 8. FIG. The melt 9 is removed by ejecting air 41 from an air nozzle 42 . That is, the melt 9 is in a high temperature and soft state due to heating, and the melt 9 is removed (blown off) by the air 41 . A suction machine 44 is provided in the direction of the air 41, and the blown molten matter 9 is sucked by this suction machine 44 and carried to the outside of the box 40 to be removed.

Here, the reason for removing the melt 9 is as follows. That is, although it depends on the size and shape, if the insulating paper 15 covers the connection portion 8 in a state where there is a convex portion due to the molten material 9, the coil bulges outward in the diameter of the coil. is hindered. In addition, the convex portion damages the surface of the insulating paper 15, resulting in insufficient insulation. Therefore, in this embodiment, the melted material 9 generated during joining is removed by blowing gas (air 41 in this example) during the joining operation. This eliminates the need for a separate work of removing with a grinder or the like after joining.

It should be noted that the melted material may not be removed at the time of joining, but may be removed using a grinder or a cutter after joining. However, the method of removing the melted material 9 with a grinder or the like not only requires a separate removal operation, but also may damage the insulating paper 15 if burrs or grinding marks remain after removal. remain. Therefore, it takes time to remove the molten material. On the other hand, as shown in FIG. 2, such a problem can be eliminated by blowing gas during bonding to remove the melted material.

In addition, when the lead wire 3 is connected to the coil wire 2 in the winding and wound in a plurality of layers, the lead wire and the coil wire are connected inside the coil 1, so after the winding of the coil 1 is completed, Removal of burrs, etc. cannot be removed. Therefore, the polishing process for removing burrs or grinding marks generated when the protrusions of the molten material 9 are removed must always be handled as one of the connection processes, resulting in poor workability. On the other hand, according to the method shown in FIG. 2, the melted material 9 can be automatically removed during the joining operation, thus eliminating such a problem. In addition, in FIG. 2, the air 41 is used as the gas, but an inert gas such as nitrogen may be ejected for removal.

Moreover, it is not preferable that the high-temperature molten material 9 jumps out when the molten material 9 is blown off by the air 41 . In this embodiment, the suction device 44 is used to prevent the molten material 9 from jumping out. In this case, a lid may be provided on the upper surface of the box 40 . By providing the lid, the molten material is prevented from jumping out of the box, and the inside of the box is more tightly sealed, so that the suction force of the suction device 44 can be increased.

In addition, in order to simplify the configuration of the connecting device of the coil wire 2 and the lead wire 3, the molten material is blown away by the air 41 without using the suction machine 44, and the molten material is blown away at one place in the box 40, for example, at a corner in the direction of air ejection. 9 (later cooled and solidified) may be collected. Alternatively, a method of removing the melted material 9 by suction with a suction device 44 without blowing off the melted material 9 with the air 41 may be used. Alternatively, a method of mechanically wiping off the melted material 9 with a stick such as a wiper may be used without blowing off the melted material 9 with the gas of the air 41 .

As described above, in the method of manufacturing an electric device (transformer) shown in FIG. Since it can be automatically removed during joining, the connection work (joining work) and the work after connection can be simplified, and the efficiency of manufacturing can be improved.

In FIG. 2, after joining the coil wire 2 and the lead wire 3, another insulating paper 15 than the insulating paper 5 wound in advance is used to separate the joint portion 2an and the lead wire 3 where the material is exposed. Insulate the ends. At this time, in order to ensure the insulation of the joint 2an, it is preferable to wrap the joint 2an and the ends of the lead wires 3 with one continuous insulating paper. A plurality of different tap voltages can be obtained by connecting the other end of the lead wire 3 (the end that is not the connecting portion) to the tap terminal of the transformer.

Next, a method different from the method described above for insulation after bonding will be described. In Example 1 of FIG. 1 described above, an example in which the ribbon-shaped insulating paper 15 is wrapped around the lead wire and the coil wire for insulation after joining is shown. It is also possible to wrap with insulating paper with a shape. That is, as shown in FIGS. 3(a) and 3(b), a tubular insulating paper 15a is used to wrap the exposed joint 2an. FIGS. 3(a) and 3(b) show one form of the insulating paper 15a attached after bonding.

FIG. 4 shows a mounting method of the insulating paper 15 when using the cylindrical insulating paper 15a shown in FIG. FIG. 4(a) shows a state after the joint portion 2an and the end portion of the lead wire 3 are joined (a state in which the materials of the joint portion 2an and the end portion of the lead wire 3 are exposed). FIG. 4(b) shows the state of the insulating paper 15 insulated by the cylindrical insulating paper 15a shown in FIG.

In the mounting method using insulating paper shown in FIG. 3A, a cylindrical insulating paper 15a and a sheet-like insulating paper 15b are used as the insulating paper. In the state shown in FIG. 4(a), the cylindrical insulating paper 15a shown in FIG. 3(a) is inserted from the end of the lead wire 3, and the end of the lead wire 3 is passed through the pipe to the connection point. . On the other hand, the sheet-like insulating paper 15b of FIG. 3(a) is folded back along the fold line 31, the joint 2an of the coil wire 2 is lifted, and the insulating paper 15b and the joint 2an of the coil wire 2 are separated from the lower layer. Put it in between, fold it and wrap it as shown in Fig. 4(b). When wrapped, the cylindrical insulating paper 15a through which the lead wire 3 has already passed is overlapped and covered, and the insulating paper 15a and the insulating paper 15b are fastened and fixed with an insulating tape (not shown) or the like.

In the mounting method using the insulating paper 15a shown in FIG. Cut along 30 and open the cut portion as shown on the right side of FIG. 3(b). FIG. 3(b) is a single insulating paper 15 instead of the two insulating papers 15a and 15b divided in FIG. 3(a).

In the state after joining shown in FIG. 4(a), the insulating paper 15a shown in FIG. Pass the lead wire 3 and insert it up to the connection point 8. Subsequently, the joint 2an of the coil wire 2 is lifted, and the sheet-like portion of the insulating paper 15a is placed between the lower layer and the joint 2an of the coil wire 2 lifted, and then folded as shown in FIG. 4(b). The joint portion 2an of the connecting portion 8 and the lead wire 3 are wrapped together. As a result, the joints and the ends of the lead wires are covered with the insulating paper 15 without exposing the material, and an insulating tape (not shown) is applied so that the cylindrical and sheet-like insulating papers 15a do not open. etc. to fasten. Using the tubular insulating paper shown in FIGS. 3A and 3B is more efficient than the method of winding the ribbon-like insulating paper 15 . It should be noted that the insulating paper may be replaced with resin or other cylindrical insulating material to provide the same effect.

Thus, in the connection method of this embodiment, the lead wire 3 is connected inside the coil 1 without drawing out the coil wire. Therefore, it is not necessary to pull out part of the coil wire 2 from the coil for connection, or to fold it back to the original position of the coil. In addition, complicated connection work such as press-fitting with adjustment becomes unnecessary. Furthermore, since no lead wire or folded wire is used, the length of the coil wire can be shortened, and an efficient transformer can be realized.

<<Example 2>>
Next, Embodiment 2 of the present invention will be described with reference to FIG. FIG. 5 shows a manufacturing method in Example 2 of the present invention. Example 2 of the present invention has basically the same configuration as Example 1, but differs in that a plurality of lead wires are joined at one joining portion. Therefore, the description of the second embodiment will focus on the points of difference.

In FIG. 5, the step of peeling off the insulating paper 5 from the joint 2an of the coil wire 2 and the lead wire is the same as in the first embodiment. Also, in this state, a box 40 is prepared, the end of the lead wire 3 for connecting to the coil wire 2 is pressed against the joining portion 2an at a substantially right angle, and heat joining is performed in a state of moderate pressure. It is the same. In the second embodiment, since there are a plurality of lead wires 3 (two in this example) that are connected to the coil wire 2, each lead wire 3 is pressed into contact with the joint 2an to be joined. different. In other words, at the junction 2an, the ends of the two lead wires are brought into contact with the respective connection points 8 of the junction 2an with a predetermined pressure. Joining is performed in that state. After joining, the ends of the lead wires and the joining portion are insulated with insulating paper 15 separately prepared. This insulation is the same work as in the first embodiment.

According to the second embodiment, the coil wire and the lead wire can be easily connected. can. Although the number of lead wires is two in this example, it may be three or more if necessary.

<<Other Examples>>
In the above-described embodiments, the present invention has been described with the example of a transformer, but the present invention is not limited to transformers and can be applied to electrical equipment having coils and methods of manufacturing electrical equipment. Moreover, the above-described embodiments have been described in detail in order to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those having all the described configurations.

DESCRIPTION OF SYMBOLS 1... Coil, 1L... Low-voltage coil, 1H... High-voltage coil, 2... Coil wire, 2a... Upper layer coil wire, 2b... Lower layer coil wire, 2an... Joint, 3... Lead wire, 5... Insulating paper, 7 Winding frame 8 Connection point 9 Molten material 15 Insulating paper 30 Cut line 31 Broken line 40 Box 41 Air 42 Air nozzle 43 Heater 44 Suction machine

Claims (12)

An electrical device having a coil configured by winding a coil wire covered with an insulator around an iron core, a lead wire, and a connection portion connecting the coil wire and the lead wire,
The connection portion is joined to the lead wire by removing the insulator from the joint portion to be joined to the lead wire, and joining the end of the lead wire in contact with the joint portion of the coil from which the insulator has been stripped off. An electrical device in which the joint and the end of the lead wire are insulated with an insulator after joining. 2. The electrical equipment according to claim 1, wherein said coil wire is an aluminum wire. 2. The electrical equipment according to claim 1, wherein said electrical equipment is a transformer. 2. The electrical equipment according to claim 1, wherein the melt generated in said joining is removed. 2. The electrical equipment according to claim 1, wherein said insulator is insulating paper. A method for manufacturing an electric device, comprising connecting a coil formed by winding a coil wire covered with an insulator around an iron core, a lead wire, and a part of the coil and the lead wire,
The insulation of the coil wire at the joint connected to the lead wire is peeled off, and the end of the lead wire is brought into contact with the joint from which the insulation has been removed by applying pressure to the contact state. and joining the joint portion and the end portion of the lead wire, and insulating the joint portion and the end portion of the lead wire with an insulator after the joint is completed. 7. The method of manufacturing an electric device according to claim 6, wherein the coil wire used for said coil is an aluminum wire. 7. The method of manufacturing an electric device according to claim 6, wherein said joining uses heat joining, and a melt generated during said joining is removed. 9. The method of manufacturing an electric device according to claim 8, wherein said melt is removed by gas ejected from a nozzle. 10. The method of manufacturing an electric device according to claim 9, wherein the removed melt is sucked by a suction machine. 7. The method of manufacturing an electric device according to claim 6, wherein when performing the bonding, the bonding portion and the end portion of the lead wire are covered with a box, and the bonding is performed within the box. manufacturing method of electrical equipment. 12. The method of manufacturing an electric device according to claim 11, wherein molten matter generated during said joining is removed in said box by blowing gas.

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