JP2006204029A - Structure of connection and fixation between wire and connected material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a novel structure of connection and fixation between a wire 2 and a connected material 3. <P>SOLUTION: A cylindrical body 6 for fastening is inserted into an insertion hole 5 in the connected material 3. A cylindrical connector 7 with the terminal 2a, 2b of a wire inserted in it is fit into the cylindrical body 6. The fitting faces 6b and 7b of the cylindrical body 6 and the connector 7 are tapered before the connector 7 is fit into the cylindrical body 6. Thus, the diameter of the cylindrical body 6 is expanded, and the cylindrical body is pressure welded to and fixed on the inner face of the insertion hole in the connected material. Further, the diameter of the connector 7 is reduced to fasten the end 2a, 2b of the wire. With respect to fitting by the tapered faces 6b and 7b, any strength of fixation can be obtained by arbitrarily selecting their taper angle. This is mechanical fixation, and thus it can be easily automatized. Or, the structure may be constructed by taking the measure that the cylindrical body for fastening is inserted into the insertion hole in the connected material; the connector with the terminal of a wire fixed in it is inserted into the cylindrical body; the fitting faces of the cylindrical body and the connector are tapered, before the connector is fit into the cylindrical body; the diameter of the cylindrical body is expanded, and the cylindrical body is pressure welded to and fixed on the inner face of the insertion hole in the connected material; and the connector is fastened. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a connection and fixing structure for a wire and a connected material such as a connection between a stator coil and a bus bar in a rotating electric machine for a hybrid vehicle and a fuel cell vehicle.

The connection and fixing of a wire material such as a coil and a connected material such as a bus bar are generally performed by soldering, laser brazing, laser welding, electron beam welding, ultrasonic welding, pressure welding, crimping, etc., and tightening with a taper surface is used. There is also a method for connecting the electric wires (see Patent Document 1).
The connection method using the tapered surface is formed by forming a tapered hole in the material to be connected, and fitting a fastener having the same tapered outer surface into the hole, and in the fastener or the inner surface of the fastener and the tapered hole. A wire rod is inserted between the two, and the wire rod is fastened by reducing the diameter of the fastener by the tapered hole and the taper surface of the fastener or by reducing between the fastener and the inner surface of the tapered hole.
Japanese Patent Laid-Open No. 9-204941

These connection means are effective as they are, but soldering and laser electron beam are problems that destroy the insulating resin due to heat at the time of connection. There is a problem of space securing.
Moreover, since the taper hole is formed in the to-be-connected material, fastening of the wire by the tapered surface requires accuracy in the hole processing in order to obtain a reliable connection strength, and the work becomes complicated.

  Under such circumstances, an object of the present invention is to provide a strong connection strength with a simple structure when fastening a wire rod with a tapered surface.

In order to achieve the above object, the present invention uses a tapered surface and fastens the wire by fitting the tapered surface by two members, as in the technique described in Patent Document 1. It was decided to fix the connection.
In the fitting by the tapered surface, the fixing strength can be arbitrarily obtained by arbitrarily selecting the taper angle. Further, the fitting by the tapered surface facilitates the positioning of the fitting (insertion) member at the time of the fitting (insertion), and the assembly (fixing) is also easy.
Further, according to the two members, the hole of the connected material into which the member fits does not need to be a tapered surface, and the formation thereof is easy, and automation is also easy because of mechanical fixation. Further, if the two members having the fastening action are mass-produced products, it is possible to obtain a product that is inexpensive and has high manufacturing accuracy.

  As a specific means, a fastening cylinder is inserted into the insertion hole of the connected material, and a cylindrical connector with a wire end inserted is inserted into the fastening cylinder, and connected to the fastening cylinder. Both fitting surfaces of the child are tapered, and by inserting the connector into the fastening cylinder, the fastening cylinder expands and presses against the inner surface of the insertion hole and is fixed to the connected material. The connector employs a configuration in which the connector is fastened to the fastening cylinder and the connector is reduced in diameter to fasten the wire rod end.

  As other specific means, a fastening cylinder is inserted into the insertion hole of the material to be connected, and a connector in which the end of the wire is fixed is inserted into the fastening cylinder, and the fastening cylinder and the connector Both fitting surfaces are tapered, and by inserting a connector into the fastening cylinder, the diameter of the fastening cylinder expands and is pressed against the inner surface of the insertion hole and fixed to the material to be connected. Adopts a structure fastened to the fastening cylinder.

The connection and fixing structure of these wire and connected material can be adopted for various things.For example, a coil is wound around each of the split cores arranged in an annular shape, and each coil is connected to each phase. It can employ | adopt for the aspect connected by the cyclic | annular bus bar along the annular arrangement | positioning of a division | segmentation core. At this time, the wire is a coil, the connected material is a bus bar, and the bus bar is made of a copper rectangular wire (square copper material).
If the bus bar is a copper rectangular wire, the mechanical strength of the bus bar is increased, and the copper rectangular wire can be manufactured at low cost by drawing, and the shape can be easily changed by forming. Also, the insertion hole can be easily formed, and the strength is sufficient.

  In the present invention, as described above, since the wire rod is fastened and connected and fixed to the material to be connected by the fitting of the tapered surfaces by the two members, sufficient connection strength can be obtained and the taper of the taper surface can be obtained. By arbitrarily selecting the angle, the connection strength can be arbitrarily obtained, and automation is also easy due to mechanical fixation.

An embodiment is shown in FIGS. 1 to 6, and this embodiment relates to a stator S of a rotating electric machine for a fuel cell vehicle or a rotating electric machine for a hybrid vehicle, and a coil is wound around each of the split cores 1 arranged in an annular shape. The outer end 2b of each coil is connected for each phase by an annular bus bar 3 (3a, 3b, 3c) along the annular arrangement of each divided core 1, and each inner end 2a is connected by an annular bus bar 3d. Connected. Each divided core 1 is integrated by resin molding C and fixing a coil, and then fitting a metal cylinder (tag) 4 by shrinkage or the like, and the inner and outer ends 2a of the winding layer of each coil. 2b stands up to C ₁ and C ₂ on the same circumference of the bus bar mounting surface.

Each bus bar 3a, 3b, 3c, 3d is made of a drawn copper flat wire, and the three 3a, 3b, 3c located outside thereof are connected to the coil terminal 2b corresponding to the phase of each coil. 5 is formed, so that the respective connection holes 5 becomes the same circumference on C _2, the respective bus bars 3a, 3b, 3c are formed in a wave shape. Inside the bus bar 3d, equidistantly and number of connection holes of the coil (insertion hole) 5 is formed, the connection hole 5 has a same circumference on C _1.

  Connection of the coil terminals (connection ends) 2a and 2b to each bus bar 3 is as shown in FIGS. 6 and 7A to 7C (the resin mold 11 and organic resin coating described later are omitted, and the same applies hereinafter). The fastening cylinder 6 is inserted into the connection hole 5, and the cylindrical connector 7 is fitted into the fastening cylinder 6. The fastening cylinder 6 and the connector 7 are formed with slits 6 a and 7 a in the axial direction, both fitting surfaces 6 b and 7 b are tapered, and the connector 7 is inserted into the fastening cylinder 6. Then, the diameter of the fastening cylinder 6 is increased and the diameter of the connector 7 is reduced. The fastening cylinder 6 and connector 7 are inexpensive as mass-produced products.

Therefore, as shown in FIG. 7A, the fastening cylinder 6 and the connector 7 are fitted into the connection hole 5 of the bus bar 3, and the terminal 7a of the coil is connected to the connector 7 as shown in FIG. 7B. 2b is inserted, and when the fastening cylinder 6 is further fitted into the bus bar 3 by driving or the like as shown in (c), the fastening cylinder 6 and the connector 7 are integrated, and the tapered surface 6b, 7b, the fastening cylinder 6 is subjected to a diameter expansion action, the connector 7 is subjected to a diameter reduction action, and the connection hole 5 is not diameter-expanded. The fastening cylinder 6 is firmly pressed against the inner surface of the connection hole 5, and the coil terminals 2 a and 2 b are firmly fastened to the bus bar 3.
At this time, since the connector 7 has a truncated cone shape and its fitting surface is tapered, the connector 7 can be easily positioned at the time of fitting (insertion) (see FIG. 11A). Also, assembly (fitting and fixing of the fastening cylinder 6 to the connector 7) is easy (see FIG. 11 (b) to FIG. 11 (c)).

  As shown in FIGS. 3 and 4, the bus bars 3 a, 3 b, 3 c, and 3 d are integrated into a flat ring shape by the resin mold 11 to form a coupling unit 10. At this time, as shown in FIG. 5, the outer bus bars 3a, 3b, 3c and the inner bus bar 3d can be combined with the resin mold 11 separately. Connection terminals 12a, 12b, and 12c of the bus bars 3a, 3b, and 3c are drawn out from the coupling unit 10, and the coils are connected to an external controller or the like by the connection terminals 12a, 12b, and 12c. The power is appropriately supplied.

In the case of the embodiment of FIG. 5, if the inner bus bar 3d is resin-molded as shown in FIG. 5, there is an advantage that the height of the inner bus bar 3d is the same as the coupling unit 10 of the outer bus bars 3a, 3b, 3c. It is possible to connect to the terminal 2a of the coil as it is without resin molding.
The bus bar 3 may be a bare copper rectangular wire, but may be one covered with an organic resin such as polyamide imide, and may be combined and bonded together with an adhesive to form an integrated coupling unit 10. Higher heat resistance can be obtained by coating with an organic resin such as polyamideimide.

The fastening cylinder 6 and the connector 7 are fitted into the connection holes 5 of the bus bars 3 of the coupling unit 10, and as shown in FIG. 3, each terminal 2 a of the coil protruding from the resin-molded core in the casing 4. 2b, the coupling unit 10 is overlaid on the resin-molded core so that the connection holes 5 of the respective bus bars 3 coincide with each other, and the terminals 2a and 2b of the respective coils are inserted into the connection holes 5 (connectors 7). Then, the fastening cylinder 6 is driven to connect the coil to each bus bar 3 (see FIGS. 7A to 7C).
Thereafter, if necessary, the core 1 and the coupling unit 10 are integrated by a resin mold or the like, and the bus bars 3 of the respective phases are provided so as to be opposed to the respective coil surfaces on the side surfaces of the annularly arranged divided cores 1. A stator S of a rotating electric machine is obtained in which the bus bars 3 of each phase are arranged in parallel on the side surfaces of the annularly arranged split cores 1.

The bus bars 3a, 3b, 3c of the respective phases are not the wave shape shown in FIG. 2, but are polygonal as shown in FIG. It may be the upper _{C 2.}
Further, as shown in FIG. 9, the bus bars 3 a, 3 b, 3 c of each phase are annular, and the terminals 2 b from the winding layers of the coils are arranged in the circumferential direction of the annular arrangement of the divided cores 1. It is also possible to start up in a staggered pattern along the bus bar 3a, 3b, 3c of each phase.

  As a means for connecting the coil terminals 2a, 2b to the bus bar 3, as shown in FIGS. 10 and 11, after connecting the terminal of the coil to the connector 7 by crimping or the like in advance, The coil terminals 2a and 2b can also be connected to the bus bar 3 by fastening 7 to the connection hole 5 via the fastening cylinder 6 (FIGS. 11A to 11C).

  Although this embodiment relates to a stator S of a rotating electrical machine, it is needless to say that the present invention can be adopted in a connection fixing structure of various wire materials and connected materials.

Schematic perspective view of one embodiment The same plan view The assembly action diagram Cross-sectional view of busbar coupling unit The other coupling | bonding unit is shown, (a) is sectional drawing, (b) is a perspective view. Assembly explanatory diagram of the same embodiment Coil terminal connection action explanation diagram to bus bar Action diagram Action diagram Partial removal plan view of another embodiment Partial removal plan view of another embodiment Perspective view for explaining coil terminal connection jig to bus bar Coil end connection action explanation to bus bar by the jig

Explanation of symbols

1 Split core 2a, 2b Coil (wire) terminal 3, 3a, 3b, 3c, 3d Bus bar (connected material)
4 Casing 5 Bus terminal coil terminal connection hole (insertion hole)
6 Fastening cylinder 7 Cylindrical connector 10 Bus bar coupling unit 11 Resin mold C for bus bar Resin mold S for coil S Stator C ₁ and C ₂ for rotating electric machine Pitch circle of each connection hole of coil and each end of coil

Claims (3)

  A wire rod terminal is connected and fixed to a material to be connected, and a fastening cylinder is inserted into the insertion hole of the material to be connected, and the wire rod terminal is inserted into the fastening cylinder. A cylindrical connector is inserted, both the fitting surfaces of the fastening cylinder and the connector are tapered, and by inserting the connector into the fastening cylinder, the fastening cylinder is The diameter is expanded and pressed against the inner surface of the insertion hole and fixed to the material to be connected. The connector is fastened to the fastening cylinder and the connector is reduced in diameter to fasten the wire end. A wire connection fixing structure characterized by this.   A structure in which the end of the wire is connected and fixed to the connected material, and the fastening cylinder is inserted into the insertion hole of the connected material, and the end of the wire is fixed to the fastening cylinder A fitting member is inserted, and both fitting surfaces of the fastening cylinder and the connector are tapered, and by inserting the connector into the fastening cylinder, the fastening cylinder is expanded in diameter. A connecting and fixing structure for a wire, wherein the connecting member is fixed to a material to be connected by being pressed against the inner surface of the insertion hole, and the connector is fastened to a fastening cylinder. The wire connection fixing structure according to claim 1 or 2, wherein a coil is wound around each of the split cores 1 arranged in an annular shape, and each of the coils is arranged in an annular shape for each phase. Adopted in the stator S of the rotating electrical machine connected by the annular bus bar 3 along the arrangement,
A stator of a rotating electrical machine in which the wire is the coil, the connected material is the bus bar 3, and the bus bar 3 is a copper rectangular wire.

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