JP2000164043A - Electric wire for joining and method for joining the same - Google Patents

Electric wire for joining and method for joining the same

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Publication number
JP2000164043A
JP2000164043A JP11223440A JP22344099A JP2000164043A JP 2000164043 A JP2000164043 A JP 2000164043A JP 11223440 A JP11223440 A JP 11223440A JP 22344099 A JP22344099 A JP 22344099A JP 2000164043 A JP2000164043 A JP 2000164043A
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Japan
Prior art keywords
joining
formed
end
electric wire
portion
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Granted
Application number
JP11223440A
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Japanese (ja)
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JP3303854B2 (en
Inventor
Takeshi Kato
Mamoru Urushizaki
剛 加藤
守 漆崎
Original Assignee
Denso Corp
株式会社デンソー
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Priority to JP26786798 priority Critical
Priority to JP10-267867 priority
Application filed by Denso Corp, 株式会社デンソー filed Critical Denso Corp
Priority to JP22344099A priority patent/JP3303854B2/en
Publication of JP2000164043A publication Critical patent/JP2000164043A/en
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Publication of JP3303854B2 publication Critical patent/JP3303854B2/en
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Abstract

(57) [Problem] To provide a joining electric wire and a joining method thereof that can reduce the amount of heat input required for joining. SOLUTION: A joining electric wire 100 is a rod-shaped conductor member having a circular cross-sectional shape, and a cutout portion 114 is formed at an end portion 112. The end portion 112 has a shape in which approximately half of the circular cross section is cut out by the notch portion 114, and the cross-sectional area is reduced to approximately half as compared with a portion connected to the end portion 112. Therefore, the amount of heat input when the ends 112 of the two joining wires 100 are joined to each other by TIG welding or the like can be reduced, the temperature rise in the adjacent portions is suppressed, and the deterioration of the coating 116 due to heat is reduced. Is done.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a joining wire whose ends are joined by welding or the like and a joining method thereof.

[0002]

2. Description of the Related Art Conventionally, various electric wires have been used in various electric appliances according to their applications, and the electric wires may be joined to each other for the convenience of drawing and assembling the electric wires. FIG. 19 is a diagram illustrating a joining process of two electric wires on which an insulating coating is formed. First, two electric wires to be joined are arranged with their ends aligned, and the insulating coating formed on the ends is removed (step 1). Next, the ends of the two electric wires are joined to each other (Step 2), and then a new insulating coating is applied to a portion where the insulating coating including the joined portion has peeled off (Step 3). Specific joining methods include welding, soldering, and brazing.

[0003]

However, according to the above-described conventional joining method, joining is performed so as to cover the whole of the two electric wires to be joined, so that a large amount of heat is required for joining. There was a problem. For example, when the ends of the electric wires are joined by welding, it is necessary to melt the entire end, so that the amount of heat input required for joining increases, which undesirably increases the size of the equipment.

[0004] Further, as the amount of heat input at the time of joining increases, the temperature near the end of the electric wire rises, and if a coating is formed on the electric wire, a region where the coating deteriorates at the time of joining is enlarged. Evils also occur. For this reason, the range in which the coating is removed in step 1 shown in FIG.
In step 3, it is necessary to form a new coating over this wide range, which leads to a decrease in work efficiency due to an increase in work area.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a joining wire and a joining method capable of reducing the amount of heat input required for joining. .

[0006]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a bonding wire and a bonding method thereof according to the present invention include:
A notch is formed at a predetermined position near the end of the joining electric wire, and the ends are joined together in such a state that the ends of the joining electric wire are aligned. The notch may be formed at the end itself or at a position close to the end. When the notch is formed at the end itself, the cross-sectional area of the end is smaller than the cross-sectional area of other parts, so the heat capacity of the end is small, and joining should be performed with a small heat input. Becomes possible. For this reason, since the temperature rise of the other part connected to the end can be suppressed, when the coating is formed around the joining electric wire, the range in which the coating is deteriorated by heat can be reduced. Also,
If the notch is formed at a position close to the end, the cross-sectional area is reduced at the position where the notch is formed. Blocked by. Therefore, since the end portion where the joining is performed is prevented from being cooled by the heat transfer, the joining can be performed with a small heat input amount. In addition, since heat is not easily transmitted through the notch, it is possible to suppress a rise in temperature at an end or a portion other than the notch, and when a coating is formed around the bonding wire, Can be reduced by heat.

[0007] An electric apparatus according to the present invention includes a winding in which ends of conductor segments formed by the above-described bonding wires are bonded to each other. When a winding is formed by joining the ends of a plurality of conductor segments to each other, the joining operation can be performed with a small amount of heat input, so that thermal damage to the winding can be reduced.

[0008] It is desirable that the joining wire forming the conductor segment is formed with cutouts at both ends and on the same side surface. By folding back both end portions on the side surface opposite to the side surface on which the notch portion is formed, the end portions on which the notch portion is formed can be arranged adjacent to each other, so that a plurality of conductor segments are connected in series. When forming a winding by winding, the ends to be joined can be easily aligned.

Further, the above-described winding is formed by connecting the conductor segments in the circumferential direction, and a notch is formed in the outer peripheral side surface near the end of the joining wire located at the outermost periphery. It is preferable to form a notch on the inner peripheral side surface near the end of the joining electric wire located on the inner periphery. By setting the formation positions of the cutout portions in this manner, it is easy to combine and join the outer layer conductors and the inner layer conductors of the conductor segments, and the manufacturing process of the winding can be simplified.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

[First Embodiment] FIG. 1 is a perspective view showing a detailed shape of a joining electric wire according to a first embodiment. The joining electric wire 100 of the first embodiment shown in FIG. 1 is a rod-shaped conductor member having a circular cross-sectional shape, and has a cutout 114 formed at an end 112. The end portion 112 has a shape in which approximately half of the circular cross section is cut out by the notch portion 114, and the cross-sectional area is reduced to approximately half as compared with a portion connected to the end portion 112. A coating 116 is formed on the outer peripheral surface of the joining electric wire 100 except for the end 112.
Are formed, and a good insulation state is maintained with other electric conductors.

FIG. 2 is a view showing a joining process of the joining electric wire 100 shown in FIG. First, two electric wires 100A to be joined are introduced, and the coating 116 formed around the end of each electric wire 100A is removed (step 1). Next, the end 112 of the electric wire 100A from which the coating 116 has been removed.
By performing the processing to form the notch 114 on the
Two joining wires 100 having the shape shown in FIG. 1 are formed (Step 2). In the two electric wires 100, the formation positions of the respective notches 114 are set such that the respective ends 112 are arranged close to each other. The electric wires 100 are arranged in parallel with the ends 112 aligned. The cutouts 114 are arranged so as to be outwardly directed with respect to the direction in which the two electric wires 100 are arranged.

Next, the ends 11 of the two joining wires 100
The two are joined (step 3). For example, TIG (tungst
en inert-gas) welding is performed. After the joining is completed, a new coating 120 is applied to the area where the coating 116 was removed in Step 1 (Step 4). This allows
A coating 120 is formed to cover the joint 118 and its vicinity.

As described above, the bonding wire 10 of the present embodiment is
In No. 0, since the notch 114 is formed at the end 112, the cross-sectional area of the end 112 is smaller than the cross-sectional area of a portion connected to the end 112. Therefore,
The heat capacity of the end portion 112 is reduced, and the amount of heat input required for performing joining can be reduced.

Further, since the amount of heat input is small and the cross-sectional area of the portion adjacent to the end portion 112 sharply increases, the temperature increase of this adjacent portion is suppressed, and the heat applied at the time of bonding causes the coating 116 to be formed. The range of deterioration can be reduced. For this reason, the region where the coating 120 is formed after the joining can be reduced, and the labor of removing the coating 116 before the joining and applying the coating 120 after the joining can be reduced. Note that, as shown in FIG. 20A, the lower end of the cutout portion 114a may have a predetermined distance from the end surface of the coating 116.

[Second Embodiment] FIG. 3 is a perspective view showing a detailed shape of a joining electric wire according to a second embodiment. The joining electric wire 200 of the second embodiment shown in the figure is a rod-shaped conductor member having a circular cross-sectional shape, and has a notch 214 formed at a position adjacent to the end 212. The joining electric wire 200 has a shape in which substantially half of a circular cross section is cut off at a position where the notch 214 is formed.
The cross-sectional area is reduced to approximately half as compared with the end 212 and other portions. In addition, the end 212 and the notch 214
Coating 2 is formed on the outer peripheral surface of the joining electric wire 200 excluding the position where
16 are formed, and a good insulation state is maintained with other electric conductors.

FIG. 4 is a view showing a joining process of the joining electric wire 200 shown in FIG. First, two electric wires 200A to be joined are introduced, and an end 2 of each electric wire 200A is introduced.
The film 216 formed on the periphery of each of the region 12 and the adjacent region is removed (Step 1). Next, by forming a notch 214 at a position adjacent to the end 212 of the electric wire 200A, two joining electric wires 200 having the shape shown in FIG. 3 are formed (Step 2). In the two joining wires 200, the positions where the notches 214 are formed are set such that the conductor portions that are not cut away and are not cut out are close to each other. I have.

Next, the ends 21 of the two joining wires 200
The two are joined (step 3). For example, as in the case of the above-described first embodiment, joining by TIG welding is performed. After the joining is completed, a new coating 220 is applied to the area where the coating 216 was removed in Step 1 (Step 4).

As described above, the joining electric wire 20 of the present embodiment is
0 is a notch 21 at a position adjacent to the end 212 thereof.
4, the cross-sectional area at the adjacent position is partially reduced. Therefore, when the end portions 212 are joined by welding or the like, the end portions 212 that are joint portions are formed.
Flowing from the wire into the opposite end of the joining electric wire 200 is blocked at the adjacent position where the cross-sectional area is reduced.
Heat accumulates on the surface, and the amount of heat required for joining can be reduced. Further, since the heat flowing through the portion where the notch 214 is formed is blocked, the joining electric wire 200
The temperature rise in the portion where the coating 216 is formed on the outer periphery of the substrate is suppressed, and the range in which the coating 216 deteriorates due to the heat applied at the time of joining can be reduced.

By the way, in each of the embodiments described above, the joining wires 100 and 200 having a circular cross section have been considered. However, a joining wire having a cross section other than a circular shape can be similarly considered. For example, as shown in FIG. 5, a rectangular cutout portion 134 is formed at an end 132 of the joining electric wire 130 having a rectangular cross section, or a joining electric wire having a rectangular cross section as shown in FIG. A rectangular cutout 234 may be formed at a position adjacent to the end 232 of the 230. FIG.
As shown in FIG. 0 (b), a coating 136 is provided on the outer periphery of the joining electric wire 130 having a flat cross section of a rectangular shape or an elliptical cross section.
6 may be located substantially at the same position as the upper end. Further, FIG.
As shown in (c), the lower end of the cutout portion 134a is covered with the coating 1.
It may have a predetermined distance from the upper end of 36. In addition, as shown in FIG.
May be formed with a triangular cutout portion 134 at the end 132 of the notch.

Further, as shown in FIGS. 21 (a), 21 (b) and 21 (c), a rectangular cutout 234 formed at a position adjacent to the end 232 of the joining electric wire 230 is formed into an oval shape. It may be triangular.

[Application Example of Joining Wire] Next, an application example in which a stator winding of an automotive alternator is formed using the joining wire of the above-described embodiment will be described. FIG. 7 is a diagram showing the overall configuration of the vehicle alternator. The vehicle alternator 1 shown in FIG. 7 includes a stator 2, a rotor 3, a frame 4, a rectifier 5, and the like. The stator 2
A stator core 22, a plurality of conductor segments 23 constituting a stator winding, a stator core 22 and each conductor segment 2
And an insulator 24 that electrically insulates the insulator 3 from the other. The stator core 22 is formed by laminating thin steel plates, and has a number of slots formed on the inner peripheral surface thereof. In addition, the conductor segments 23 exposed from the stator core 22 cause the coil ends 2 of the stator windings to rotate.
1 is formed. The method of forming the stator 2, particularly the stator winding, will be described later.

The rotor 3 sandwiches a field winding 8 in which an insulated copper wire is cylindrically and concentrically wound around a shaft 6 through pole shafts 7 each having six claws. It has a rigid structure. An axial-flow-type cooling fan 11 is attached to the end face of the pole core 7 on the front side by welding or the like to discharge the cooling air sucked from the front side in the axial direction and the radial direction. Similarly, a centrifugal cooling fan 12 is attached to the end face of the rear pole core 7 by welding or the like to discharge the cooling air sucked from the rear side in the radial direction.

The frame 4 accommodates the stator 2 and the rotor 3, and the rotor 3 is supported rotatably around a shaft 6, and is provided on the outer peripheral side of the pole core 7 of the rotor 3. Stator 2 arranged via a predetermined gap
Has been fixed. The frame 4 has a cooling air discharge window 42 at a portion facing the coil end 31 of the stator 2.
However, suction windows 41 are respectively provided on the axial end surfaces.

Vehicle alternator 1 having the above-described structure
When a rotational force from an engine (not shown) is transmitted to the pulley 20 via a belt or the like, the rotor 3 rotates in a predetermined direction. In this state, by applying an excitation voltage to the field winding 8 of the rotor 3 from the outside, each claw portion of the pole core 7 is excited, and a three-phase AC voltage can be generated in the stator winding. A predetermined direct current is extracted from the output terminal of the rectifier 5.

Next, details of the stator 2 will be described.
FIG. 8 is a perspective view of the conductor segment 23 constituting the stator winding, and shows a state before the conductor segment 23 is assembled to the stator core 22. FIG. 9 is a partial sectional view of the stator 2. FIG. 10 is a partial perspective view of the stator 2. FIG. 11 and FIG. 12 are perspective views showing the detailed shapes of the joints of the conductor segments constituting the stator winding.

As shown in FIG. 8, the conductor segments 23
Is formed in a substantially U-shape by bending a rod-shaped or plate-shaped metal material (for example, copper) having a rectangular cross section at the turn portion 23c.
And an outer-layer-side conductor portion 23b disposed on the outer periphery side of the slot 25 with respect to the turn portion 23c.

The stator winding of the stator 2 includes a stator core 22
The two conductor segments 23 are inserted into the respective slots 25, and the conductor segments 2 inserted into different slots 25
3 are connected to each other. As shown in FIG.
Each of the inner-layer-side conductor portions 23a and the outer-layer-side conductor portions 23b has a rectangular shape longer in the radial direction than in the circumferential direction, and the long sides of the rectangle are arranged along the radial direction. In addition to the case where an insulating coating is formed on the surface of the conductor segment 23, the case where the insulating coating is not formed may be considered.

As shown in FIG. 10, each conductor segment 23 constituting the stator winding has a turn portion 23c on one of the axial side surfaces of the stator core 22 and a turn portion 2 on the other side.
An end 23d opposite to 3c is arranged. Also, the skewed portions 23e of the conductor segments 23 forming one of the coil ends 21 of the stator 2 are inclined in the opposite direction between the outer layer and the inner layer, and are inclined in the same direction in each layer.

The end 23d of each conductor segment 23
It is preferable that the connection be made by, for example, joining by TIG welding. In general, TIG welding is a method in which an arc is generated between a tungsten electrode and a base material in an inert gas atmosphere, and the heat of the arc is used to melt the base material and the filler material to perform welding. There is an advantage that the amount of heat and the amount of additive can be controlled independently.

As shown in FIG. 8, a notch 23f is formed in the inner peripheral side surface at the inner layer end 23d of the conductor segment 23, and the outer peripheral side end 23d is formed at the outer layer side end 23d. A notch 23f is formed at the bottom. Inner layer side end 2 having cut-out portion 23f formed to reduce cross-sectional area
3d and the outer layer side end 23d are arranged adjacent to each other.
IG welding is performed to form a joint 23g. As shown in FIG. 11 and FIG. 12, the joint 23g is arranged in a state where the ends 23d of the adjacent conductor segments 23 are in contact with each other, and then makes the noise containing the tungsten electrode approach the adjacent portion. And formed by TIG welding. For example, when the conductor segment 23 is formed of copper having a high thermal conductivity, the joining portion 23g
Is rounded by surface tension to form a drop-shaped ball shape without edges. The end portion 23d has a smaller heat capacity due to a reduced cross-sectional area as compared with the inner conductor portion 23a and the outer conductor portion 23b connected to the end portion 23d. , The amount of heat input can be reduced, and the cost can be reduced by downsizing and simplifying the welding equipment. Further, it is possible to prevent the phenomenon of melting and splitting with a small amount of heat. Also, TI
By reducing the amount of heat input during G welding, the joining portion 23g
The temperature rise of the inner-layer-side conductor portion 23a and the outer-layer-side conductor portion 23b leading to the above is suppressed, and the range in which the insulating coating formed on the surface deteriorates can be reduced.

Next, the manufacturing process of the stator winding will be described below. The outer conductor 23b and the inner conductor 23a shown in FIG.
A U-shaped conductor segment 23 having substantially the same shape and composed of a turn portion 23c is overlapped so that the turn portion 23c is aligned with the same side of the axial side surface of the stator core 22, and the outer layer is formed as shown in FIG. Each conductor segment 23 is fixed to the slot 25 of the stator 2 so that the side conductor portion 23b is located at the back of the slot 25 and the inner layer side conductor portion 23a is located at the opening side of the slot 25.
Insert

As shown in FIG. 12, the conductor segment 23 has cutouts 23 on the same side surface of both ends 23d of a rod-shaped or plate-shaped metal material formed in a linear shape.
After f is formed, approximately U as shown in FIG.
The outer conductor 23b and the inner conductor 2 are formed on the substantially parallel side surfaces of the slot.
3a is press-fitted so that both side surfaces come into contact with each other via the insulator 34.

Next, as shown in FIG.
After bending the end 23d located on the opposite side to the coil end 21 including the c in the circumferential direction opposite to each other, the ends 23d of the other conductor segments 23 of the different layer are joined by TIG welding. Are connected at this joint 23g. The joint 23g of each conductor segment 23 thus formed is formed to have substantially the same height from the stator core 22.

Next, the stator 2 is arranged so that the joints 23g face downward, and the joints 23g are immersed in, for example, a liquid insulating material tank and then pulled up. By drying the insulating material, an insulating film 23h is formed on each joint 23g.

As described above, by forming the notch 23f at the end 23d of each conductor segment 23 constituting the stator winding, the sectional area of the end 23d is reduced, and the heat capacity of the end 23d is reduced. Become smaller. For this reason, the amount of heat input when joining the end portions 23d of the conductor segments 23 in different layers by TIG welding can be reduced, and downsizing and simplification of the welding equipment can be achieved. Also, as a result of the reduced heat input to the end 23d, the amount of heat transmitted to the inner conductor 23a and the outer conductor 23b connected to the end 23d is reduced, so that the temperature rise of these parts during welding is reduced, and The range in which the coating is deteriorated by heat can be reduced. Therefore, after welding is completed, the axial length of the region where the insulating coating 23h is newly formed can be reduced.

FIGS. 13 to 18 are diagrams for explaining the effect when the axial length of the region where the insulating film 23h is formed is shortened. FIG. 13 is a diagram showing a schematic configuration of a stator formed using a conductor segment when a notch is not formed at an end. FIG. 14 is a diagram showing a structure near a joint of each conductor segment used in the stator winding shown in FIG. If a notch is not formed at the end of the conductor segment, TIG
The amount of heat input required for joining by welding increases, and the range in which the insulating coating near the ends of the conductor segments deteriorates is widened.
Therefore, as shown in FIG. 14, the application range of the insulating film 23h formed after the completion of the bonding step is widened.

FIG. 15 shows a case where a conductor segment having a cutout at the end is used, and the stator is reduced in length in the axial direction of the insulating film 23h formed after the joining step. It is a figure which shows the schematic structure of the stator which shortened the axial length of the winding. FIG. 16 is a diagram showing a structure near a joint of each conductor segment used in the stator winding shown in FIG. As described above, in the case where the stator winding is formed using the conductor segment having the notch formed at the end, the axial length of the insulating coating 23h formed after the joining step is reduced. Can be. Therefore, as shown in FIG. 16, the axial length L of the stator winding, which is the length from each conductor segment turn to the insulating coating 23h, is reduced by the reduced axial length of the insulating coating 23h. Can be shorter. This makes it possible to reduce the amount of heat generated by reducing the winding resistance and to reduce the size of the product by reducing the axial dimension of the stator 2.

Incidentally, the stator winding is made up of the stator core 22.
Cooling is performed by blowing cooling air to the coil ends exposed from the air. Further, when the stator windings are formed by joining the ends 23d of the conductor segments 23 as described above, the coil ends including the joints 23g are efficiently cooled, so that the entire stator windings are cooled. Temperature rise can be suppressed. However, a new insulating film 23h is formed around the bonding portion 23g after bonding, and the insulating film 23h formed by immersion in the liquid insulating material layer is formed around the copper wire or the like. Since the film thickness is thicker than the initial film made of polyimide resin or the like, a sufficient cooling effect cannot be obtained even if cooling air is applied to this portion.
Therefore, it is necessary to cool the portion where the initial coating is formed.

FIG. 17 shows a case where a conductor segment having a cutout at the end is used, and shows a schematic configuration of a stator in which the axial length of the stator winding is set long. It is. FIG. 18 is a diagram showing a configuration near a joint of each conductor segment used in the stator winding shown in FIG. As described above, in the case where the stator winding is formed using the conductor segment having the notch formed at the end, the axial length of the insulating coating 23h formed after the joining step is reduced. As compared with the case where the conductor segment having no notch shown in FIG. 14 is used, the length of the portion where the initial coating is formed is increased, and a stator winding with improved cooling efficiency is realized. can do.

In each of the embodiments described above, the cross section of the joint wire is formed in a circular shape or a rectangular shape. However, the cross section may be formed in any other shape, for example, an elliptical shape or a polygonal shape other than a rectangle.

The vehicle alternator 1 shown in FIG.
Uses the bonding wire 130 shown in FIG. 5 to form the conductor segment 23 shown in FIG.
The conductor segments may be formed using the various types of joining wires shown in FIGS.

Also, as an example of using the joining wires of the first and second embodiments, the case where the stator winding of the automotive alternator 1 is formed has been described. The present invention can be applied.

Further, in the first and second embodiments, the description has been made of the joining electric wire having the outer periphery formed with the insulating coating. However, the present invention can be applied to a bare wire having no insulating coating formed thereon. it can. Even when the insulating film is not formed, there is an effect that the amount of heat input required for bonding can be reduced.

In each of the above-described embodiments, the shape of the notch formed at or near the end of the joining wire may be determined in consideration of ease of processing. As for the method of processing the notch, various processing methods, such as a case of cutting and a case of punching with a die, are conceivable.

Further, as shown in FIGS. 22 and 23,
In contrast to the shape before welding (a), the molten shape after welding (b) has a shape in which the molten cross-sectional area increases at a position away from the tip. As a result, the fusion depth tends to be constant, and the fusion thickness L2 (the direction in which the shape of the tip is not reduced) after fusion is small because the fusion volume is small, and the fusion thickness caused by surface tension is stably reduced. 1. For the previous thickness L1.
It falls between 1 and 1.8 times.

Also, due to this effect, the welding width W2 after welding is obtained.
Is from 0.5 times to 1.times. The width W1 of two wires before welding.
It stably fits within 1 time.

As described above, the shape of the welded portion can be reduced, and the size of the entire product can be reduced.

FIG. 24 shows the efficiency of the weld joint (%) with respect to the weld thickness (L2 / L1) (horizontal axis) as the weld shape.
It is a graph which shows the distribution range of (vertical axis). Here, the welded joint efficiency (%) indicates the strength of the welded portion with respect to the original strength of the electric wire without welding. When the welding thickness is 1.1 or more of the thickness before welding, a joint efficiency of 20% or more can be stably secured. The welding thickness is desirably small in order to increase the distance between adjacent joints, but is set to 1.1 times or more in order to increase the joint efficiency to 20% or more. On the other hand, the upper limit of the welding thickness is naturally determined in order to set the interval between adjacent joints to a predetermined value, for example, 0.5 mm or more. Here, the upper limit is 1.8 times. Further, the upper limit of the weld thickness also has a meaning as an upper limit capable of holding a droplet in a molten state in a predetermined shape. From these, the range of the welding thickness is set to 1.1 times to 1.8 times.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a detailed shape of a joining electric wire according to a first embodiment.

FIG. 2 is a view showing a joining step of the joining electric wire shown in FIG.

FIG. 3 is a perspective view showing a detailed shape of a joining electric wire according to a second embodiment.

FIG. 4 is a view showing a joining step of the joining electric wire shown in FIG. 3;

FIG. 5 is a perspective view showing a detailed shape of another joining electric wire.

FIG. 6 is a perspective view showing a detailed shape of another joining electric wire.

FIG. 7 is a diagram showing an overall configuration of a vehicle alternator.

FIG. 8 is a perspective view of a conductor segment constituting a stator winding.

FIG. 9 is a partial sectional view of a stator.

FIG. 10 is a partial perspective view of a stator.

FIG. 11 is a perspective view showing a detailed shape of an end of a conductor segment constituting a stator winding.

FIG. 12 is a perspective view showing a detailed shape of a joint portion of a conductor segment constituting a stator winding.

FIG. 13 is a diagram showing a schematic configuration of a stator formed using a conductor segment when a notch is not formed at an end;

FIG. 14 is a view showing a structure near a joint between conductor segments used in the stator winding shown in FIG. 13;

FIG. 15 is a diagram showing a schematic configuration of a stator in which a conductor segment having a cutout portion formed at an end is used, and the axial length of a stator winding is reduced.

16 is a diagram showing a structure near a joint of each conductor segment used in the stator winding shown in FIG.

FIG. 17 is a diagram illustrating a schematic configuration of a stator in which a conductor segment having a cutout portion formed at an end is used, and an axial length of a stator winding is set long.

18 is a diagram showing a configuration near a joint of each conductor segment used in the stator winding shown in FIG. 17;

FIG. 19 is a view showing a conventional joining process of two electric wires on which an insulating coating is formed.

FIG. 20 is a perspective view showing a detailed shape of another joining electric wire.

FIG. 21 is a perspective view showing a detailed shape of another joining electric wire.

FIG. 22 is a diagram showing before and after joining of two electric wires on which an insulating coating is formed.

FIG. 23 is a diagram showing before and after joining of two electric wires on which an insulating coating is formed.

FIG. 24 is a characteristic diagram showing a relationship between a welding thickness and a welding joint efficiency.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 22 Stator core 23 Conductor segment 24 Insulator 100, 200 Joining electric wire 112, 212 End 114, 214 Notch

Claims (8)

[Claims]
1. A joining electric wire, wherein a notch is formed at a predetermined position near an end.
2. The electric wire according to claim 1, wherein the two end portions are aligned, and the end portions are joined to each other.
3. A step of forming a notch so that a cross-sectional area of a predetermined position near an end of two joining wires is smaller than a cross-sectional area of another part, and the notch is formed. And after arranging the ends of the two joining wires so as to be aligned, and joining the ends to each other.
4. A joining wire having a cutout formed at a predetermined position near an end portion is used as a conductor segment, and the ends of two different conductor segments are aligned and arranged.
An electric machine comprising a winding formed by joining these ends.
5. The electric device according to claim 4, wherein the cutout portions are formed at both ends of the joining electric wire and on the same side surface.
6. The wire according to claim 4, wherein the winding is formed by connecting the conductor segments in a circumferential direction, and the winding is formed in the vicinity of the end of the joining wire located at the outermost periphery. The notch portion is formed on the outer peripheral side surface, and the notch portion is formed on the inner peripheral side surface near the end of the joining wire located at the innermost periphery. Electrical equipment.
7. The method according to claim 6, wherein a circumferential thickness of the conductor segments welded in a circumferential direction is 1.1 times to 1.times. A thickness of the joining electric wire before welding.
An electric device characterized by being joined between eight times.
8. The method according to claim 7, wherein the width of the joined portion in the radial direction (normal direction) of the fused portion after joining is 0.5 to 1.1 times the combined width of the two joining wires before joining. Electrical equipment characterized by being doubled.
JP22344099A 1998-09-22 1999-08-06 Joint wire and joining method Expired - Lifetime JP3303854B2 (en)

Priority Applications (3)

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US8772995B2 (en) * 2010-11-26 2014-07-08 Denso Corporation Stator for electric rotating machine
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US9906086B2 (en) 2012-08-31 2018-02-27 Hitachi Automotive Systems, Ltd. Rotating electric machine including a stator with a connection portion having a corner portion and method for manufacturing same
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WO2017026306A1 (en) * 2015-08-10 2017-02-16 アイシン・エィ・ダブリュ株式会社 Insulating resin coating method and stator
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JP2016041011A (en) * 2015-12-17 2016-03-24 日立オートモティブシステムズ株式会社 Stator coil, stator core, and rotary electric machine

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