JP2005093146A - Connection structure and method for connecting conductors, and rotary electric machine and ac generator using same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connection structure and method capable of preventing local heat radiation and metallically jointing a wire with insulation coating and a conductor member without removing an insulation coating of the wire, a rotary electric machine with the connection structure, and an AC generator using the same. <P>SOLUTION: By applying pressure and electricity by an electrode of resistance welding, a current is made to flow to radiate heat, with which, a coating of the wire with the insulation coating is softened, and released, and the wire with the insulation coating and the conductor member can be metallically jointed by a connection supporting member. By using this connection structure and the connection method, the stabilization of a jointing process and connection quality can be attained. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a novel connection structure, a connection method thereof, a rotating electrical apparatus having the connection structure, and an AC generator using the same.

  Conventionally, a method for connecting an electric wire having an insulation coating of an electric device is to remove the insulation coating of the electric wire having an insulation coating by a mechanical or chemical method and expose the metal surface to be wound on a conductive member, or to add a conductive member. After fastening, the joining aid is melted and connected. In addition, as a method of directly connecting the insulating coating of the electric wire having the insulating coating to the conductive member without peeling off, the conductive member is formed in a U shape, and the electric wire having the insulating coating is inserted between them and added by resistance welding electrodes. The conductive member and the electrode generate heat when pressed and energized. There is a method in which the insulating coating is softened and discharged by the generated heat, and the electric wire having the insulating coating is connected to the conductive member. Further, JP-A-2-137306 is known. This publication discloses a method of connecting coils by heat of a junction terminal that generates heat due to resistance caused by energization. These connection methods are efficient because they can eliminate the coating peeling step.

JP-A-2-137306

  However, it is difficult to remove the coating in a stable manner by mechanically removing the coating, and it is difficult to remove the coating. . The chemical method has a large influence on safety and the environment, and the connection method using solder has a problem that the mechanical strength at high temperature is lowered and the reliability is inferior. Further, in the connection method in which the coating aid is not used without peeling off the coating, the electric wire and the conductive member are only in contact with each other and are not metallicly joined. For this reason, although the connection force is ensured by caulking of the conductive member, the caulking strength is lowered due to vibration or a thermal cycle, and there is a problem in electrical characteristics and strength reliability. Therefore, in the above-mentioned publication, a bonding aid is applied to the U-shaped connection terminal in advance, an electric wire having an insulation coating is inserted, pressurized, energized, and an electric wire and a conductor member having an insulation coating are applied by resistance heat of the bonding terminal. To connect. An object of the present invention is to provide a connection structure capable of metallically joining an electric wire having an insulating coating and a conductor member without removing the insulating coating of the electric wire having the insulating coating and preventing local heating, and a method for connecting the same. An object of the present invention is to provide a rotating electrical apparatus having the connection structure and an AC generator using the rotating electrical apparatus.

  In the method for connecting an electric wire having an insulating coating and a conductor member according to the present invention, the conductor member is disposed so as to contact a connection terminal on the surface side on which a bonding aid has been previously applied. This is pressurized and energized by resistance welding electrodes, current flows through the conductor member and the connection terminal, each generates heat, the joining aid melts, and the conductor member and the connection terminal are metallicly joined. Further, a wire having an insulation coating is inserted into a connection terminal provided with a bonding aid on the U-shaped, circular inner surface in advance, and thereafter, the wire having the insulation coating is added by a resistance welding electrode so as to contact the connection terminal. Press. And when it supplies with electricity, an electric current will flow through the bending part of a connecting terminal. At this time, the connecting terminal generates heat, and the generated heat softens and discharges the insulating coating of the electric wire having the insulating coating, and the electric wire having the insulating coating can be metal-bonded by the bonding aid. To connect wires with multiple insulation coatings, arrange the wires in parallel or in a grid shape so that all the wires with insulation coating are in contact with the connection terminals, and add the electrodes so that the conductor members are in contact with the connection terminals. It can be connected by pressing and energizing. By using the connection structure and connection method of the present invention, the number of man-hours can be reduced, and the connection quality can be stabilized.

  Wires with insulation coating have a cross-sectional shape that is either round, square, or polygonal. Wires with insulation coating at the time of joining are connected by pressure applied to the welding electrode for resistance welding or molding in the previous process It is in contact with the terminal, the joining aid for the connection terminal is either brazing material, solder, or a metal having a lower melting point than the connection terminal material, and the connection terminal material is copper, copper alloy, iron, iron-based alloy, aluminum One of the aluminum alloys was used.

  As the brazing material according to the present invention, by weight, P 3-8%, Ag 4-17%, balance Cu phosphorous copper brazing, JIS standard BAg-1, 2, 7 silver brazing, and the like can be used.

  A specific example of the present invention includes a stator core having a stator coil and a rectifier between end frames, a rotor having a field coil wound around a shaft so as to be rotatable in the stator core, and slipping onto the field coil. In an AC generator for a vehicle or construction machine that has a terminal connected to the field coil and a connection terminal that connects the slip ring while energizing through the ring, the field coil is an electric wire having an insulation coating, and slipping The ring is a conductor member, and the field coil and the slip ring have any one of the connection structures described above or a connection structure connected by any one of the connection methods described above.

  According to the present invention, an electric wire having an insulating coating and a conductor member are metallurgically connected by an alloy layer using a joining aid for a connection terminal, which is excellent in heat resistance, and further has an electrically stable and reliable connection. Can be obtained.

  According to the present invention, since the electric wire having the insulating coating and the conductor member can be metallurgically joined without removing the insulating coating of the electric wire having the insulating coating, the pre-connection process can be simplified. Further, it is possible to provide a connection structure and a connection method that can ensure electrical characteristics and strength reliability.

  Hereinafter, Examples 1 to 8 show structures and methods for metallically joining an electric wire having an insulating coating of the present invention and a conductor member. Moreover, the Example of the electric equipment using them is shown.

In this embodiment, as shown in FIG. 1, the conductor member 3 is arranged on the connection terminal 1 on the surface side where the bonding aid 2 has been applied in advance, and the connection terminal 1 is formed in a U shape so that the bonding aid 2 becomes the inner surface. Then, the electric wire 4 having an insulating coating is inserted. Heat is generated by pressurizing and energizing resistance welding so that the conductor side 3 shown in FIG. 2 (a) and the connecting terminal 1 on the surface side where the joining aid 2 is applied in advance are in contact with each other, as shown in FIG. 2 (b). The conductor member 3 and the connection terminal 1 are joined together by the joining aid 2. Next, as shown in FIG. 1, the end of the connection terminal 1 is formed in a U shape so that the bonding aid 2 is disposed on the inner surface, and the electric wire 4 having an insulating coating is inserted. As shown in FIG. 3 (a), when the electric wire 4 having an insulation coating is inserted into the connection terminal 1 and pressurized and energized by resistance welding, the insulation coating 7 is softened by heat generation and discharged from the joint surface. ), The electric wire 4 having an insulating coating and the connection terminal 1 are joined by the joining aid 2. The electric wire 4, the conductor member 3, and the connection terminal 1 are all copper. Further, the bonding aid 2 is obtained by clad a copper copper brazing material (by weight, P5%, Ag15%, Cu80%) with a thickness of 0.07 mm on one side of the copper plate of the connection terminal 1.

  In this embodiment, as shown in FIG. 4, the bonding aid 2 is a ring of the connection terminal 1 that is formed by bending one of the connection terminals 1 provided with the joining aid 2 into a U shape so that the bonding aid 2 becomes the inner surface. The conductor member 3 and the bonding aid 2 are joined by being inserted and arranged on the inner diameter side of the conductor member 3 and then being pressurized and energized by resistance welding electrodes.

  In the present embodiment, as shown in FIG. 5, the connection terminals 1 formed in the same manner as in the second embodiment can be connected even if they are integrated with an insulating coating (film) 7 made of resin, and the same effect can be obtained.

  In the present embodiment, as shown in FIG. 6, the conductor member 3 and the connection terminal 1 of Embodiments 2 and 3 can be prevented from being deformed by handling by being fixed with a resin so as to be integrated. Furthermore, the shaft 5 shown in FIG. 7 can be press-fitted and fixed.

  In the present embodiment, the same effect as in the fourth embodiment can be obtained even if the conductor member 3, the connecting terminal 1 and the shaft 5 of the second and third embodiments are integrally formed of the resin 6 as shown in FIG.

  In this embodiment, as shown in FIG. 8, the connection terminal 1 having the joining aid 2 of Embodiments 4 and 5 is bent into a U shape, and an electric wire 4 having an insulation coating is inserted into a processed portion, and resistance welding is used. When the pressure is applied and energized, heat is generated and the insulating coating 7 is softened or carbonized and discharged, and the electric wire 4 having the insulating coating and the connection terminal 1 can be connected by bonding with the bonding aid 2.

  In this embodiment, as shown in FIGS. 9 and 10, the connection terminal 1, the conductor member 3, and the electric wire 4 having an insulating coating can be joined by the joining aid 2 by applying pressure with the resistance welding electrode 8. The conductor member 3 and the electric wire 4 having an insulation coating can be connected.

  The embodiment of the present invention is a specific example applied to the vehicle alternator 20 shown in FIG. In the vehicular AC generator 20, as shown in FIG. 11, both ends of a field coil 33 in which an electric wire having an insulation coating is wound in a coil shape are connected to a slip ring 31 which is a conductor member by a connection terminal 1. Similarly to Embodiment 1, the joining aid 2 of the connection terminal 1 is previously provided with a phosphor copper brazing material (P: 5%, Ag: 15%, Cu: 80%) with a thickness of 0.07 mm. The connection terminal 1 is made of a copper material and has a thickness of 0.8 mm and a width of 3 mm. The field coil 33 terminal of the electric wire 4 having an insulating coating and the slip ring 31 of the conductor member are connected to the connection terminal 1 by the bonding aid 2. According to this method, the step of stripping the insulation coating of the electric wire having the insulation coating of the field coil 33 can be omitted, and the number of work steps can be reduced. Further, since the field coil 33 and the slip ring 31 of the electric wire having a metallurgical insulation coating are connected to the joining aid 2 using a phosphor copper brazing material, the heat resistance and the reliability are improved.

The perspective view which shows the connection structure of the electric wire which has the conductor member of Example 1, and insulation coating (film | membrane). Sectional drawing which shows the connection structure of the conductor member of Example 1, and a connection terminal (a) Cross-sectional view before joining, (b) Cross-sectional view after joining. Sectional drawing which shows the connection structure of the electric wire which has insulation coating (film | membrane) of Example 1, and a connection terminal (a) Cross-sectional view before joining, (b) Cross-sectional view after joining. Sectional drawing which shows the connection structure of the conductor member of Example 2, and a connection terminal. Sectional drawing which shows the connection structure of the conductor member of Example 3, and a connection terminal. Sectional drawing which shows the connection structure of the conductor member of Example 4, and a connection terminal. Sectional drawing which shows the connection structure of the conductor member of Example 5, and a connection terminal. Sectional drawing which shows the connection structure of the electric wire which has the insulation coating (film | membrane) of Example 6, and a conductor member, and a connection terminal. Sectional drawing which shows the connection method of the conductor member of Example 7, and a connection terminal. Sectional drawing which shows the connection method of the electric wire which has the insulation coating (film | membrane) of Example 7, and a connection terminal. Sectional drawing of the alternating current generator for vehicles using this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Connection terminal, 2 ... Joining aid, 3 ... Conductive member, 4 ... Electric wire which has insulation coating (film | membrane), 5,26 ... Shaft, 6 ... Resin, 7 ... Insulation coating (film | membrane), 8 ... Electrode, 20 ... AC generator for vehicles, 21, 25 ... End frame, 22 ... Stator coil, 23 ... Stator core, 24 ... Pole core, 27, 28 ... Bearing, 29 ... Brush holder, 30 ... Regulator, 31 ... Slip ring, 32 ... Cooling Centrifugal fan 33, field coil.

Claims (8)

  In the connection structure for connecting conductors formed by connecting the insulated coated electric wires and the non-insulated coated conductors that are located apart via a conductive member, the conductive members are respectively connected via a bonding aid that is melted by energization heating. The connection structure which connects the conductors characterized by being joined with the conductor of.   2. The connection structure for connecting conductors according to claim 1, wherein the connection conductive member has a shape surrounding the insulating coated electric wire.   3. The connection structure for connecting conductors according to claim 2, wherein the connection conductive member is U-shaped and surrounds the insulation-coated electric wire.   The connection structure for connecting conductors according to claim 1, wherein the joining aid is a brazing material or solder.   4. The connection structure for connecting conductors according to claim 1, wherein the connection conductive member is any one of copper, a copper alloy, an iron alloy, aluminum, and an aluminum alloy. In the connection structure for connecting conductors formed by connecting the insulated coated electric wire and the non-insulated coated conductor located apart via a conductive member,
The wiring connection method, wherein the electric wire and the non-insulated coated conductor are held via a conductive member provided with a bonding aid, and the portion thereof is connected together with the other portion by energizing heating and pressing.   A rotating electrical apparatus having a connection structure connected by the connection method according to claim 6. A stator core having a stator coil and a rectifier between the end frames, a rotor having a field coil wound around a shaft so as to be rotatable in the stator core, and energizing the field coil via a slip ring and the field In a vehicular AC generator having a connection terminal for connecting a terminal of a magnetic coil and a slip ring, the insulation-coated electric wire of the field coil is bonded to the connection conductor via a bonding aid that melts by energization heating, and the bonding The other end of the conductor is joined via a joining aid that melts by energization heating in the same manner as the slip ring.

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