JP2004165065A

JP2004165065A - Connection conductor for circuit breaker and manufacturing method of the same

Info

Publication number: JP2004165065A
Application number: JP2002331298A
Authority: JP
Inventors: Hideki Kondo; 日出樹近藤
Original assignee: Matsushita Electric Works Ltd
Current assignee: Panasonic Electric Works Co Ltd
Priority date: 2002-11-14
Filing date: 2002-11-14
Publication date: 2004-06-10

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connection conductor for a circuit breaker having a better material yield comparing with a yield when a metal plate is used. <P>SOLUTION: The connection conductor 10 is used for connecting a connection terminal 4b and a movable contactor 3b so as not to interfere with a conductor plate 7a at the inside of the circuit breaker. The connection conductor made of a round rod-shaped conductive material is composed of a crank-shaped main body 11 having a central piece 11a with arm pieces 11b extended from its both ends, and tips of respective arm pieces 11b have connection parts 12, 13 overlapping with the connection terminal 4b and the movable contactor 3b, respectively. The body part 11 is formed by bending a round rod, and both the connection parts 12, 13 are formed by coinning from the same direction so that surfaces of the connection parts 12, 13 form a prescribed angle relative to a flat plane including the main body 11. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、回路遮断器の内部において２つの導体間を電気的に接続する回路遮断器用接続導体およびその製造方法に関するものである。
【０００２】
【従来の技術】
従来から、図１３に示す構成の回路遮断器が知られている。この回路遮断器は住宅用の分電盤において分岐ブレーカとして用いられるものであって、器体１に２個の接点装置２ａ，２ｂを内蔵している。一方の接点装置２ａを開閉する可動接触子３ａは接続端子４ａとの間に異常電流検出装置５が挿入され、また、他方の接点装置２ｂを開閉する可動接触子３ｂは、板ばねにより形成されるとともに一端部が延長されて接続端子４ｂに接続されている。異常電流検出装置５は、トリップ機構６のトリガであって、器体１の上面に対して起伏するハンドル７を倒して図１３の状態にトリップ機構６をセットすると接点装置２ａ，２ｂが閉極した状態に保たれ、トリップ機構６がセットされた状態において異常電流検出装置５が異常電流（過電流や短絡電流）を検知すると、トリップ機構６のラッチを解除して、トリップ機構６を作動させるものである（たとえば、特許文献１参照）。
【０００３】
ところで、図示例では接続端子４ａと異常電流検出装置５との間は導体板７ａにより接続してあり、接続端子４ｂには可動接触子３ｂの一端部を延長した接続部７ｂを接続してある。また、接続端子４ａ，４ｂは上下に離間して配置されており、下側の接続端子４ａに接続された導体板７ａと異常電流検出装置５との接続部位は、上側の接続端子４ｂと電気的に接続される可動接触子３ｂよりも上方に位置している。したがって、導体板７ａと接続部７ｂとは互いに立体交差が可能な形状に形成される。つまり、図示例では、導体板７ａとして帯状の金属板を厚み方向において折曲したものを用い、接続部７ｂは厚み方向に直交する面内において導体板７ａを回避可能な形状に形成されている。
【０００４】
【特許文献１】
特開２００２−２５４１５号公報（第５−８頁、図１）
【０００５】
【発明が解決しようとする課題】
上述した構成では、接続部７ｂを含む可動接触子３ｂを形成するために、金属板を打抜加工の後に折曲するのであって、上述したように接続部７ｂは厚み方向に直交する面内において導体板７ａを回避可能な形状に形成しているものであるから、接続部７ｂを打ち抜く金属板において接続部７ｂ以外の余剰部分が比較的多くなり、結果的に材料歩どまりが比較的悪いという問題がある。また、曲げ加工だけではなく打抜加工が必要であり、バリ取りなどの作業も必要になるなど製造に手間がかかるという問題がある。
【０００６】
本発明は上記事由に鑑みて為されたものであり、その目的は、金属板を用いる場合に比較して材料歩どまりがよい回路遮断器用接続導体を提供するとともに、金属板を用いる場合に比較して製造作業の手間が少ない回路遮断器用接続導体の製造方法を提供することにある。
【０００７】
【課題を解決するための手段】
請求項１の発明は、回路遮断器の内部において２つの導体間を結ぶ直線上に存在する他部材を回避して前記両導体間を電気的に接続する接続導体であって、導電材料からなる丸棒を２箇所以上屈曲させて前記他部材を迂回する形状に形成された本体部と、本体部の両端部に形成され前記各導体にそれぞれ重ねて接続される一対の接続部とを備え、前記接続部のそれぞれは前記丸棒の各端部を丸棒の軸方向に直交する一つの方向かつ同方向からコイニングにより形成されていることを特徴とする。
【０００８】
請求項２の発明では、請求項１の発明において、前記本体部は中央片の両端部からそれぞれ中央片に直交するとともに互いに逆向きの腕片が一体に延設されたクランク状であって、前記接続部のそれぞれは本体部を含む平面に対して各腕片の回りで規定の角度をなすことを特徴とする。
【０００９】
請求項３の発明では、請求項１または請求項２の発明において、前記接続部の両側部に接続部の一面側に立ち上がるとともに前記導体に対して接続部を位置決めする位置決め片が形成されていることを特徴とする。
【００１０】
請求項４の発明では、請求項１ないし請求項３の発明において、前記接続部の中央部に接続部の一面側に突出するとともに前記導体に形成した結合孔に係合してかしめ固定される結合凸部が形成されていることを特徴とする。
【００１１】
請求項５の発明は、回路遮断器の内部において２つの導体間を結ぶ直線上に存在する他部材を回避して前記両導体間を電気的に接続する接続導体を製造する方法であって、導電材料からなる所定長さの丸棒の中央部をクランプに設けた一対のあごにより挟持した状態で、あごの側面に沿って移動する一対のロールを用いて丸棒の両端部を中央部に対して屈曲させることにより中央片の両端部からそれぞれ中央片に直交するとともに互いに逆向きの腕片が一体に延設されたクランク状の本体部を形成し、次に両腕片の先端部を腕片の軸方向に直交する一つの方向において型締めされる型を用いて同時にコイニングを行う際に、型が型締めされる方向に対して本体部を含む平面が腕片の回りで規定の角度をなすように本体部を保持しておき、本体部の両端部に各導体にそれぞれ重ねて接続される一対の接続部を本体部が含まれる平面に対して各腕片の回りで規定の角度をなす形に形成することを特徴とする。
【００１２】
請求項６の発明は、請求項５の発明において、前記接続部をコイニングにより形成する際に、接続部の両側部に接続部の一面側に立ち上がるとともに前記導体に対して接続部を位置決めする位置決め片を形成することを特徴とする。
【００１３】
請求項７の発明は、請求項５または請求項７の発明において、前記接続部をコイニングにより形成する際に、接続部の中央部に接続部の一面側に突出するとともに前記導体に形成した結合孔に係合してかしめ固定される結合凸部を形成することを特徴とする。
【００１４】
【発明の実施の形態】
本実施形態は図２に示す構成の回路遮断器の内部において接続端子４ｂと可動接触子３ｂとの間を電気的に接続する接続導体１０について説明する。ただし、本発明の技術思想は他の部位や他の構成の回路遮断器においても適宜に採用することが可能である。本実施形態において説明する回路遮断器は一部構成が異なるものの基本的な構成は、図１３に示した構成と同様である。
【００１５】
本実施形態で用いる接続導体１０は、図１に示すように、銅ないし銅合金のような導電材料からなる丸棒を用いて形成されたものであって、丸棒を２箇所屈曲させた形状の本体部１１と、丸棒の両端部をそれぞれ塑性変形させて形成した一対の接続部１２，１３とを備える。本体部１１は、中央片１１ａの両端部からそれぞれ中央片１１ａに直交する腕片１１ｂが互いに逆向きに延設されたクランク状に形成されている。
【００１６】
接続部１２，１３は、図３に示すように、両腕片１１ｂの先端部をそれぞれ丸棒の軸方向に直交する一つの方向かつ同方向からコイニングにより同時に形成し、丸棒の両端部を押し潰した形状に形成される。さらに、本体部１１を含む平面に対して接続部１２，１３の厚み方向の両面は傾斜しており、かつ両接続部１２，１３の本体部１１を含む平面に対する傾斜角度は等しくなっている。また、各接続部１２，１３において腕片１１ｂの軸方向に沿った両側部には接続部１２，１３の一面側に立ち上がる位置決め片１２ａ，１３ａがそれぞれ形成される。つまり、接続部１２，１３をコイニングを行う際の材料の延びを利用し、延び分を接続部１２，１３の厚み方向に立ち上げることによって位置決め片１２ａ，１３ａを形成する。また、接続部１２，１３の中央部には位置決め片１２ａ，１３ａと同じ向きに突出する結合凸部１２ｂ，１３ｂを形成してある。結合凸部１２ｂ、１３ｂも位置決め片１２ａ，１３ａと同様に、接続部１２，１３をコイニングを行う際の材料の延びを利用して形成してある。要するに、コイニングの際の材料の延びによって生じる応力を位置決め片１２ａ，１３ａおよび結合凸部１２ｂ，１３ｂに逃がすことによって、コイニングに伴う材料の割れなどを防止することができる。ここに、位置決め片１２ａ，１３ａは平板状ではなく、腕片１１ｂの軸方向における中央部が結合凸部１２ｂ，１３ｂに近付く向きに湾曲した形状に形成される。
【００１７】
接続部１２および接続部１３は、図１に示すように、導体である接続端子４ｂおよび可動接触子３ｂの一部にそれぞれ重ねて接続されるのであって、各接続部１２，１３に設けた各一対の位置決め片１２ａ，１３ａの間に接続端子４ｂあるいは可動接触子３ｂを挟むことによって、接続部１２が接続端子４ｂに位置決めされるとともに、接続部１３ｂが可動接触子３ｂに位置決めされる。また、接続端子４ｂおよび可動接触子３ｂにおいて接続部１２，１３が重なる部位には結合凸部１２ｂ、１３ｂが挿入される結合孔１４がそれぞれ形成され、結合凸部１２ｂ，１３ｂを結合孔１４に挿入した後に、結合凸部１２ｂ、１３ｂをかしめ固定することによって、接続部１２，１３を接続端子４ｂおよび可動接触子３ｂに固着することができる。
【００１８】
接続端子４ｂおよび可動接触子３ｂを器体１に収納した状態では、接続端子４ｂにおいて接続部１２が重なる部位と可動接触子３ｂにおいて接続部１３が重なる部位とは略直交するから、接続部１２を接続端子４ｂに固着するとともに接続部１３を可動接触子３ｂに固着した後に、接続部１３の中間部を折曲することによって、接続端子４ｂと可動接触子３ｂとを器体１の中の所定位置に収納する。また、本体部１１がクランク状であり、かつ本体部１１を含む平面に対して接続部１２，１３が所定角度で傾斜していることによって、接続端子４ｂと可動接触子３ｂと接続導体１０とを器体１の所定位置に収納した状態で、本体部１１が他部材である導体板７ａを迂回して導体板７ａとの接触を回避することが可能になる。逆に言えば、導体板７ａとの接触を回避するように、本体部１１の形状と接続部１２，１３の角度とが設定される。なお、接続部１２，１３は本体部１１を含む平面に対して必ずしも傾斜している必要はなく、本体部１１が他部材に接触せずに迂回することができればよい。
【００１９】
次に、上述した接続導体１０を製造する工程について説明する。製造工程は基本的には図４に示す順序であって、導電材料からなる断面円形の線材を所定長さに切断して丸棒を形成する材料切断工程Ｐ１、丸棒をクランク状に折曲するクランク曲げ工程Ｐ２、後工程であるコイニングに用いる型の型締め方向に対してクランク状の丸棒を含む平面がなす角度を設定する姿勢変更工程Ｐ３、接続部１２，１３を形成するコイニング加工工程Ｐ４、接続部１２，１３に設けた結合突起１２ｂ，１３ｂを接続端子４ｂおよび可動接触子３ｂにかしめ固定するかしめ工程Ｐ５、接続部１３と可動接触子３ｂとを固着した状態で接続部１３の中間部を折曲する曲げ工程Ｐ６を備える。
【００２０】
以下では、各工程についてさらに具体的に説明する。線材から丸棒を形成する材料切断工程Ｐ１では、図５に示すように、コイル状に巻回した線材２１をアンコイラ３１に装着するとともに、線材２１の先端部を２個のクランプ３２，３３により保持する。両クランプ３２，３３は線材２１を切断する切断機３４の近傍に配置され、切断機３４により線材２１を一定長さに切断した丸棒はフィーダ３５に排出され、フィーダ３５から次工程に送られる。切断機３４は、矩形枠状のガイド３４ａの中に直進往復移動するカッタ３４ｂを備え、カッタ３４ｂの移動方向に沿ったガイド３４ａの両側壁に切欠溝３４ｃ，３４ｄを備える。したがって、切欠溝３４ｃ，３４ｄに重ならないようにカッタ３４ｂを後退させた状態で（図５に示す位置）、切欠溝３４ｃからガイド３４ａに線材２１を導入し、カッタ３４ｂを図５の前方に移動させると線材２１を切断することができる。ここに、各クランプ３２，３３は図５に矢印で示す向きに移動可能であって、線材２１の先端側の一方のクランプ３２で線材２１を保持し、他方のクランプ３３をアンコイラ３１に近付く向きに一定距離だけ後退させた後、両クランプ３２，３３を切欠溝３４ｃに対応する位置まで側方に移動させ、次に、クランプ３２を緩めた状態でクランプ３３を切断機３４に近付く向きに移動させると、クランプ３３の移動に伴って線材２１が切欠溝３４ｃからガイド３４ａに導入されるのである。
【００２１】
切断機３４の側方には切欠溝３４ｃ、３４ｄを結ぶ直線上を往復移動する突き出し棒３６が設けられており、上述のようにして、線材２１が所定長さに切断された後にカッタ３４ｂが元の位置に復帰すると、突き出し棒３６が切欠溝３４ｃから切断機３４に導入され、線材２１を切断して得た丸棒が突き出し棒３６に押されて切欠溝３４ｄからフィーダ３５に排出される。フィーダ３５は円筒状のフィーダ本体３５ａの内周部に螺旋状の搬送路３５ｂを有するとともにフィーダ本体３５ａが加振されているものであって、フィーダ３５に落下した丸棒は搬送路３５ｂを上昇することによって整列され、搬送路３５ｂに一体に連続する排出路３５ｃから次工程に排出される。
【００２２】
次工程は、フィーダ３５から排出された丸棒２２をクランク状に折曲するクランク曲げ工程Ｐ２であって、図６のような構成の曲げ加工機４０を用いる。曲げ加工機４１は、円形のテーブル４１の一端部にストッパ４１ａが突設されており、テーブル４１の中央部には一対のあご４２ａ，４２ｂを備えたクランプ４２を備える。また、クランプ４２の両側方にはあご４２ａ，４２ｂの両側面に沿って往復移動する一対のロール４３，４４が配置される。各ロール４３，４４は糸巻き状であって、ロール４３，４４の軸方向におけるロール４３，４４の周面中央部が周面周部よりも凹んだ形に形成されている。
【００２３】
クランプ４２は、図７に示すように、丸棒２２の軸方向の一端がストッパ４１ａに当接した状態で丸棒２２を保持できるように配置されている。つまり、クランプ４２のあご４２ａ，４２ｂを開いた状態で、フィーダ３５から曲げ加工機４０に丸棒２２が導入されると、丸棒２２の先端はストッパ４１ａに当接して位置決めされる。この状態でクランプ４２のあご４２ａ，４２ｂが閉じられ、丸棒２２が保持される。ここで、２個のロール４３，４４は丸棒２２を挟んで互いに反対側に位置しており、クランプ４２が丸棒２２を保持した後に、図８に示すように、各ロール４３，４４はそれぞれクランプ４２のあご４２ａ，４２ｂの側面に沿って移動する。つまり、クランプ４２に対してストッパ４１ａとは反対側のロール４３はあご４２ａの側方に位置している状態からあご４２ｂの側方に向かって移動し、クランプ４２に対してストッパ４１ａに近い側のロール４４はあご４２ｂの側方に位置している状態からあご４２ａの側方に向かって移動する。その結果、丸棒２２のうちクランプ４２に保持されている部位が中央片１１ａになり、ロール４３，４４により折曲された部位から先端側が腕片１１ｂになる。
【００２４】
上述のように、丸棒２２をクランク状に折曲する際にロール４３，４４を用いているから、ロール４３，４４を用いずに丸棒２２を押し曲げる場合に比較すると、丸棒２２を折曲する部材（ロール４３，４４）が回転するから寿命が長くなる。丸棒２２を折曲してクランク状に形成した後には、図９のようにクランプ４２を開くとともに、ロール４３，４４を元の位置に復帰させてクランク状に折曲された丸棒２２を曲げ加工機４０から取り出す。
【００２５】
次の姿勢変更工程Ｐ３は、図１０のように、丸棒２２を保持型５１に装着する工程である。保持型５１はクランク状の丸棒２２が装着される嵌め溝５１ａを有し、嵌め溝５１ａはクランク状の丸棒２２を含む平面が、図１０における保持型５１の上面に対して傾斜するように形成されている。つまり、嵌め溝５１ａの形状によって本体部１１に対する接続部１２，１３の角度が決定される。保持型５１に丸棒２２が装着された状態で、保持型５１はコイニングを行う型５２の中に導入されコイニング加工工程Ｐ４に移行する。型５２は２個のコイニング型５３，５４を備え、各コイニング型５３，５４は、図１０に矢印Ａで示す方向に直進往復移動する下型５３ａ，５４ａと、図１０に矢印Ｂで示す方向に直進往復移動する上型５３ｂ，５４ｂとからなる。下型５３ａ，５４ａには上型５３ｂ，５４ｂとの対向面に突台５３ｃ，５４ｃが突設される。保持型５１は両下型５３ａ，５４ａの距離を引き離した状態で突台５３ｃ，５４ｃの間に挿入され、その後、両下型５３ａ，５４ａが互いに近付いて図１１のように突台５３ｃ，５４ｃの間に保持型５１が挟まれる。
【００２６】
図１１に示すように、保持型５１が突台５３ｃ，５４ｃの間に挟まれた状態で、突台５３ｃ，５４ｃの先端面には丸棒２２の各端部（腕片１１ｂに相当する部位）がそれぞれ載置される。ここで、クランク状の丸棒２２を含む平面は保持型５１の上面に対して傾斜しているから、突台５３ｃと突台５４ｃとの突出寸法は互いに異ならせてある。各突台５３ｃ，５４ｃの上面には丸棒２２の先端部の両側方に位置する各一対の凸ピン５３ｄ，５４ｄが突設されている。各凸ピン５３ｄ，５４ｄはそれぞれ先端部が先細り状に形成され、また丸棒２２の先端部と各凸ピン５３ｄ，５４ｄとの距離は略等距離に設定される。さらに、各突台５３ｃ，５４ｃにおいて丸棒２２に干渉しない位置には位置決め孔５３ｅ，５４ｅが穿孔され、上型５３ｂ，５４ｂの下面に突設された位置決め棒５３ｆ，５４ｆが位置決め孔５３ｅ，５４ｅに挿入されることによって、下型５３ａ，５３ａと上型５３ｂ，５４ｂとが位置合わせされる。ところで、上型５３ｂ，５４ｂの下面には図１２（ａ）に斜線部で示す押し突部５３ｇ，５４ｇが突設されている。押し突部５３ｇ，５４ｇは、凸ピン５３ｄ，５４ｄの間に対応する部位が他の部位よりも幅狭に形成され、さらに幅狭に形成されている部位の幅方向の中央部に凹所５３ｈ，５４ｈが形成されている。
【００２７】
下型５３ａ，５４ａに対して上型５３ｂ，５４ｂの型締めを行うと、図１２（ｂ）のように、押し突起５３ｇ，５４ｇと下型５３ａ，５４ａとの間で丸棒２２の一部が押し潰されることによって接続部１２，１３が形成され、このとき、材料の延びによって押し突起５３ｇ，５４ｇの幅狭部分と凸ピン５３ｄ，５４ｄとの間の隙間に逃げた部分は凸ピン５３ｄ，５４ｄに沿って曲がることによって位置決め片１２ａ，１３ａを形成し、また材料の延びによって凹所５３ｈ，５４ｈに逃げた部分は結合凸部１２ｂ，１３ｂを形成する。接続部１２，１３の成形後に上型５３ｂ，５４ｂを開き、下型５３ａ，５４ａを開けば接続導体１０を取り出すことができる。回路遮断器に組み込むにあたっては、接続導体１０を接続端子４ｂと可動接触子３ｂとにかしめ固定し（かしめ工程Ｐ５）、さらに接続部１３の中間部を折曲する（曲げ工程Ｐ６）。
【００２８】
なお、上述した接続導体１０は、中央片１１ａの両端から腕片１１ｂを延設したクランク状に形成しているが、接続導体１０は必ずしもクランク状でなくてもよく、他部材に干渉しない形状であれば適宜形状に形成することができる。たとえば、中央片１１ａに対して両腕片１１ｂは必ずしも直交している必要はなく、中央片１１ａと腕片１１ｂとが適宜角度で交差していてもよい。また、上述した実施形態では本体部１１における屈曲箇所を２箇所としているが、必要に応じて３箇所以上で屈曲させることも可能である。さらに、本体部１１を含む平面に対して接続部１２，１３の表面が傾斜していることも必須ではなく、本体部１１を含む平面と接続部１２，１３の表面とのなす角度は０度（本体部１１を含む平面と接続部１２，１３の表面とが平行）であってもよい。
【００２９】
【発明の効果】
請求項１の発明の構成によれば、回路遮断器の内部において２つの導体間を結ぶ直線上に存在する他部材を回避して両導体間を電気的に接続する接続導体を導電材料からなる丸棒により形成しているから、金属板を用いてこの種の接続導体を形成する場合に比較すると、材料に無駄がなく材料歩どまりを向上させることができるという利点がある。また、本体部は丸棒を２箇所以上屈曲させて形成してあり、導体に接続するための接続部は丸棒の端部を丸棒の軸方向に直交する一つの方向かつ同方向からコイニングにより形成しているので、本体部の曲げ加工に際しては金属板に曲げ加工を行う場合のようなプレス加工が不要であり、接続部の加工に際しては導体と接続するための形状をコイニングによって容易に形成することができるという利点がある。
【００３０】
請求項２の発明では、請求項１の発明において、本体部をクランク状とし、本体部を含む平面と接続部とを規定の角度にしているから、２つの導体にそれぞれ重ねることを可能としながらも比較的簡単な形状であって、容易に作製することができるという利点がある。
【００３１】
請求項３の発明では、請求項１または請求項２の発明において、接続部の両側部に接続部の一面側に立ち上がるとともに導体に対して接続部を位置決めする位置決め片を形成しているから、各導体に対する位置決めが容易になり、しかも位置決め片はコイニングにより形成される接続部に設けているから、接続部に別途の加工を施すことなく接続部を形成する際に位置決め片を同時に形成することができるという利点がある。
【００３２】
請求項４の発明では、請求項１ないし請求項３の発明において、接続部の中央部に接続部の一面側に突出するとともに導体に形成した結合孔に係合してかしめ固定される結合凸部が形成されているから、導体に設けた結合孔に結合凸部を係合させることによって接続部と導体との位置決めが容易になるとともに、結合凸部をかしめ固定することにより、溶接などの作業を伴うことなく導体と接続導体とを機械的かつ電気的に接続することができる。しかも、結合凸部はコイニングにより形成される接続部に設けているから、接続部に別途の加工を施すことなく接続部を形成する際に結合凸部を同時に形成することができるという利点がある。
【００３３】
請求項５の発明は、回路遮断器の内部において２つの導体間を結ぶ直線上に存在する他部材を回避して両導体間を電気的に接続する接続導体を製造する方法であって、導電材料からなる所定長さの丸棒の中央部をクランプに設けた一対のあごにより挟持した状態で、あごの側面に沿って移動する一対のロールを用いて丸棒の両端部を中央部に対して屈曲させることにより中央片の両端部からそれぞれ中央片に直交するとともに互いに逆向きの腕片が一体に延設されたクランク状の本体部を形成し、次に両腕片の先端部を腕片の軸方向に直交する一つの方向において型締めされる型を用いて同時にコイニングする際に、型が型締めされる方向に対して本体部を含む平面が腕片の回りで規定の角度をなすように本体部を保持しておき、本体部の両端部に各導体にそれぞれ重ねて接続される一対の接続部を本体部が含まれる平面に対して各腕片の回りで規定の角度をなす形に形成することを特徴としており、丸棒をクランプで保持した状態で一対のロールにより丸棒の両端部を曲げることによってクランク状の本体部を形成するので、ロールを用いることなく丸棒に曲げ加工を施す場合に比較すると、丸棒の延びが少なく断面積の変化が少なくなり、結果的に設計値に対する電流容量の低減を防止することができるという利点がある。また、丸棒を曲げる際にロールが丸棒に沿って回転するから、回転することなく丸棒を押し曲げる加工機を用いる場合に比較すると、丸棒との接触部分の摩耗が少なく加工機の寿命が長くなるという利点がある。さらに、導体間を電気的に接続する接続導体を丸棒により形成しているから、金属板を用いてこの種の接続導体を形成する場合に比較すると、材料に無駄がなく材料歩どまりを向上させることができるという利点がある。また、本体部はクランク状に形成してあり、導体に接続するための接続部はコイニングにより形成しているので、本体部の曲げ加工に際しては金属板に曲げ加工を行う場合のようなプレス加工が不要であり、接続部の加工に際しては導体と接続するための形状をコイニングによって容易に形成することができるという利点がある。しかも、２つの導体にそれぞれ重ねることを可能としながらも比較的簡単な形状であって、容易に作製することができるという利点がある。
【００３４】
請求項６の発明は、請求項５の発明において、接続部をコイニングにより形成する際に、接続部の両側部に接続部の一面側に立ち上がるとともに導体に対して接続部を位置決めする位置決め片を形成するので、接続部を形成する際に同時に位置決め片を形成することができ、接続部に別途の加工を施すことなく接続導体を接続対象である導体に位置合わせするための構造を簡単に作製することができるという利点がある。
【００３５】
請求項７の発明は、請求項５または請求項７の発明において、接続部をコイニングにより形成する際に、接続部の中央部に接続部の一面側に突出するとともに導体に形成した結合孔に係合してかしめ固定される結合凸部を形成するので、接続部を形成する際に同時に結合凸部を形成することができ、接続部に別途の加工を施すことなく接続導体を接続対象である導体に機械的かつ電気的に接続するための構造を簡単に作製することができるという利点がある。
【図面の簡単な説明】
【図１】本発明の実施形態の使用例を示し、（ａ）は斜視図、（ｂ）は正面図である。
【図２】同上を用いた回路遮断器の内部を示す側面図である。
【図３】同上の斜視図である。
【図４】同上の製造工程を示す工程図である。
【図５】同上の製造工程のうちの切断工程を示す斜視図である。
【図６】同上の製造工程のうち曲げ工程を示す斜視図である。
【図７】同上の製造工程のうち曲げ工程を示す斜視図である。
【図８】同上の製造工程のうち曲げ工程を示す斜視図である。
【図９】同上の製造工程のうち曲げ工程を示す斜視図である。
【図１０】同上の製造工程のうち姿勢変更工程を示す斜視図である。
【図１１】同上の製造工程のうちコイニング工程を示す斜視図である。
【図１２】同上の製造工程のうちコイニング工程を示し、（ａ）は平面図、（ｂ）はＡ−Ａ線断面図である。
【図１３】従来の回路遮断器の内部を示す側面図である。
【符号の説明】
３ｂ可動接触子
４ｂ接続端子
７ａ導体板
１０接続導体
１１本体部
１１ａ中央片
１１ｂ腕片
１２，１３接続部
１２ａ，１３ａ位置決め片
１２ｂ，１３ｂ結合凸部
１４結合孔
２２丸棒
４２クランプ
４２ａ，４２ｂあご
４３，４４ロール
５１保持型
５２型
５３，５４コイニング型[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a connection conductor for a circuit breaker for electrically connecting two conductors inside a circuit breaker and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, a circuit breaker having a configuration shown in FIG. 13 is known. This circuit breaker is used as a branch breaker in a residential power distribution panel, and has two contact devices 2a and 2b built in a body 1. The movable contact 3a for opening and closing the one contact device 2a has an abnormal current detection device 5 inserted between it and the connection terminal 4a, and the movable contact 3b for opening and closing the other contact device 2b is formed by a leaf spring. And one end is extended and connected to the connection terminal 4b. The abnormal current detection device 5 is a trigger of the trip mechanism 6, and when the handle 7 that rises and falls with respect to the upper surface of the body 1 is set down and the trip mechanism 6 is set to the state shown in FIG. 13, the contact devices 2a and 2b close. When the abnormal current detection device 5 detects an abnormal current (overcurrent or short-circuit current) while the trip mechanism 6 is set, the latch of the trip mechanism 6 is released, and the trip mechanism 6 is operated. (For example, see Patent Document 1).
[0003]
Incidentally, in the illustrated example, the connection terminal 4a and the abnormal current detection device 5 are connected by a conductor plate 7a, and the connection terminal 4b is connected to a connection portion 7b extending one end of the movable contact 3b. . The connection terminals 4a and 4b are vertically spaced apart from each other, and the connection between the conductor plate 7a connected to the lower connection terminal 4a and the abnormal current detector 5 is electrically connected to the upper connection terminal 4b. It is located above the movable contact 3b which is connected to the terminal. Therefore, the conductor plate 7a and the connection portion 7b are formed in a shape that allows three-dimensional intersection with each other. That is, in the illustrated example, a strip-shaped metal plate bent in the thickness direction is used as the conductor plate 7a, and the connection portion 7b is formed in a shape that can avoid the conductor plate 7a in a plane orthogonal to the thickness direction. .
[0004]
[Patent Document 1]
JP-A-2002-25415 (page 5-8, FIG. 1)
[0005]
[Problems to be solved by the invention]
In the above-described configuration, in order to form the movable contact 3b including the connection portion 7b, the metal plate is bent after punching, and the connection portion 7b is formed in an in-plane orthogonal to the thickness direction as described above. Since the conductor plate 7a is formed in a shape that can be avoided, the metal plate from which the connection portion 7b is punched has a relatively large excess portion other than the connection portion 7b, and as a result, the material yield is relatively poor. There is a problem. In addition, not only bending but also punching is required, and operations such as deburring are also required, so that there is a problem that manufacturing is troublesome.
[0006]
The present invention has been made in view of the above circumstances, and an object thereof is to provide a connection conductor for a circuit breaker having a better material yield as compared with the case of using a metal plate, and to provide a connection conductor in which a metal plate is used. Another object of the present invention is to provide a method for manufacturing a connection conductor for a circuit breaker, which requires less time and effort for manufacturing.
[0007]
[Means for Solving the Problems]
The invention according to claim 1 is a connection conductor that electrically connects the two conductors while avoiding another member existing on a straight line connecting the two conductors inside the circuit breaker, and is made of a conductive material. A main body formed in a shape of detouring the other member by bending a round bar at two or more locations, and a pair of connecting portions formed at both ends of the main body portion and connected to the conductors respectively, Each of the connecting portions is formed by coining each end of the round bar from one direction orthogonal to the axial direction of the round bar and from the same direction.
[0008]
According to a second aspect of the present invention, in the first aspect of the invention, the main body has a crank shape in which arm pieces orthogonal to the central piece and extending in opposite directions to each other extend integrally from both ends of the central piece, Each of the connecting portions makes a predetermined angle around each arm piece with respect to a plane including the main body.
[0009]
According to a third aspect of the present invention, in the first or second aspect of the present invention, positioning pieces are formed on both sides of the connecting portion so as to stand on one side of the connecting portion and to position the connecting portion with respect to the conductor. It is characterized by the following.
[0010]
According to a fourth aspect of the present invention, in the first to third aspects of the present invention, the central portion of the connecting portion protrudes toward one surface side of the connecting portion and is fixed by caulking by engaging a coupling hole formed in the conductor. It is characterized in that a connecting projection is formed.
[0011]
The invention according to claim 5 is a method of manufacturing a connection conductor that electrically connects the two conductors while avoiding other members existing on a straight line connecting the two conductors inside the circuit breaker, With a central portion of a round bar of a predetermined length made of a conductive material sandwiched between a pair of jaws provided on a clamp, both ends of the round bar are brought to the center using a pair of rolls moving along the side of the jaw. By bending the arm against the center piece from both ends of the center piece, a crank-shaped main body is formed in which arm pieces orthogonal to the center piece and extending in opposite directions are integrally formed. When performing coining simultaneously using a mold that is clamped in one direction perpendicular to the axial direction of the arm piece, the plane including the main body with respect to the direction in which the mold is clamped is defined around the arm piece. Hold the main unit so that it forms an angle, and And forming the shape of an angle defined around each arm piece a pair of connecting portions which are connected to overlap to each conductor at both ends with respect to a plane including the body of the.
[0012]
According to a sixth aspect of the present invention, in the invention of the fifth aspect, when the connecting portion is formed by coining, the connecting portion stands on one side of the connecting portion on both sides of the connecting portion and positions the connecting portion with respect to the conductor. Forming a piece.
[0013]
According to a seventh aspect of the present invention, in the fifth or seventh aspect of the present invention, when the connection portion is formed by coining, the connection portion is formed at the center of the connection portion on one surface side of the connection portion and formed on the conductor. It is characterized in that a connecting projection which is engaged with the hole and fixed by caulking is formed.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
In the present embodiment, a connection conductor 10 that electrically connects between the connection terminal 4b and the movable contact 3b inside the circuit breaker having the configuration shown in FIG. 2 will be described. However, the technical idea of the present invention can be appropriately applied to circuit breakers having other parts and other configurations. Although the circuit breaker described in the present embodiment has a partly different configuration, the basic configuration is the same as the configuration shown in FIG.
[0015]
As shown in FIG. 1, the connection conductor 10 used in the present embodiment is formed by using a round bar made of a conductive material such as copper or a copper alloy, and is formed by bending a round bar at two places. And a pair of connecting portions 12 and 13 formed by plastically deforming both ends of the round bar. The main body 11 is formed in a crank shape in which arm pieces 11b orthogonal to the center piece 11a extend in opposite directions from both ends of the center piece 11a.
[0016]
As shown in FIG. 3, the connection portions 12 and 13 are formed by coining the tip portions of the both arm pieces 11 b in one direction perpendicular to the axial direction of the round bar and simultaneously from the same direction. It is formed into a crushed shape. Further, both surfaces in the thickness direction of the connection portions 12 and 13 are inclined with respect to the plane including the main body 11, and the inclination angles of both the connection portions 12 and 13 with respect to the plane including the main body 11 are equal. Positioning pieces 12a and 13a are formed on both sides of the connecting portions 12 and 13 along the axial direction of the arm piece 11b so as to rise on one surface side of the connecting portions 12 and 13, respectively. That is, the positioning pieces 12a and 13a are formed by utilizing the extension of the material when coining the connection portions 12 and 13 and raising the extension in the thickness direction of the connection portions 12 and 13. Further, coupling projections 12b, 13b projecting in the same direction as the positioning pieces 12a, 13a are formed at the center of the connection parts 12, 13. Similarly to the positioning pieces 12a, 13a, the connecting projections 12b, 13b are also formed by utilizing the extension of the material when coining the connecting portions 12, 13. In short, the stress generated by the elongation of the material during coining is released to the positioning pieces 12a, 13a and the coupling protrusions 12b, 13b, so that cracking of the material due to coining can be prevented. Here, the positioning pieces 12a and 13a are not formed in a flat plate shape, but are formed in a shape in which the central portion in the axial direction of the arm piece 11b is curved so as to approach the coupling protrusions 12b and 13b.
[0017]
As shown in FIG. 1, the connecting portions 12 and 13 are connected to the connecting terminals 4b and the movable contact 3b, which are conductors, respectively, so as to overlap with each other. By sandwiching the connection terminal 4b or the movable contact 3b between each pair of positioning pieces 12a, 13a, the connection portion 12 is positioned at the connection terminal 4b and the connection portion 13b is positioned at the movable contact 3b. In the connection terminal 4b and the movable contact 3b, a connection hole 14 into which the connection protrusions 12b and 13b are inserted is formed at a portion where the connection portions 12 and 13 overlap, and the connection protrusions 12b and 13b are connected to the connection hole 14. After insertion, the connecting portions 12 and 13 can be fixed to the connection terminal 4b and the movable contact 3b by caulking and fixing the coupling protrusions 12b and 13b.
[0018]
In a state in which the connection terminal 4b and the movable contact 3b are housed in the body 1, the portion of the connection terminal 4b where the connection portion 12 overlaps is substantially orthogonal to the portion of the movable contact 3b where the connection portion 13 overlaps. Is fixed to the connection terminal 4b and the connection part 13 is fixed to the movable contact 3b, and then the intermediate part of the connection part 13 is bent to connect the connection terminal 4b and the movable contact 3b to each other in the body 1. Store in a predetermined position. Further, since the main body 11 has a crank shape and the connecting portions 12 and 13 are inclined at a predetermined angle with respect to a plane including the main body 11, the connection terminal 4b, the movable contact 3b, the connection conductor 10 When the main body 11 is stored in a predetermined position of the container 1, the main body 11 can bypass the conductor plate 7a, which is another member, to avoid contact with the conductor plate 7a. Conversely, the shape of the main body 11 and the angles of the connecting portions 12 and 13 are set so as to avoid contact with the conductor plate 7a. In addition, the connection parts 12 and 13 do not necessarily need to be inclined with respect to the plane including the main body part 11, as long as the main body part 11 can be bypassed without contacting other members.
[0019]
Next, a process of manufacturing the connection conductor 10 described above will be described. The manufacturing process is basically in the order shown in FIG. 4, and a material cutting step P1 of cutting a wire having a circular cross section made of a conductive material into a predetermined length to form a round bar, bending the round bar into a crank shape. C2, a crank bending step P2, a posture changing step P3 for setting an angle formed by a plane including a crank-shaped round bar with respect to a mold clamping direction of a die used for coining as a subsequent step, and coining processing for forming the connection portions 12 and 13. Step P4, a caulking step of caulking and fixing the coupling projections 12b, 13b provided on the connection portions 12, 13 to the connection terminal 4b and the movable contact 3b, and connecting portion 13 in a state where the connection portion 13 and the movable contact 3b are fixed. Is provided with a bending step P6 for bending an intermediate portion of.
[0020]
Hereinafter, each step will be described more specifically. In a material cutting step P1 for forming a round bar from a wire, as shown in FIG. 5, the wire 21 wound in a coil shape is mounted on an uncoiler 31, and the tip of the wire 21 is clamped by two clamps 32 and 33. Hold. Both clamps 32 and 33 are arranged in the vicinity of a cutting machine 34 for cutting the wire 21, and a round bar obtained by cutting the wire 21 to a certain length by the cutting machine 34 is discharged to a feeder 35 and sent from the feeder 35 to the next process. . The cutting machine 34 includes a cutter 34b that reciprocates straight in a rectangular frame-shaped guide 34a, and cutout grooves 34c and 34d on both side walls of the guide 34a along the moving direction of the cutter 34b. Therefore, with the cutter 34b retracted so as not to overlap the notches 34c and 34d (position shown in FIG. 5), the wire 21 is introduced from the notch 34c into the guide 34a, and the cutter 34b is moved forward in FIG. Then, the wire 21 can be cut. Here, each of the clamps 32 and 33 is movable in a direction indicated by an arrow in FIG. 5, and the one clamp 32 on the distal end side of the wire 21 holds the wire 21 and the other clamp 33 approaches the uncoiler 31. Then, the clamps 32, 33 are moved sideways to a position corresponding to the notch groove 34c, and then the clamp 33 is moved in a direction to approach the cutting machine 34 with the clamp 32 loosened. Then, the wire rod 21 is introduced into the guide 34a from the cutout groove 34c with the movement of the clamp 33.
[0021]
A protruding rod 36 that reciprocates on a straight line connecting the notch grooves 34c and 34d is provided on the side of the cutting machine 34. As described above, after the wire 21 is cut to a predetermined length, the cutter 34b When returning to the original position, the protruding rod 36 is introduced into the cutting machine 34 from the notch groove 34c, and the round bar obtained by cutting the wire 21 is pushed by the protruding rod 36 and discharged from the notch groove 34d to the feeder 35. . The feeder 35 has a spiral feed path 35b in the inner peripheral portion of a cylindrical feeder body 35a and the feeder body 35a is vibrated. The round bar dropped on the feeder 35 rises up the feed path 35b. Then, the sheet is aligned, and is discharged to the next step from a discharge path 35c that is integrally connected to the transport path 35b.
[0022]
The next step is a crank bending step P2 for bending the round bar 22 discharged from the feeder 35 into a crank shape, and uses a bending machine 40 having a configuration as shown in FIG. The bending machine 41 has a stopper 41a protruding from one end of a circular table 41 and a clamp 42 having a pair of jaws 42a and 42b at the center of the table 41. Further, a pair of rolls 43 and 44 that reciprocate along both side surfaces of the jaws 42a and 42b are arranged on both sides of the clamp 42. Each of the rolls 43 and 44 has a thread winding shape, and is formed such that the central portion of the peripheral surface of the rolls 43 and 44 in the axial direction of the rolls 43 and 44 is recessed from the peripheral portion.
[0023]
As shown in FIG. 7, the clamp 42 is arranged so as to be able to hold the round bar 22 in a state where one end in the axial direction of the round bar 22 is in contact with the stopper 41a. That is, when the round bar 22 is introduced from the feeder 35 into the bending machine 40 with the jaws 42a and 42b of the clamp 42 opened, the tip of the round bar 22 comes into contact with the stopper 41a and is positioned. In this state, the jaws 42a and 42b of the clamp 42 are closed, and the round bar 22 is held. Here, the two rolls 43 and 44 are located on opposite sides of the round bar 22, and after the clamp 42 holds the round bar 22, as shown in FIG. Each of them moves along the side surface of the jaws 42a and 42b of the clamp 42. That is, the roll 43 on the side opposite to the stopper 41a with respect to the clamp 42 moves toward the side of the jaw 42b from the state of being located on the side of the jaw 42a, and is closer to the clamp 42 than the stopper 41a. Roll 44 moves from the state located on the side of the jaw 42b toward the side of the jaw 42a. As a result, the portion of the round bar 22 held by the clamp 42 becomes the central piece 11a, and the tip side from the portion bent by the rolls 43 and 44 becomes the arm piece 11b.
[0024]
As described above, since the rolls 43 and 44 are used when the round bar 22 is bent into a crank shape, compared with the case where the round bar 22 is pushed and bent without using the rolls 43 and 44, the round bar 22 is Since the members (rolls 43 and 44) that bend rotate, the life is prolonged. After the round bar 22 is bent and formed into a crank shape, the clamp 42 is opened as shown in FIG. 9 and the rolls 43 and 44 are returned to the original positions, and the round bar 22 bent into the crank shape is removed. Take out from the bending machine 40.
[0025]
The next posture changing step P3 is a step of attaching the round bar 22 to the holding mold 51 as shown in FIG. The holding mold 51 has a fitting groove 51a on which the crank-shaped round bar 22 is mounted, and the fitting groove 51a is such that a plane including the crank-shaped round bar 22 is inclined with respect to the upper surface of the holding mold 51 in FIG. Is formed. That is, the angle of the connection parts 12 and 13 with respect to the main body part 11 is determined by the shape of the fitting groove 51a. With the round bar 22 mounted on the holding die 51, the holding die 51 is introduced into the coining die 52, and the process proceeds to the coining process P4. The mold 52 includes two coining molds 53 and 54. Each of the coining molds 53 and 54 is a lower mold 53a and 54a that reciprocates rectilinearly in a direction indicated by an arrow A in FIG. 10 and a direction indicated by an arrow B in FIG. And upper dies 53b and 54b which reciprocate linearly. On the lower dies 53a and 54a, protruding bases 53c and 54c are provided so as to project from surfaces facing the upper dies 53b and 54b. The holding mold 51 is inserted between the pedestals 53c, 54c while keeping the distance between the two lower dies 53a, 54a apart. Thereafter, the two lower dies 53a, 54a approach each other, and as shown in FIG. The holding mold 51 is sandwiched between the two.
[0026]
As shown in FIG. 11, in a state where the holding mold 51 is sandwiched between the protruding bases 53c and 54c, each end of the round bar 22 (a part corresponding to the arm piece 11b) is provided on the distal end surface of the protruding bases 53c and 54c. ) Are placed respectively. Here, since the plane including the crank-shaped round bar 22 is inclined with respect to the upper surface of the holding mold 51, the projecting dimensions of the abutment 53c and the abutment 54c are different from each other. A pair of convex pins 53d, 54d located on both sides of the tip of the round bar 22 are provided on the upper surfaces of the protruding tables 53c, 54c. Each of the convex pins 53d and 54d has a tapered tip, and the distance between the distal end of the round bar 22 and each of the convex pins 53d and 54d is set to be substantially equal. Further, positioning holes 53e, 54e are drilled at positions that do not interfere with the round bar 22 in each of the abutments 53c, 54c, and positioning rods 53f, 54f projecting from the lower surfaces of the upper dies 53b, 54b are provided with positioning holes 53e, 54e. The lower molds 53a, 53a and the upper molds 53b, 54b are aligned. By the way, on the lower surfaces of the upper dies 53b and 54b, pushing projections 53g and 54g indicated by oblique lines in FIG. The pushing protrusions 53g and 54g are formed such that a portion corresponding to the space between the convex pins 53d and 54d is formed narrower than the other portions, and a recess 53h is formed at the center in the width direction of the narrower portion. , 54h.
[0027]
When the upper dies 53b and 54b are clamped to the lower dies 53a and 54a, as shown in FIG. 12B, a part of the round bar 22 is formed between the push projections 53g and 54g and the lower dies 53a and 54a. Are crushed to form the connecting portions 12 and 13. At this time, the portion which has escaped to the gap between the narrow portions of the pushing protrusions 53g and 54g and the projecting pins 53d and 54d due to the extension of the material is the projecting pin 53d. , 54d form the positioning pieces 12a, 13a, and the portions which have escaped to the recesses 53h, 54h due to the extension of the material form the coupling projections 12b, 13b. After forming the connecting portions 12 and 13, the upper dies 53b and 54b are opened, and the lower dies 53a and 54a are opened, so that the connection conductor 10 can be taken out. When incorporated in the circuit breaker, the connection conductor 10 is caulked and fixed to the connection terminal 4b and the movable contact 3b (caulking step P5), and the intermediate portion of the connection portion 13 is bent (bending step P6).
[0028]
Although the connection conductor 10 described above is formed in a crank shape in which the arm pieces 11b extend from both ends of the central piece 11a, the connection conductor 10 does not necessarily have to have a crank shape and may have a shape that does not interfere with other members. If it is, it can be formed in an appropriate shape. For example, the both arm pieces 11b need not necessarily be orthogonal to the center piece 11a, and the center piece 11a and the arm piece 11b may intersect at an appropriate angle. Further, in the above-described embodiment, the number of bent portions in the main body 11 is two, but it is also possible to bend at three or more portions as necessary. Further, it is not essential that the surfaces of the connection portions 12 and 13 are inclined with respect to the plane including the main body portion 11, and the angle between the plane including the main body portion 11 and the surfaces of the connection portions 12 and 13 is 0 degree. (The plane including the main body 11 and the surfaces of the connection portions 12 and 13 are parallel).
[0029]
【The invention's effect】
According to the configuration of the first aspect of the invention, the connection conductor that electrically connects the two conductors while avoiding other members existing on a straight line connecting the two conductors inside the circuit breaker is made of a conductive material. Since the connection conductor is formed of a round bar, there is an advantage that the material yield can be improved and the material yield can be improved as compared with a case where this kind of connection conductor is formed using a metal plate. In addition, the main body is formed by bending a round bar at two or more places, and a connecting portion for connecting to a conductor is formed by coining the end of the round bar in one direction orthogonal to the axial direction of the round bar and in the same direction. When bending the main body, press work is not necessary as in the case of bending a metal plate, and when processing the connection part, the shape for connecting to the conductor is easily formed by coining. There is an advantage that it can be formed.
[0030]
According to the second aspect of the present invention, in the first aspect of the present invention, the main body is formed in a crank shape, and the plane including the main body and the connection portion are formed at a predetermined angle. Also has the advantage that it is relatively simple in shape and can be easily manufactured.
[0031]
According to the third aspect of the present invention, in the first or second aspect of the present invention, positioning pieces are formed on both sides of the connecting portion so as to stand on one side of the connecting portion and to position the connecting portion with respect to the conductor. Positioning of each conductor is easy, and positioning pieces are provided at the connection part formed by coining. Therefore, it is necessary to form the positioning pieces at the same time when forming the connection part without performing additional processing on the connection part. There is an advantage that can be.
[0032]
According to a fourth aspect of the present invention, in the first to third aspects of the present invention, the coupling projection is formed at the central portion of the connection portion and protrudes to one surface side of the connection portion and is fixed by caulking by engaging with a coupling hole formed in the conductor. Since the portion is formed, positioning of the connection portion and the conductor is facilitated by engaging the coupling convex portion with the coupling hole provided in the conductor, and by caulking and fixing the coupling convex portion, welding or the like is performed. The conductor and the connection conductor can be mechanically and electrically connected without any operation. In addition, since the connecting protrusion is provided at the connecting portion formed by coining, there is an advantage that the connecting protrusion can be formed at the same time when the connecting portion is formed without separately processing the connecting portion. .
[0033]
According to a fifth aspect of the present invention, there is provided a method of manufacturing a connection conductor for electrically connecting between two conductors while avoiding other members existing on a straight line connecting the two conductors inside the circuit breaker, With a central portion of a round bar of a predetermined length made of a material sandwiched between a pair of jaws provided on a clamp, a pair of rolls moving along the side of the jaw is used to move both ends of the round bar to the central portion. To form a crank-shaped main body in which arm pieces perpendicular to the center piece and opposite to each other extend integrally from both ends of the center piece, and then the ends of both arm pieces are attached to the arms. When coining simultaneously using a mold that is clamped in one direction perpendicular to the axial direction of the piece, the plane including the main body with respect to the direction in which the mold is clamped has a specified angle around the arm piece. Hold the main unit so that A pair of connecting portions, which are connected to the respective conductors so as to overlap with the respective conductors, are formed so as to form a prescribed angle around each arm piece with respect to a plane including the main body portion, and a round bar is clamped. Since the crank-shaped main body is formed by bending both ends of the round bar with a pair of rolls in a state where the roll is held, compared to a case where the round bar is bent without using a roll, the extension of the round bar is There is an advantage that the change in the cross-sectional area is small and the current capacity can be prevented from being reduced with respect to the design value. In addition, since the roll rotates along the round bar when bending the round bar, compared to using a processing machine that pushes and bends the round bar without rotating, the abrasion of the contact portion with the round bar is less and the processing machine There is an advantage that the life is extended. In addition, since the connecting conductors that electrically connect the conductors are formed by round bars, compared to the case of using a metal plate to form this type of connecting conductor, there is no waste of material and the material yield is improved. There is an advantage that it can be done. In addition, the main body is formed in a crank shape, and the connecting part for connecting to the conductor is formed by coining, so when bending the main body, press working like bending a metal plate This is advantageous in that the shape for connecting to the conductor can be easily formed by coining when the connecting portion is processed. Moreover, there is an advantage that it is relatively simple in shape, and can be easily manufactured, while being able to be superimposed on the two conductors.
[0034]
According to a sixth aspect of the present invention, in the invention of the fifth aspect, when forming the connection portion by coining, positioning pieces for standing on one side of the connection portion on both sides of the connection portion and positioning the connection portion with respect to the conductor are provided. Since it is formed, the positioning piece can be formed at the same time as forming the connection part, and the structure for aligning the connection conductor with the conductor to be connected can be easily manufactured without performing additional processing on the connection part. There is an advantage that can be.
[0035]
According to a seventh aspect of the present invention, in the fifth or seventh aspect of the present invention, when the connecting portion is formed by coining, the connecting portion protrudes toward the one surface side of the connecting portion at a central portion of the connecting portion and is formed in a coupling hole formed in the conductor. Since the connecting protrusion is formed by being engaged and caulked, the connecting protrusion can be formed at the same time when the connecting portion is formed, and the connecting conductor can be connected to the connecting object without performing additional processing on the connecting portion. There is an advantage that a structure for mechanically and electrically connecting to a certain conductor can be easily manufactured.
[Brief description of the drawings]
FIG. 1 shows an example of use of an embodiment of the present invention, wherein (a) is a perspective view and (b) is a front view.
FIG. 2 is a side view showing the inside of the circuit breaker using the above.
FIG. 3 is a perspective view of the same.
FIG. 4 is a process chart showing a manufacturing process of the same.
FIG. 5 is a perspective view showing a cutting step in the manufacturing steps of the above.
FIG. 6 is a perspective view showing a bending step in the manufacturing process of the above.
FIG. 7 is a perspective view showing a bending step in the manufacturing process of the embodiment.
FIG. 8 is a perspective view showing a bending step in the manufacturing process of the embodiment.
FIG. 9 is a perspective view showing a bending step in the manufacturing process of the above.
FIG. 10 is a perspective view showing a posture changing step in the manufacturing steps of the embodiment.
FIG. 11 is a perspective view showing a coining step in the manufacturing process of the above.
FIGS. 12A and 12B show a coining step in the manufacturing process, and FIG. 12A is a plan view and FIG.
FIG. 13 is a side view showing the inside of a conventional circuit breaker.
[Explanation of symbols]
3b Movable contact
4b connection terminal
7a conductor plate
10 Connecting conductor
11 Body
11a Central piece
11b Arm piece
12, 13 connection
12a, 13a Positioning piece
12b, 13b Coupling projection
14 coupling hole
22 round bar
42 Clamp
42a, 42b chin
43,44 rolls
51 Holding type
Type 52
53, 54 coining type

Claims

A connecting conductor for electrically connecting the two conductors while avoiding other members existing on a straight line connecting the two conductors inside the circuit breaker, wherein a round bar made of a conductive material is bent at two or more places. And a pair of connecting portions formed at both ends of the main portion and connected to the conductors, respectively, and each of the connecting portions is A connection conductor for a circuit breaker, wherein each end of the round bar is formed by coining from one direction orthogonal to the axial direction of the round bar and from the same direction.

The main body portion is a crank shape in which arm pieces that are orthogonal to the central piece and extend in opposite directions to each other are integrally extended from both ends of the central piece, and each of the connection portions is formed on a plane including the main body portion. 2. The connection conductor for a circuit breaker according to claim 1, wherein a predetermined angle is formed around each arm piece.

The connection for a circuit breaker according to claim 1 or 2, wherein a positioning piece that stands on one side of the connection part and positions the connection part with respect to the conductor is formed on both sides of the connection part. conductor.

2. A connecting projection formed at a central portion of said connecting portion, said connecting projecting portion projecting to one surface side of said connecting portion and engaging with a connecting hole formed in said conductor and fixed by caulking. Item 4. The connection conductor for a circuit breaker according to any one of items 3.

A method of manufacturing a connection conductor for electrically connecting between two conductors while avoiding other members existing on a straight line connecting two conductors inside the circuit breaker, comprising a predetermined length made of a conductive material. While the center of the round bar is sandwiched between a pair of jaws provided on the clamp, the center of the round bar is bent by bending both ends of the bar relative to the center using a pair of rolls that move along the side of the jaw. From both ends of the piece, a crank-shaped main body is formed in which arm pieces perpendicular to the center piece and opposite to each other are integrally formed, and then the ends of both arm pieces are perpendicular to the axial direction of the arm piece. When performing coining at the same time using a mold that is clamped in one direction, the main unit is configured such that a plane including the main unit forms a specified angle around the arm piece with respect to the direction in which the mold is clamped. And hold each conductor at both ends of the body. Method of manufacturing a circuit breaker connecting conductor, wherein a pair of connecting portions to the plane including the body portion is formed in the shape of an angle defined around each arm pieces which are connected to overlap respectively.

6. The positioning piece according to claim 5, wherein when forming the connection portion by coining, positioning pieces are formed on both sides of the connection portion so as to rise on one surface side of the connection portion and position the connection portion with respect to the conductor. Manufacturing method of connection conductor for circuit breaker.

When forming the connection portion by coining, it is preferable to form a connection protrusion that is protruded to one surface side of the connection portion at the center portion of the connection portion and that is engaged with a connection hole formed in the conductor and fixed by caulking. The method for manufacturing a connection conductor for a circuit breaker according to claim 5 or 6, wherein: