JP2006260921A - Ultrasonic welding device, manufacturing method of welded power transmission cable, and manufacturing method of motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an ultrasonic welding device provided with a head part developed so as to have a new structure for improving ultrasonic a cable welding property. <P>SOLUTION: The ultrasonic welding device 10 is provided with an upper side head part 26 and a lower side head part 32. The upper side head part is ultrasonically vibrated by an ultrasonic wave oscillator 22. Both head parts are arranged at both sides of compression faces 42, 52 compressing the power transmission cable, and provided with guides 44, 46, 54, 56 having a shape of protruding in compression direction. Welding efficiency is improved by guiding the cable toward central side of both heads by the guides. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a technique for ultrasonic welding of a plurality of power transmission lines, and particularly to a structure of a head portion used for welding.

  In the manufacture and maintenance of various electric devices and facilities, joining of one electric wire and another electric wire is often performed for the extension, branching and merging of electric circuits. For example, also in manufacturing a motor, joining which relays the motor winding as an electric wire or branches and merges motor windings of the same phase is performed.

  As a technique widely used in the process of joining the motor windings, there can be energized caulking technique in which both windings are inserted into a metal tubular container and each container is welded by energization. However, in the current caulking technology, it is necessary to use a metal container, and there is a problem that it is difficult to realize space saving.

  Another technique for joining motor windings is ultrasonic welding. Ultrasonic welding is a technique in which welding is performed by applying vibrations by applying a head part subjected to ultrasonic vibration to a welded part, thereby generating heat and melting the welded part. The following patent documents 1 thru | or 3 can be mentioned as literature regarding ultrasonic welding.

  The following Patent Document 1 discloses an apparatus that increases the wire gripping force by combining compression bonding (cold pressure welding) and ultrasonic bonding (ultrasonic pressure welding) when bonding an electric wire and a terminal. In this apparatus, first, compression bonding is performed by applying a pressurizing force to a bonding portion through a processing tool, and after releasing the pressurizing force, ultrasonic bonding is performed by applying vibration through the same processing tool.

  Further, in Patent Document 2 below, a technique for providing a weld strength maintaining surface with irregularities and a tensile strength maintaining surface adjacent to the compressed surface of a head (anvil or horn tip) for ultrasonic welding of a plurality of electric wires. Is disclosed. In this technique, the cross section of the anvil is formed in a U shape, and the cross section of the horn chip is formed in a quadrangular shape that fits in the U shape.

  Patent Document 3 listed below describes a technique for ultrasonically welding a winding in a rotor of a motor. Here, when applying ultrasonic vibration, a non-metallic guide is separately installed on both sides of the wire to be welded to prevent misalignment.

JP 2003-117666 A JP 2004-220933 A Japanese Patent Laid-Open No. 5-292707

  When the electric wires are joined by ultrasonic welding, if a plurality of thin conducting wires constituting the electric wires are scattered, ultrasonic vibration does not act on the portions, resulting in poor melting. Further, when melting progresses during ultrasonic welding, the gap between the wires disappears and the overall thickness decreases, and the pressure transmitted from the head is insufficient, which may cause poor melting.

  Although it can be said that the technique of performing compression bonding as preprocessing as in Patent Document 1 is an aspect for solving such a problem, it is not preferable in that the apparatus configuration becomes complicated. On the other hand, in an aspect in which a U-shaped head and a square-shaped head are combined as in Patent Document 2, an electric wire is guided by a U-shaped anvil, and there is an advantage that melting failure due to scattering can be prevented. However, in this case, three sides of the electric wire are surrounded by the fixed anvil, and there is a possibility that the transmission of vibration becomes inefficient. In general, an anvil has a large heat capacity, which may cause a temperature drop in the melted portion. Furthermore, the technique disclosed in Patent Document 3 below has a disadvantage that the number of steps increases because a separate guide is provided.

  An object of the present invention is to develop a head portion having a new structure with improved ultrasonic welding performance of electric wires.

  Another object of the present invention is to pursue a head shape excellent in heat retention in ultrasonic welding of electric wires.

  Still another object of the present invention is to realize a new welding mode that enables welding of a plurality of cross-sectional areas in ultrasonic welding of electric wires.

  The ultrasonic welding apparatus of the present invention surrounds and combines a plurality of power transmission lines, and ultrasonically vibrates two head parts that compress these power transmission lines and at least one head part during compression, and these power transmission lines. An ultrasonic vibration mechanism that melts each of the heads, and each head portion has a compression surface that compresses these power transmission lines and a shape that protrudes forward from at least one end of the compression surface in the compression direction. And a guide for holding the electric wire in the compression surface.

  A power transmission line is a conducting wire through which electric power flows, such as a motor winding, and is typically formed by bundling a plurality of thin conducting wires. The ultrasonic welding apparatus is an apparatus that joins a plurality of conductive wires by ultrasonic welding. The two head portions are combined so as to be disposed so as to surround these power transmission lines and compress (press) the power transmission lines. The compression is performed using, for example, an elastic force such as a spring, gravity, mechanical force, electromagnetic force, and the like, and is continuously performed following the progress of melting. Then, the ultrasonic vibration mechanism ultrasonically vibrates at least one of the head portions being compressed, and melts the vicinity of the portion where vibration is transmitted among these power transmission lines. Thereby, a plurality of electric wires are welded.

  Here, one characteristic point is that each head portion includes a compression surface and a guide. The compression surface is a surface that plays a central role in compressing the power transmission line in the progress of welding, and may be a flat surface or a curved surface. The compression surface is provided so that the normal direction thereof is substantially parallel to the compression direction. Further, the guide has a shape protruding forward from the at least one end of the compression surface in the compression direction, and plays a role of holding the power transmission line in the compression surface. The ultrasonic vibration is transmitted to the electric wire from the compression surface of the head portion that transmits the vibration, but can also be transmitted through the guide portion of the head portion.

  According to this configuration, at least two of the four surfaces that surround the electric wire (in a typical case surrounded by a quadrangular shape) are configured by a head portion that vibrates ultrasonically. Thereby, it can be expected that the transmission efficiency of vibration is increased and melting is likely to occur.

  In one aspect of the ultrasonic welding apparatus of the present invention, each head portion has guides at both ends of the compression surface, and one head portion is inserted between both guides of the other head portion. Thus, the ultrasonic vibration mechanism is combined with the other head part so as to be fitted, and at least the inner head part is ultrasonically vibrated. That is, each head portion has a cross-sectional shape such as a U-shape or a U-shape. Then, in such a direction that the opening shapes face each other, one head portion is combined so as to be inserted into the opening shape formed by both guides of the other head portion. Since the ultrasonic vibration is transmitted to the inner head portion, the electric wire is vibrated from almost three surfaces, and an improvement in transmission efficiency can be expected.

  In one aspect of the ultrasonic welding apparatus of the present invention, each head portion has a guide at an end portion on one side of the compression surface and on a different side from the other head portion. That is, each head portion has a cross-sectional shape such as an L shape or a J shape, and is combined so that the mutual guide portions are not located on the same side. One aspect of the ultrasonic welding apparatus of the present invention includes a gathering mechanism that drives at least one head portion in a direction perpendicular to the compression direction and gathers together the power transmission lines to be enclosed using a guide. Thereby, the efficiency which sets a power transmission line between head parts improves. The driving in the gathering mechanism can be performed by, for example, a motor, and the driving control can be performed based on programming or based on the detection result of the power transmission line by the sensor.

  In one aspect of the ultrasonic welding apparatus of the present invention, the compression surface of at least one head portion is formed in a concave arc shape. In other words, the cross-sectional shape of the compression surface of the head portion is formed into a shape that envelops the power transmission line in a round shape (although depending on the curvature). Thereby, the effect which increases the area which transmits a vibration can be anticipated. Also, by keeping the side of the wire to be welded in a shape close to a sphere, it is possible to reduce the surface area per cross-sectional area, improving the heat retention efficiency and ease of melting. it can.

  In one aspect of the ultrasonic welding apparatus of the present invention, the guide is formed in a shape that expands outward at the front end (front end side) at least at the front end. That is, the guide has a divergent shape, and the electric wires can be collected from the periphery to the inside.

  In one aspect of the ultrasonic welding apparatus of the present invention, at least one of the head portions is a surface facing the power transmission line, and has a non-contact surface that is provided behind the compression surface in the compression direction and does not contact the power transmission line. During the ultrasonic vibration, a heat insulating space is formed between the non-contact surface and the power transmission line. Thereby, the heat retention effect of the power transmission line is enhanced, and melting of the power transmission line is facilitated.

  In one aspect of the ultrasonic welding apparatus of the present invention, at least one alternative for performing ultrasonic welding of power transmission lines having different composition ratios of the compression surface and the head portion in the direction perpendicular to the compression direction and different cross-sectional areas. A head part is provided. Typically, an alternative head portion is provided for the head portion that is subjected to ultrasonic vibration. In addition, it is also possible to provide an alternative head unit having a different guide length or compression surface shape.

  In one aspect of the ultrasonic welding apparatus of the present invention, each head portion has a guide at an end portion on one side of the compression surface and different from the other head portion. The compression surface is formed in a concave arc shape, and includes a slide mechanism that performs ultrasonic welding of power transmission lines having different cross-sectional areas by sliding a combination position of each head portion in a direction orthogonal to the compression direction.

  The non-welded power transmission line manufacturing method of the present invention welds a plurality of power transmission lines using the ultrasonic welding apparatus, and manufactures a welded power transmission line. Moreover, in one aspect of the ultrasonic welding apparatus of the present invention, the power transmission line is a winding of a motor, and the motor manufacturing method of the present invention uses the ultrasonic welding apparatus to wind a motor winding as a power transmission line. Welding, thereby producing a motor.

  Hereinafter, a plurality of embodiments of the present invention will be described.

[First Embodiment]
FIG. 1 is a schematic diagram illustrating a schematic configuration of an apparatus according to an example of the present embodiment. Fig.1 (a) is sectional drawing at the time of seeing a head part from a front direction, FIG.1 (b) is the figure which looked at the ultrasonic welding apparatus 10 containing this head part from the side surface direction.

  As shown in FIG. 1B, the ultrasonic welding apparatus 10 includes a main body 20. The main body 20 has a housing, and an ultrasonic transmitter 22 is stored inside the housing in addition to a control unit, a power circuit, and the like. The ultrasonic transmitter 22 is a device that generates vibration having an ultrasonic frequency. An upper arm (ultrasonic horn) 24 is attached to the ultrasonic transmitter 22, and an upper head portion (horn chip) 26 is provided at the tip of the upper arm 24. A lower arm 30 attached to the main body 20 by a hinge portion 28 is attached to the lower side of the upper arm 24, and a lower head portion (anvil) 32 is provided at the tip of the lower arm 30. It has been. The lower arm 30 is supported from below by a spring 34 as an elastic body. The spring 34 is installed on a spring support 36 that protrudes forward from the lower part of the main body, and presses the lower head 32 against the upper head 26 by pressing the lower arm 30 upward. Playing a role.

  FIG. 1A is a cross-sectional view of the upper head portion 26 and the lower head portion 32 as seen from the AA ′ plane in FIG. The upper head portion 26 includes a thick base 40 having a rectangular cross section, and the lower surface of the base 40 is a compression surface 42. The compression surface 42 is a surface that presses the welding object during welding and mainly transmits ultrasonic vibrations. Rectangular guides 44 and 46 extending downward are provided at the lower ends of both ends of the base 40, respectively. The guides 44 and 46 support the object to be welded in the compression surface 42 and assist the fitting with the lower head portion 32. With these configurations, the upper head portion 26 has a U-shape and is disposed with the opening facing downward.

  The lower head portion 32 has a U-shape like the upper head portion 26, and is arranged with its opening facing upward. That is, the lower head portion 32 includes a thick base 50 having a rectangular cross section, and the upper surface of the base 50 is a compression surface 52. In addition, rectangular guides 54 and 56 extending upward are provided at upper ends of both ends of the base 50. The guides 54 and 56 are used when the lower head portion 32 is fitted inside thereof, and also play a role of holding the welding object in the compression surface 52.

  The upper head part 26 is fitted inside the lower head part 32. Thereby, a welding work space 60 surrounded by both head portions is formed between the two. A welding object is set in the welding work space 60 in a state where the fitting of the upper head portion 26 and the lower head portion 32 is released.

  Next, a state in which welding is performed by the ultrasonic welding apparatus 10 will be described with reference to FIGS. 2 and 3.

  FIG. 2 is a side view showing a state in which two electric wires 70 and 80 are set as objects to be welded to the upper head portion 26 and the lower head portion 32 and are ultrasonically welded. The upper electric wire 70 extending from the left side of the drawing and the lower electric wire 80 extending from the right side of the drawing are overlapped at the fitting position of the upper head portion 26 and the lower head portion 32 and are subjected to welding. .

  FIG. 3 is a cross-sectional view showing the process of this welding, which is drawn with time in the order of FIG. 3 (a) to FIG. 3 (d). FIG. 3A shows a stage where the electric wire 70 and the electric wire 80 are set between the upper head portion 26 and the lower head portion 32. The electric wire 70 is formed of thin conductive wires 72, 74,. . . Are bundled, and the electric wire 80 is formed of thin conductive wires 82, 84,. . . Is made by bundling. The ends of these electric wires 70 and 80 are overlapped between the upper head part 26 and the lower head part 32 by an operator's manual work or by a setting device.

  FIG. 3B is a diagram illustrating a state in which the upper head portion 26 and the lower head portion 32 are fitted to compress the electric wires 70 and 80 and the vibration of the upper head portion 26 is started. At this stage, the melting of the electric wires 70 and 80 has not yet started, and a small gap exists between the conducting wires constituting the electric wires 70 and 80.

  FIG. 3C is a diagram illustrating a state at the time when melting starts in a part of the electric wires 70 and 80. The melting region 90 appears in the center where the electric wires 70 and 80 are overlapped. This is because the conversion from vibration energy to heat energy occurs almost the same in the entire area of the electric wires 70 and 80, but the temperature decreases in the peripheral part due to heat conduction to the upper head part 26 or the lower head part 32, and the relative This is because the temperature tends to increase at the center. In the melting region 90, since there is no gap between the thin conducting wires due to melting, the lower head portion 32 is displaced upward by the spring, and the distance from the upper head portion 26 is shortened.

  FIG. 3D is a diagram illustrating a state where the melting region 90 has spread over the entire area of the electric wires 70 and 80. As the entire surface is melted, the distance between the upper head portion 26 and the lower head portion 32 is further reduced, and the tips of the guides 44 and 46 of the upper head portion 26 are connected to the compression surface 52 of the lower head portion 32. It has almost reached the touching position. Both can be set to contact. In this case, it is considered that the structural stability is increased. However, since a part of the vibration of the upper head portion 26 directly reaches the lower head portion 32, the vibration energy used for melting the wires 70 and 80 is increased. Will decrease. Therefore, in order to avoid this, it is possible to set the two so as not to contact each other.

  After sufficient melting has occurred, the ultrasonic vibration is weakened or stopped to lower the temperature of the melted portion and solidify. Thereby, welding is completed and the long electric wire which the two electric wires 70 and 80 couple | bonded is formed.

  Here, points to be noted when using the ultrasonic welding apparatus 10 shown in FIG. 1 will be described with reference to FIG. FIG. 4 is a view substantially similar to FIG. 3 (d), and shows a stage where a large melting region 90 is formed between the upper head portion 26 and the lower head portion 32. However, here, the thin conductors 84 and 78 separated from the electric wire 80 and the electric wire 70 are not yet melted between the guides 44 and 46 at both ends of the upper head portion 26 and the compression surface 52 of the lower head portion 32. To remain.

  These thin conducting wires 84 and 78 receive vibrations from the guides 44 and 46, and there is room for melting by continuing to apply ultrasonic vibrations. In addition, when melted, it may be absorbed by other melted portions due to surface tension and shift to the state shown in FIG. However, it is not preferable in that the time required for welding becomes long. Therefore, it is desirable to work with caution when welding easily broken wires.

[Second Embodiment]
Next, a mode for effectively preventing the occurrence of the situation shown in FIG. 4 in the first embodiment will be described with reference to FIG. In FIG. 5, each process of welding is shown in order of time by FIG. 5 (a)-FIG.5 (c). In this aspect, the same lower head part 32 and a different upper head part 100 as in the first embodiment are used. The upper head portion 100 is the same as the first embodiment in that the flat compression surface 102 is provided and the guides 104 and 106 are provided at both ends. However, inclined portions 108 and 110 are formed at the distal ends of the guides 104 and 106 of the upper head portion 100 so as to be inclined outward so that the opening area increases toward the distal end side.

  In the stage of taking in the electric wires 70 and 80 shown in FIG. 5A, the inclined portions 108 and 110 play a role of smoothly guiding the electric wires 70 and 80 to the compression surface 102 side. In addition, in the semi-melting stage shown in FIG. 5B, the inclined portions 108 and 110 move the thin conducting wires 84 and 78 separated from the electric wires 80 and 70 to the inside. As a result, as shown in FIG. 5C, between the upper head portion 100 and the lower head portion 32, all the electric wires are quickly melted, and a slightly trapezoidal melting region 120 is formed. Yes.

[Third Embodiment]
Next, a third embodiment will be described with reference to FIG. FIG. 6 shows the structure of the upper head portion 130 and the lower head portion 32 in this embodiment, FIG. 6 (a) is a cross-sectional view taken along the plane BB ′ in FIG. 6 (b), and FIG. FIG. The lower head portion 32 used in this configuration is the same as that shown in the first embodiment. Further, the upper head portion 130 is provided with guides 132 and 134 at both ends thereof, like the upper head portion 26 shown in FIG. However, in the upper head portion 130, unlike the upper head portion 26 in FIG. 1, a flat non-contact surface 136 and a protruding portion having a sharp tip extending in the lateral direction at a position corresponding to the compression surface 42 of the upper head portion 26. 138.

  The functions of the non-contact surface 136 and the protrusion 138 will be described with reference to FIG. FIG. 7 is a cross-sectional view from the side illustrating how ultrasonic welding of the electric wires 70 and 80 is performed using the upper head portion 130 and the lower head portion 32 shown in FIG. 6. FIG. 7A is a diagram immediately after starting welding. At this time, the lower electric wire 80 is in wide contact with the compression surface 52 of the lower head portion 32 and pressed upward. On the other hand, the upper electric wire 70 is not in contact with the non-contact surface 136 of the upper head portion 130 and is compressed only by the tip of the protruding portion 138. Therefore, in this aspect, the protrusion 138 plays a role as a compression surface.

  The ultrasonic vibration generated by the upper head unit 130 is transmitted to the electric wires 70 and 80 through the protrusion 138. Therefore, the electric wires 70 and 80 are heated at the protrusion 138, and the melting region 140 is generated. Part of the heat generated in this process escapes through the compression surface 52 that is in full contact with the electric wire 80 in the lower head portion 32. However, in the upper head part 130, the only part in direct contact is the protrusion 138, and a heat insulating layer is formed on the lower side of the non-contact surface 136. Therefore, the amount of heat released by heat conduction is small, and high temperature and melting proceed quickly and efficiently.

[Fourth Embodiment]
Here, the 1st-3rd embodiment demonstrates the aspect which changed the shape of the head part large. FIG. 8 is a cross-sectional view illustrating a process of performing ultrasonic welding using the upper head unit 150 and the lower head unit 160 according to the fourth embodiment.

  Fig.8 (a) is a figure explaining the step which starts ultrasonic welding. As shown here, the upper head portion 150 includes a thick base portion 152 having a rectangular cross section, and the lower surface of the base portion 152 is a compression surface 154. An elongated guide 156 is provided at the left end of the base 152 in the drawing. In other words, the upper head portion 150 has an L-shaped cross section. The lower head portion 160 has a shape obtained by rotating the upper head portion 150 by 180 degrees. That is, the base 162, the compression surface 164 provided on the upper surface of the base 162, and the guide 166 provided on the right end of the base 162 are provided and formed in an L shape.

  The upper head portion 150 and the lower head portion 160 are combined inside the guides 156 and 166 so that the other ends of the base portions 162 and 152 of the other head portion are brought into contact with each other. As a result, a welding work space 168 surrounded by both head portions is formed between the upper head portion 150 and the lower head portion 160.

  In FIG. 8A, two electric wires 170 and 180 are taken into the welding work space 168. When taking in, a mechanism for moving the upper head portion 150 and the lower head portion 160 in the horizontal direction in the figure is provided as necessary, and the electric wires 170 and 180 are guided from other places by using long guides 156 and 166. Can be set as follows.

  The taken-in electric wires 170 and 180 are compressed in the upper limit direction (the direction in which the compression surfaces 154 and 164 approach) to the compression surfaces 154 and 164 by the effect of the spring shown in FIG. In the left-right direction in the figure, if the upper head portion 150 and the lower head portion 160 are properly positioned, the positions of both are properly maintained without using an auxiliary pressing mechanism such as a spring. Can do. However, if necessary, an auxiliary pressing mechanism may be provided so that an unnecessarily large gap does not occur between the two.

  The electric wires 170 and 180 are melted by the vibration of the upper head unit 150. FIG. 8B is a diagram showing a stage where the melting has completely progressed. At this stage, the entire melting region 190 is formed between the upper head portion 150 and the lower head portion 160.

  Here, points to be noted when adopting the configuration shown in FIG. 8 will be described with reference to FIG. FIG. 9 shows a view at a stage substantially similar to FIG. Here, between the upper head portion 150 and the lower head portion 160, a melting region 190 is formed near the center thereof. However, thin conductive wires 172, 176, 178, 182, 184, and 188 separated from the electric wires 170 and 180 remain on both sides without melting. This is due to the fact that the conductors located in the peripheral part are easily deprived of heat by heat conduction to the upper head part 150 and the lower head part 160, and the melting does not easily proceed. Of course, it is possible to melt the whole by strongly transmitting vibration over a long period of time, but this may lead to an unpreferable situation such as a longer time required for welding. Therefore, it is desirable to perform the operation with caution, particularly when welding easily broken wires.

[Fifth Embodiment]
The fifth embodiment will be described with reference to FIG. This embodiment can effectively prevent the situation shown in FIG.

  FIG. 10 is a cross-sectional view showing a process of performing ultrasonic welding using the upper head part 200 and the lower head part 210 according to this embodiment. Fig.10 (a) is a figure explaining the step which starts ultrasonic welding. As shown here, the upper head portion 200 has a thick base 202 having an arch shape bulging outward, a compression surface 204 formed by a concave bottom surface of the base 202, and an elongated shape extending from the left end of the base 202. The guide 206 is provided. The upper head portion 200 is obtained by changing the base shape of the upper head portion 150 shown in FIG. 8, and is formed so that the entire cross-sectional shape is a J-shape. The lower head portion 210 has a shape obtained by rotating the upper head portion 200 by 180 degrees. That is, the base 212, the compression surface 214, and the guide 216 are provided and formed in a J-shape.

  The upper head part 200 and the lower head part 210 are combined in the same manner as in the example shown in FIG. 8, and a welding work space 218 having an oval cross section is formed therein. In the welding work space 218, electric wires 220 and 230 are set. The set electric wires 220 and 230 are compressed by the compression surfaces 204 and 214. In this case, since the compression surfaces 204 and 214 are concave, there is an advantage that the upper head portion 200 and the lower head portion 210 are less likely to be displaced in the horizontal direction.

  FIG.10 (b) is a figure which shows the mode in the middle process of ultrasonic welding. Here, melting starts from the vicinity of the central portion where the electric wires 220 and 230 are overlapped, and a melting region 240 is formed. In addition, there are conductors 222, 224, 226, 228, 232, 234, 236, and 238 that are not yet melted around them. At this time, the welding work space 218 is reduced in size as the gap due to melting is reduced, and is substantially circular.

  FIG. 10C shows a state in which the electric wires 220 and 230 are all melted and the melted region 240 is entirely expanded between the upper head portion 200 and the lower head portion 210. In this aspect, since the melting region 240 has a shape close to a circle, the surface area (or the circumferential length of the cross section) is relatively small compared to the volume (or the cross sectional area). Accordingly, it is possible to suppress the release of the generated heat, and the melting proceeds quickly. Therefore, as compared with the embodiment shown in FIG. 9, welding is completed quickly, and poor melting is less likely to occur.

[Sixth Embodiment]
Here, even when the total cross-sectional areas of the electric wires to be welded are different, a plurality of modes for performing good welding will be described with reference to FIGS.

  FIG. 11A is a view similar to FIG. 5C shown in the second embodiment. Here, welding is performed using the upper head portion 100 and the lower head portion 32, and welding having a cross-sectional area of the melted region 120 shown in the figure is performed. On the other hand, in the aspect shown in FIG. 11B, the upper head portion 250 is employed instead of the upper head portion 100. There is no change in that the lower head portion 32 is used. However, the guides 252 and 254 provided on the upper head portion 250 are thicker than the guides 104 and 106 provided on the upper head portion 100, and are formed by the upper head portion 250 and the lower head portion 32. The cross-sectional area of the welding workspace is reduced. In other words, in this configuration, an electric wire having a relatively small cross-sectional area, that is, a cross-sectional area on the order of the melting region shown in FIG.

  It should be noted that the manner of replacing the head portion can be set in various ways. For example, the head portion may be replaced with the arm, or only the head portion may be replaced with the arm as it is. Further, it is possible to adopt a configuration in which the positions of the plurality of arms and the head unit are switched by operation buttons.

  FIG. 12A is a view similar to FIG. 8B shown in the fourth embodiment. In this embodiment, electric wires having different cross-sectional areas can be welded without exchanging the head portion. For example, when welding an electric wire having a smaller cross-sectional area than the melting region 190 shown in FIG. 12 (a), as shown in FIG. 12 (b), the upper head portion 150, the lower head portion 160, It is sufficient to perform compression and vibration by reducing the distance. As a result, the melting region 260 shown in FIG. 12B has a small cross-sectional area. However, the shape of the melting region 260 is an elongated shape, and is a shape that very easily releases heat. For this reason, it is important to carry out welding while paying sufficient attention to the precautions shown using FIG.

  FIG. 13A is a view similar to FIGS. 8B and 12A. FIG. 13B is a diagram showing a mode that can be adopted to solve the problem described in the explanation of FIG. In the configuration of FIG. 13B, an upper head portion 270 is used instead of the upper head portion 150 of FIG. The upper head portion 270 has a shape in which another guide is attached to an end portion of the base portion 152 of the upper head portion 150 opposite to the guide 156. That is, the upper head portion 270 is provided with a long-shaped guide 274 at the outer end portion of the base portion 272 and a short-shaped guide 276 at the inner end portion. The upper head portion 270 and the lower head portion 160 are combined so that the guide 276 of the upper head portion 270 is inscribed in the guide 166 of the lower head portion 160. As a result, the melting area 280 has a smaller cross-sectional area than the melting area 190 in the case of FIG. 13A, and has a shape closer to a square than the melting area 260 in the case of FIG. ing. Therefore, in this aspect, welding of an electric wire with a small cross-sectional area can be performed efficiently.

  FIG. 14A is a view similar to FIG. 10C shown in the fifth embodiment. Here, the outer end 209 on the side of the upper head portion 200 where the guide 206 is not present is inscribed in the guide 216 of the base portion 212 of the lower head portion 210, and the guide of the base portion 212 of the lower head portion 210. The outer end 219 on the side without 216 is inscribed in the guide 206 of the base 202 of the upper head unit 200, and the two are combined. On the other hand, in FIG. 14B, although the same upper head part 200 and lower head part 210 are used, the combination mode is different. That is, the upper head portion 200 and the lower head portion 210 are shifted in the combination position, the outer end 209 of the upper head portion 200 is not in contact with the guide 216, and the outer end 219 of the lower head portion 210 is the guide. 206 is not touching. As a result, the welding work space created by the upper head part 200 and the lower head part 210 is smaller than in the case of FIG. Therefore, in FIG. 14B, it is possible to weld an electric wire having a cross-sectional area of about the melting region 290 shown in the figure. Further, the melting region 290 is relatively circular, and the heat radiation amount can be made relatively small.

  In addition, when implementing the aspect of FIG.14 (b), it may be difficult to weld by this positional relationship from the beginning of welding. This is because when there is a gap between the conductors at the beginning of welding, the upper head portion 200 and the lower head portion 210 are located apart from each other, so that molten metal may leak from the gap. In such a case, the positional deviation may be reduced immediately after the start of the work, and the movement may be controlled so as to increase the positional deviation as the melting progresses so that there is no gap between the two.

It is the schematic which shows the apparatus structure concerning 1st Embodiment. It is a figure which shows the welding process of the electric wire in 1st Embodiment. It is a figure which shows the welding process of the electric wire in 1st Embodiment. It is a figure which shows the welding process of the electric wire in 1st Embodiment. It is a figure which shows the welding process of the electric wire in 2nd Embodiment. It is the schematic which shows the structure of the head part in 3rd Embodiment. It is a figure which shows the welding process of the electric wire in 3rd Embodiment. It is a figure which shows the welding process of the electric wire in 4th Embodiment. It is a figure which shows the welding process of the electric wire in 4th Embodiment. It is a figure which shows the welding process of the electric wire in 5th Embodiment. It is a figure which shows the welding process of the electric wire in 6th Embodiment. It is a figure which shows the welding process of the electric wire in 6th Embodiment. It is a figure which shows the welding process of the electric wire in 6th Embodiment. It is a figure which shows the welding process of the electric wire in 6th Embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 Ultrasonic welding apparatus, 20 Main-body part, 22 Ultrasonic transmitter, 24 Upper arm, 26 Upper head part, 28 Hinge part, 30 Lower arm, 32 Lower head part, 34 Spring, 36 Spring support base, 40, 50 base, 42, 52 compression surface, 44, 54 guide, 60 welding work space, 70, 80 wire.

Claims (11)

Two heads that are combined around a plurality of transmission lines and compress these transmission lines;
An ultrasonic vibration mechanism that ultrasonically vibrates at least one head part during compression and melts these power transmission lines;
With
Each head portion includes a compression surface that compresses these power transmission lines, and a shape that protrudes forward in the compression direction from at least one end of the compression surface, and a guide that holds these power transmission lines in the compression surface. An ultrasonic welding apparatus characterized by comprising. The ultrasonic welding apparatus according to claim 1,
Each head has a guide at each end of the compression surface,
One head part is combined so that both guides are inserted between both guides of the other head part and fitted with the other head part,
An ultrasonic vibration device characterized in that the ultrasonic vibration mechanism ultrasonically vibrates at least the inner head portion. The ultrasonic welding apparatus according to claim 1,
Each head portion has an end portion on one side of the compression surface and a guide on an end portion on a different side from the other head portion. In the ultrasonic welding apparatus according to claim 3,
An ultrasonic welding apparatus comprising: a gathering mechanism that drives at least one head portion in a direction perpendicular to the compression direction and gathers together the power transmission lines to be enclosed using a guide. The ultrasonic welding apparatus according to claim 1,
The ultrasonic welding apparatus, wherein the compression surface of at least one of the head portions is formed in a concave arc shape. The ultrasonic welding apparatus according to claim 1,
The ultrasonic welding apparatus characterized in that the guide is formed in a shape that expands outward as it is forward in the compression direction at least at its tip. The ultrasonic welding apparatus according to claim 1,
At least one head portion is a surface facing the power transmission line, and has a non-contact surface that is provided behind the compression surface in the compression direction and does not contact the power transmission line.
An ultrasonic welding apparatus, wherein a heat insulating space is formed between a non-contact surface and a power transmission line during ultrasonic vibration. The ultrasonic welding apparatus according to claim 1,
Ultrasonic waves characterized by comprising at least one alternative head portion for performing ultrasonic welding of power transmission lines having different cross-sectional areas and different composition ratios between the compression surface and the head portion in a direction orthogonal to the compression direction Welding equipment. The ultrasonic welding apparatus according to claim 1,
Each head portion has a guide at an end portion on one side of the compression surface and on a different side from the other head portion,
The compression surface of each head part is formed in a concave arc shape,
An ultrasonic welding apparatus comprising: a slide mechanism that performs ultrasonic welding of power transmission lines having different cross-sectional areas by sliding a combination position of each head portion in a direction orthogonal to a compression direction.   A welded power transmission line manufacturing method for manufacturing a welded power transmission line by welding a plurality of power transmission lines using the ultrasonic welding apparatus according to any one of claims 1 to 9.   The motor manufacturing method which welds the winding of the motor as a power transmission line using the ultrasonic welding apparatus of any one of Claim 1 thru | or 9, and manufactures a motor by this.

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