CN104114314A - Method for materially bonding at least three components and armature for an electrical machine with correspondingly bonded components - Google Patents

Method for materially bonding at least three components and armature for an electrical machine with correspondingly bonded components Download PDF

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Publication number
CN104114314A
CN104114314A CN201280070238.0A CN201280070238A CN104114314A CN 104114314 A CN104114314 A CN 104114314A CN 201280070238 A CN201280070238 A CN 201280070238A CN 104114314 A CN104114314 A CN 104114314A
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CN
China
Prior art keywords
external member
armature
commutator segment
upper strata
lower floor
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
CN201280070238.0A
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Chinese (zh)
Inventor
J.温克勒
B.迪德里希
A.库德莱克
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Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
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 Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of CN104114314A publication Critical patent/CN104114314A/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00Resistance welding; Severing by resistance heating
    • B23K11/002Resistance welding; Severing by resistance heating specially adapted for particular articles or work
    • B23K11/0033Welding locally a thin plate to a large piece
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R39/00Rotary current collectors, distributors or interrupters
    • H01R39/02Details for dynamo electric machines
    • H01R39/32Connections of conductor to commutator segment
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214Resistance welding
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K13/00Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
    • H02K13/04Connections between commutator segments and windings
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0062Manufacturing the terminal arrangement per se; Connecting the terminals to an external circuit
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00Articles made by soldering, welding or cutting
    • B23K2101/36Electric or electronic devices
    • B23K2101/38Conductors

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Motor Or Generator Current Collectors (AREA)

Abstract

A method is described for materially bonding at least three components (6, 8, 9), such as an upper layer (9), a lower layer (8) and a commutator plate (6) of an armature (1) for an electrical machine. The three components (9, 8, 6) are arranged in a stack and an electric current is caused to flow from the one outer component (6, 9) through the central component (8) to the other outer component (9, 6). In a welding area (11), through which the electric current (13, 14) thus effected flows, the central component (8) is provided with surface deviations (12) in the form of corrugations or roughness for example, on both the surface of the central component facing the one outer component (9) and on the surface of the central component facing the other outer component (6). When an electric current (13, 14) is conducted through, local current concentrations and increases in the current density, along with associated locally concentrated heat generation, occur due to the non-smooth, textured surfaces of the central component (8). In this way, subregions of the interfaces between the components (9, 8, 6) can be fused with comparatively low currents (13, 14), and can create a material bond between the three components (6, 8, 9) upon subsequent solidification, analogously to resistance welding.

Description

For method that at least three construction materials are connected and for the armature of member motor, that there is corresponding connection
Technical field
The present invention relates to a kind of for by least three members, for example, for the commutator segment of the armature of motor and the method that element of winding upper strata, lower floor couples together.In addition, the present invention relates to a kind of that correspondingly form, for the armature of motor.
Background technology
In electric connection technology, for example, when manufacturing the armature that is used for motor, in the procedure of processing of being everlasting, with by the use of thermal means, a plurality of members are joined together, for it mechanically and/or electricly is joined to one another.
For example, for the commutator of the element of winding of armature and this armature is coupled together, often use diffusion brazing process.In order to prepare described process, first with flux, the element of winding end through peeling is wetting in infiltration is bathed, and then in slicken solder, to it, carry out zinc-plated.Described engaging process itself in general in the situation that layer of contact commutator and the element of winding or two layers by means of contact electrode and the loading current in the situation that, carry out.Member to be joined for example consists of copper or copper alloy in this case.Described slicken solder is because the heating that the electric current that passes through to flow through of member causes is melted.Due to diffusion process, in bonding land, form tin-copper-mixed crystal, described tin-copper-mixed crystal has the intensity mechanical and/or heat than described this height of scolder in desired mode.
But described diffusion soldering method is seen from equipment and technology aspect may be more expensive and cost is very high.In general element of winding end is carried out with flux wetting and subsequently zinc-plated are the technique that can not create new value, and cause the significant material cost for the manufacture of armature.
Summary of the invention
According to the embodiment of the present invention, proposed as an alternative, method at least three construction materials are connected.The method proposing can realize the technology controlling and process of simplification or for the expense of the reduction of equipment and technology at this.Especially can abandon zinc-plated.Diffusion brass solder technique can be replaced in simpler technique aspect some.
Proposed in this respect, for the method that at least three construction materials are connected first comprise described member cloth is set to one stacking, described stacking in a middle part member intermediate arrangement between the first external member and the second external member.So cause subsequently electric current, make described electric current by described middle part member, flow to described another external member from one of described external member.Described middle part member not only points on the surface of described the first external member but also on it points to the surface of described the second external member, is provided with so-called structure special-shaped at it in welding region at this, wherein caused electric current flows through from described welding region, wherein said structure special-shaped should be about smooth surperficial one-level, secondary and/or tertiary structure abnormity.
The design of the method proposing can be at this, is replaced for the diffusion brass solder technique that a plurality of members of the armature of for example motor are coupled together by resistance-welding process in the past.In such resistance-welding process, the temperature causing due to the electric current by flowing through raises and the material that has member to be connected is placed in to the state of melting.When these contact-making surfaces are cooling subsequently, the material solidification melting, and between described member, cause the connection that material coordinates like this.
Have been found that now that the heating phenomena causing largely depends on the local current density existing when described electric current flows through.Therefore proposing, is not to make by entire surface member to be connected be adjacent to each other in described welding region.On the contrary, described middle part member should have non-smooth surface in described welding region on two points to the surface of adjacent outside first or second component, namely has macroscopic structure special-shaped surface.Due to this non-smooth surface, described middle part member is only preferably only resisted against point by point the surface of corresponding adjacency of first or second component of described outside in less part surface.In the subregion between it, there is not mechanical contact, and do not have electric contact thus yet.The electric current flowing through from described consist of member stacking is concentrated in these subregions that electrically contact thus between described member.Therefore, the current density that has occurred partly improving, and there is thus the local heating that strengthens.The heating of this enhancing may cause having the local fusing of the material of member to be connected, may between described member, cause the composite construction that local material coordinates thus when cooling subsequently.
In other words, preferably so regulate the intensity of caused electric current, make the fusing partly in some regions of described member, at the member of middle part described in these regions, in welding region, with it, structure special-shaped surface is resisted against on the adjacent surface of first or second component of described outside.Sense of current is unimportant to a great extent at this, that is to say that DC current can flow to described the second external member by described middle part member from described the first external member or vice versa, or can cause alternating current.
In other words, can so select the surface texture of described middle part member and by the described stacking electric current conducting being formed by member, the only tip of described surface texture be melted because the local resistance existing there raises.Described surface texture not only can be configured to for example form of coarse tip at this on microcosmic, and can in macroscopic view, be configured to the form of groove line, screw thread, protuberance etc.
Only described middle part member is provided with a kind of surface texture, can between middle part member and the first external member and on the other hand, in two bonding lands between middle part member and the second external member, occur contact zone targetedly and in defined mode on the one hand thus.
Point out, the surperficial structure special-shaped structural deviation in other words (Gestaltabweichung) of technology can be understood to " being divided into six different grades " according to Deutsche industry norm (DIN) DIN4760.One-level may be overlapped at this to quaternary structure abnormity, and determine thus the actual surface state of body." primary structure abnormity " can refer to the form variations about specified shape." secondary structure abnormity " can refer to a kind of ripple." tertiary structure abnormity " can refer to the coarse-texture (Rauheit) of rill form." level Four, Pyatyi and six level structures abnormity " relates separately to the cancellated structure of the coarse-texture of the form of groove, scale, projection, the coarse-texture of institutional framework or material.
According to a kind of embodiment, described middle part member lip-deep structure special-shaped be have in 50 μ m to 5mm, preferably 50 μ m are to the secondary structure abnormity of the corrugated form of the physical dimension in the scope of 1mm.
Macroscopicly so structure special-shapedly may cause following result: described contact-making surface but also in the lateral spacing between such contact-making surface all roughly in the order of magnitude in described physical dimension not only, is wherein resisted against on one of the external member of described adjacency at the member of middle part described in described contact-making surface.Not only the spacing between the size of described contact-making surface but also described adjacent contact-making surface all has impact to the current density in the region at described contact-making surface when loading welding current.
The structure example form of ripple, secondary structure abnormity, larger is as can be easily and inexpensively made.
For example thisly macroscopicly structure special-shapedly can in the welding region of described middle part member, pass through manufacture process, for example deformation technique, for example roll extrusion, annular knurl, punching press etc., for example, by forming technology, casting, by Cutting Process, for example turning, screw thread cutting etc. or form by radiation process, for example blast cleaning, blasting treatment, laser structured etc.Such manufacture method can realize surperficial, simple and with low cost, the macroscopic structuring for described middle part member.
In a kind of embodiment as an alternative, described in to be arranged on structure special-shaped in the welding region of middle part member be to have in 10 μ m to tertiary structure abnormity physical dimension, coarse-texture form in the scope of 50 μ m.
Structure special-shaped " ripple " or " coarse-texture " characteristic on solder side in described middle part member should mainly illustrate the degree for dominant physical dimension, but not necessarily comprises the explanation about described structure special-shaped special shape.For example, described structure special-shapedly can have cusped edge, jagged structure, or also can have the soft structure through rounding.Described structure special-shaped can substantially distribution in the scope of described solder side equably.
Structure special-shaped on solder side in described middle part member also can illustrate with the form of so-called average roughness value (Mittenrauwert) Ra.Average roughness value has been described the surperficial roughness of the technology of for example manufacturing by machining method, forming process or deformation method.Desirable smooth surface has average roughness value 0.The average roughness value gearing to actual circumstances is from the cutter trade of invisible Ra=0.025 μ m almost until obviously groove, scale or the projection of the observable Ra=50 of having μ m.Also can for more coarse, macroscopic structure special-shaped, for example ripple described above distribute for example may be in being obviously greater than the average roughness value within the scope of 50 μ m.
Compare with described middle part member, surface first and second member of described outside, that point to middle part member can be smooth substantially.In other words, do not need specially described external member to be processed, to obtain targetedly structure special-shaped." being smooth substantially " for example can be explained as follows at this: remaining structure special-shaped be level Four or more senior.In other words, described external member, substantially smooth surperficial average roughness value can be less than 10 μ m.
Described have that yet at least one member in member to be connected is preferably all has member to be connected to be made of copper.Compare with for example soft solder, copper has the high-melting-point of about 1083 ℃.The method of attachment proposing allows: with acceptable energy expense, produce so high temperature at least partly, although thereby and be not by entire surface but by the subregion of pointwise, weld described member, and between described member, be created in thus machinery and electric aspect connect fully.
As an alternative, described in, have at least one member in member to be connected, but preferably all have member to be connected all made of aluminum.
In a kind of concrete embodiment of the present invention, described external member is the upper strata of the armature of motor, and described middle part member is the lower floor of the armature of described motor, and described the second external member commutator segment that is the armature of described motor.
For the armature for motor, may be particularly advantageously, the upper and lower of described armature, the different winding end that is to say armature winding are stacked up and down and be placed on commutator segment.Described electric resistance welding method is particularly suitable for this.
In a kind of embodiment as an alternative of the present invention, first and second member of described outside is respectively the side of crimping (Crimp), and described side surrounds described middle part member with the structurized surface at least partly of described crimping.
Described crimping can smooth side be connected with described besieged, middle part construction material by described resistance-welding process in simple mode substantially ordinatedly with two thus.
By means of method described above, for example can manufacture a kind of armature for motor, wherein between upper strata and commutator segment intermediate arrangement lower floor, and described three members connect ordinatedly at the internal material of welding region.Described upper strata, lower floor and commutator segment in this inside at described welding region only in subregion material be connected to each other ordinatedly, wherein said subregion aspect its physical dimension corresponding to about smooth surperficial, one-level, secondary and/or tertiary structure abnormity.
In other words, due to described resistance-welding process, what on described upper strata, described lower floor, coordinate with material between described commutator segment is connected the connection that is not whole, but is limited to partly on little subregion in the inside of described welding region.Material in join domain is the material at least one member, temporary transient fusing during electric resistance welding in described member at this.In other words, the material of at least one in described lower floor, described upper strata and described commutator segment of described join domain is formed, and in lower floor described in described join domain, is connected ordinatedly with described upper strata or described commutator segment material.On described join domain, do not need to exist other, material more low melting point, for example form of solder.
The type of connection described armature member, that material coordinates can be produced by the kind of manufacture method.Thus can obtain described armature member, mechanical aspects enough firmly and aspect electric conduction when connecting fully, realize manufacturability armature, that simplify proposing.
Illustrate, in this respect partly with reference to described by the embodiment of method of the present invention and partly by the embodiment of armature of the present invention, possible feature and advantage of the present invention are described with reference to described.Those skilled in the art can find, different features can be with suitable mode combination with one another or replacing, for realizing other embodiment and possible cooperative effect.
Accompanying drawing explanation
With reference to the accompanying drawings embodiments of the present invention are described, wherein not only accompanying drawing but also description should not be designed to limitation of the present invention.
Fig. 1 is the perspective view for the armature of motor;
Fig. 2 is the viewgraph of cross-section of subregion of commutator of armature of end with two overlapping placements of the element of winding; And
Fig. 3 has according to longitudinal section view in the region of the commutator of the end of the overlapping placement of the element of winding of one embodiment of the present invention, armature, subregion.
Accompanying drawing is only schematic diagram and not to scale (NTS).
The specific embodiment
Fig. 1 shows armature 1, and this armature is motor, for example, for the part of the starter of internal combustion engine.Described armature 1 has: an armature shaft is armature spindle 2 in other words; One armature lamination or stack of laminations 3, itself and armature shaft 2 are permanently connected and in circumference range, have a plurality of elements of winding 4 with distributing; And a commutator 5, the end face of itself and armature shaft 2 is adjacent to arrange.The free end of the element of winding 4 is connected to each other regularly and is connected with commutator 5.
Fig. 2 shows the cross section of armature, and it is arranged in the region of the commutator 5 of the element of winding end 8,9 with overlapping placement on the outer surface of commutator 5.In shown embodiment, the element of winding 9 can belong to the upper strata of armature, and can refer to the first external member.The element of winding 8 can belong to the lower floor of armature and can refer to middle part member.Commutator segment 6 can refer to the second external member.In other words, the element of winding end 8,9 of two different elements of winding 4 of overlapping placement on the surface of commutator segment 6 or lateral surface, wherein two of a corresponding element of winding ends on different commutator segment 6 respectively or form upper strata and or form lower floors.Commutator segment 6 is the adjacent laminated insulation with respect to commutator 5 by insulation contact pin 7.
Fig. 3 shows commutator segment 6 together with the cutaway view of the element of winding end 8,9 of the face of being placed on it.As the element of winding end 8 of central structure element, in welding region 11, there is the structure special-shaped 12 of ripple or coarse-texture form, the described structure special-shaped outwardly directed visible tip 10 that has.Structure special-shaped 12 are arranged on two surfaces of the element of winding 8 at this, that is to say and are arranged on the surface of pointing to the element of winding 9 above it or are arranged on the surface of pointing to the commutator segment 6 below it.In shown embodiment, described structure special-shaped 12 as around element of winding end around screw thread realize.Structure special-shaped 12 physical dimension can be between 1/10th millimeters and several millimeters at this, wherein illustrated size not only can relate to surface farthest in outside region and the radial spacing between inner region farthest, and can relate in adjacent, the lateral spacing between outside region farthest.
For by element of winding end 8,9 and commutator segment 6 each other material be connected, on the element of winding 9 in outside and at opposite side on-load voltage on outside commutator segment 6.As delineated out with arrow 13,14, for example the electric current of the 10 kilo-amperes element of winding end 8 that 9 processes are arranged between it from outside element of winding end flows to commutator segment 6 subsequently.
Because electrically contacting between the middle part element of winding 8 and the outside element of winding 9 or commutator segment 6 exists only in subregion, structure special-shaped 12 the tip of stretching out 10 and smooth surface adjacency element of winding end 9 or commutator segment 6 in described subregion, so must concentrate on partly these subregions by the electric current 13,14 of the stacking conduction that consists of member 9,8,6 on the contact-making surface between member 9,8,6., at contact position place, there is thus the thermosetting strengthening in the current density because part raises.This effect is also supported in the following manner: the contact resistance that may occur improving at contact position place.The thermosetting strengthening can be for making structure special-shaped 12 tip 10 and the externally temporarily fusing partly of lip-deep neighboring region of element of winding end 9 or commutator segment 6.Cooling and while solidifying subsequently at fused mass, occur that desired material is connected.
Because the local current of the structure special-shaped surface of being provided with of element of winding end, middle part 8 and therefrom generation is concentrated and the thermosetting of concentration of local thus, less electric current 13,14 may be enough to be used in causing electric resistance welding.In the method for attachment that proposed thus, can abandon necessary traditionally zinc-plated process here, and the method that however resistance welder using for diffusion brazing traditionally can be continued on for introducing in this respect if desired.

Claims (12)

1. the method at least three members (6,8,9) material is connected, wherein said method has following steps:
-described member (6,8,9) is arranged to one there is the stacking of the first external member (9), middle part member (8) and the second external member (6);
-from one of described external member (6,9), by described middle part member (8), towards described another external member (9,6), cause electric current (13,14);
It is characterized in that,
Described middle part member (8) not only points on the surface of described the first external member (9) but also is provided with on it points to the surface of described the second external member (6) about smooth surperficial, one-level, secondary and/or tertiary structure abnormity (12) at it in welding region (11), wherein caused electric current (13,14) the described welding region (11) of flowing through.
2. by method claimed in claim 1, wherein so set the intensity of caused electric current (13,14), make described member (6,8,9) fusing partly in some regions, at the member of middle part described in these regions, in welding region (11), utilize the adjacent surface adjacency of its structure special-shaped surface (12) and the described first or second external member (9,6).
3. by the method described in claim 1 or 2, wherein said structure special-shaped (12) be have in 50 μ m special-shaped to the secondary structure of the form of the ripple of the physical dimension in the scope of 5mm.
4. by the method described in claim 1 or 2, wherein said structure special-shaped (12) are to have the tertiary structure abnormity to the form of the coarse-texture of the physical dimension in the scope of 50 μ m in 10 μ m.
5. by the method described in any one in claim 1 to 4, wherein structure special-shaped (12) in the welding region (11) of middle part member (8) consist of the process of selecting from comprise the classification of deformation technique, forming technology, Cutting Process and radiation process.
6. by the method described in any one in claim 1 to 5, surface wherein said first and second external member (9,6), that point to middle part member (8) is smooth substantially.
7. by the method described in any one in claim 1 to 6, wherein said the first external member (9), described middle part member (8) and/or described the second external member (6) consist of copper.
8. by the method described in any one in claim 1 to 6, wherein said the first external member (9), described middle part member (8) and/or described the second external member (6) consist of aluminium.
9. by the method described in any one in claim 1 to 7, wherein said the first external member (9) is the upper strata of the armature (1) of motor, described middle part member (8) is the lower floor of described armature (1), and described the second external member (6) is the commutator segment of described armature (1).
10. by the method described in any one in claim 1 to 7, wherein said the first and second external members (6,9) are respectively the sides of crimping, and described side surrounds described middle part member (8).
11. armatures for motor (1), have:
-mono-upper strata (9);
-mono-lower floor (8); And
-mono-commutator segment (6);
Wherein said lower floor (8) intermediate arrangement is between described upper strata (9) and described commutator segment (6); And
-wherein said upper strata (9), described lower floor (8) and described commutator segment (6) material in welding region (11) is connected ordinatedly;
It is characterized in that,
Described upper strata (9), described lower floor (8) and described commutator segment (6) in described welding region (11) only in subregion material be connected to each other ordinatedly, described subregion is being equivalent to aspect its physical dimension about smooth surperficial, one-level, secondary and/or tertiary structure abnormity (12).
12. by armature claimed in claim 10, wherein the material of at least one member of join domain in described lower floor (8), described upper strata (9) and described commutator segment (6) forms, and in lower floor described in described join domain (8), is connected ordinatedly with described upper strata (9) and/or described commutator segment (6) material.
CN201280070238.0A 2011-12-21 2012-10-23 Method for materially bonding at least three components and armature for an electrical machine with correspondingly bonded components Pending CN104114314A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102011089491A DE102011089491A1 (en) 2011-12-21 2011-12-21 Method for integrally joining at least three components and armature for an electric machine with correspondingly connected components
DE102011089491.8 2011-12-21
PCT/EP2012/070984 WO2013091945A1 (en) 2011-12-21 2012-10-23 Method for materially bonding at least three components and armature for an electrical machine with correspondingly bonded components

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Publication Number Publication Date
CN104114314A true CN104114314A (en) 2014-10-22

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DE (1) DE102011089491A1 (en)
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DE102010028782A1 (en) * 2010-05-10 2011-11-10 Robert Bosch Gmbh Arrangement for connecting component i.e. commutator-hook, with winding wire in e.g. electric motor, has weld seam for connecting component with wire, where weld seam crosses central axis of wire

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108604838A (en) * 2016-02-29 2018-09-28 西门子股份公司 Rotor for electric rotating machine
CN108604838B (en) * 2016-02-29 2020-12-04 西门子股份公司 Rotor for rotating electric machine
US11101706B2 (en) 2016-02-29 2021-08-24 Siemens Aktiengesellschaft Rotor for an electric machine having a sheet metal for securing a pole shoe to a shaft

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