JP2008228532A - Connecting method for lead wire, and manufacturing method for motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connecting method for a conductor capable of proper electrical connection between the conductor and a conductor member, using small-sized equipment as a whole. <P>SOLUTION: The connecting method for the conductor, which electrically connects a conductor-connecting part 19b in the conductor 20, having a conductor body 20a made by conductive metal and an insulation filter coating the conductor body 20a to a connection terminal 32 of a control unit 14, has a "filter removal process" for removing the insulation filter, by irradiating laser beam LB from the first output part 54 of a laser light irradiating device 51 to the conductor connecting part 19b; and a "conductor connecting process" for jointing and electrically connecting the conductor body 20a, exposed by removing the insulation filter to the connecting terminal 32, by bringing them into contact and irradiating the laser beam LB from the second output part 55 of the common laser light irradiating device 51, to the connection terminal 32. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention electrically connects, for example, a part of a conductive wire constituting a winding in a motor armature to a conductor member electrically connected to a control device or a conductor member extending from a commutator segment. The present invention relates to a method for connecting conductive wires and a method for manufacturing a motor.

For example, in the case of a brushless motor, a conductive wire that forms a winding in a motor armature is electrically connected to a conductor member (connection terminal) that is electrically connected to a control device. In this case, the conductor member (commutator connection piece) extending from the commutator segment is electrically connected. And as a connection method (motor manufacturing method) of such a conducting wire, for example, a conducting wire is wound (wrapped) on a conductor member, and the portion is irradiated with laser light to electrically connect them. (For example, refer to Patent Document 1).
JP-A-9-182385

  However, in the above-described method, the conductor body made of a conductive metal is irradiated with a laser beam by contacting the conductor wire that is still covered with the insulating film to the conductor member (laser welding). There is a problem that poor connection is likely to occur due to carbonization and remaining in the weld.

  In view of this, it is conceivable to remove the insulating film of the conductive wire with a blade or the like before laser welding but before contacting the conductor member. In this case, of course, the blade or the blade is driven. Special equipment or the like is required. Further, in this case, a large space for mechanically driving (moving) the blade to peel off the insulating film is required, and it is easy to require treatment for the scraped insulating film.

  The present invention has been made to solve the above-mentioned problems, and a first object of the present invention is to electrically connect a conductor and a conductor member electrically in a small scale as a whole. An object of the present invention is to provide a method for connecting conductors.

  In addition, the second purpose is to electrically connect the conductive wire constituting the winding and the conductive member electrically connected to the control device or the conductive member extended from the commutator segment with a small-scale facility as a whole. It is an object of the present invention to provide a method of manufacturing a motor that can be connected to a motor.

  According to the first aspect of the present invention, there is provided a connecting method for connecting a conductive wire having a conductive wire main body made of a conductive metal and an insulating film covering the conductive wire main body with a conductive member, A film removing step of removing the insulating film by irradiating a predetermined portion with laser light from a laser beam irradiation device, and the conductor body and the conductor member exposed by removing the insulating film after the film removing step And at least one of them is irradiated with a laser beam from the laser beam irradiation device to join and electrically connect them.

  According to the invention, in the coating removal process, the insulating film is removed by irradiating a predetermined portion of the conducting wire with the laser beam from the laser beam irradiation device, so that, for example, the insulating coating is carbonized in the subsequent wiring connection process. Thus, the remaining in the welded portion is reduced, and the conductive wire (conductive wire body) and the conductive member can be electrically connected well. In addition, since the laser beam irradiation device is used in both the film removal process and the wire connection process, for example, a blade or a special device for driving the blade tool is not required in the film removal process, and the scale is small as a whole. The equipment can be small (low cost).

  According to a second aspect of the present invention, in the conductive wire connecting method according to the first aspect, in the film removing step, the position of the conductive line is shifted from the focal position of the laser beam, whereby the longitudinal direction of the conductive line is orthogonal. The lead is irradiated with the laser beam so as to include the entire width of the direction.

  According to the invention, in the film removal step, the position of the conducting wire and the focal position of the laser beam are shifted, so that the conducting wire is irradiated with the laser beam so as to include the full width in the longitudinal direction of the conducting wire. Compared to the case where the light is scanned and irradiated in the same range, the laser beam having a reduced energy density is simultaneously irradiated over a wide range, so that the insulating film can be easily and satisfactorily removed. That is, when scanning with laser light, a separate member (movable mirror or the like) for scanning is required, and the conductor body is adversely affected by the point that the laser light has been irradiated for a longer time than others. There is a possibility, but these can be avoided.

  According to a third aspect of the present invention, in the method for connecting conducting wires according to the first or second aspect, the laser beam irradiation device includes a beam splitter, and in the film removal step, the beam splitter uses the beam splitter. The conductive wire is irradiated with a rectangular laser beam or an elliptical laser beam in which one of the divided portions is formed into a rectangle or an ellipse.

  According to the present invention, in the film removal step, the rectangular laser beam or the elliptical laser beam, one of which is divided into the rectangular or elliptical shape by the beam splitter, is irradiated to the conducting wire. Energy loss can be reduced as compared with the case where the laser beam is irradiated to the conductive wire.

  According to a fourth aspect of the present invention, in the conductive wire connecting method according to the third aspect of the present invention, in the conductive wire connecting step, a laser beam obtained by shaping the other divided by the beam splitter into a circular shape is the conductive wire main body and the conductor. Irradiate at least one of the members.

  According to the present invention, at least one of the conductor main body and the conductor member is irradiated with the laser beam in which the other divided by the beam splitter is formed into a circular shape in the conductor connecting step, so that the energy is concentrated to the conductor. It is possible to connect the main body and the conductor member electrically in an excellent manner and in a shorter time.

  According to a fifth aspect of the present invention, in the method for connecting a conductive wire according to any one of the first to fourth aspects, the conductive wire is a part constituting a winding in the armature. The manufacturing method is summarized.

According to the invention, the effect of the invention according to any one of claims 1 to 4 can be obtained in the method for manufacturing a motor.
According to a sixth aspect of the present invention, in the motor manufacturing method of the fifth aspect, the armature constitutes a stator, and the conductor member supplies a driving current to the winding. It is a connection terminal electrically connected to the control device.

According to the invention, the effect of the invention according to any one of claims 1 to 4 can be obtained in the method of manufacturing a brushless motor.
According to a seventh aspect of the present invention, in the motor manufacturing method according to the fifth aspect, the armature constitutes a rotor, and the conductor member is a commutator extending from a commutator segment. It is a connection piece.

  According to the invention, the effect of the invention according to any one of claims 1 to 4 can be obtained in a method of manufacturing a DC motor with a commutator.

  According to the invention according to any one of claims 1 to 4, the present invention provides a method for connecting a conductive wire that can electrically connect a conductive wire and a conductor member in a small scale as a whole. Can do.

  In addition, according to the invention described in any one of claims 5 to 7, the conductor wire and commutator electrically connected to the control device and the conducting wire constituting the winding with the small-scale equipment as a whole. Thus, it is possible to provide a method of manufacturing a motor that can electrically connect a conductor member extending from each segment in an excellent manner.

Hereinafter, an embodiment of the present invention will be described with reference to FIGS.
As shown in FIG. 1, the electric fan device 1 for engine cooling includes a brushless motor 11 and a fan 12 as motors. The brushless motor 11 includes a stator 13, a control device 14, and a rotor 15 that are composed of armatures.

  The stator 13 includes a cylindrical portion 17a and a stator core 17 having a plurality of teeth portions 17b (see FIG. 2) extending radially from the cylindrical portion 17a, an insulator 18 attached to the stator core 17, and an insulator 18 in each tooth portion 17b. And a conductive wire 20 that continuously forms a crossover wire (not shown) that connects the plurality of windings 19.

  Specifically, as shown in FIG. 1, the stator 13 is fixed to a center piece 21 in which a substantially cylindrical cylindrical portion 21 b is erected on a substantially disc-shaped plate portion 21 a, A cylindrical portion 17a is fitted on the cylindrical portion 21b. Twelve teeth portions 17b in stator core 17 of the present embodiment are formed.

  As shown in FIG. 2, the insulator 18 is made of resin, and covers the annular covering portion 18 a that covers the axial end surface (about half) of the cylindrical portion 17 a of the stator core 17 and the teeth portion 17 b of the stator core 17. And a teeth covering portion 18b. Further, in the insulator 18 of the present embodiment, the diameters of the placement portion 18c and the placement portion 18c are respectively located at positions corresponding to the base end portions of the three teeth portions 17b arranged in the circumferential direction in the annular covering portion 18a. A separation portion 18d formed on the outer side in the direction and a locking portion 18e formed on the inner side in the radial direction of the placement portion 18c are formed. As shown in FIG. 1, the mounting portion 18c of the present embodiment is formed so as to protrude in the axial direction, and the separation portion 18d and the locking portion 18e protrude further in the axial direction than the mounting portion 18c. Is formed. The radial width of the mounting portion 18c, in other words, the interval between the separating portion 18d and the locking portion 18e is set to be substantially the same as the diameter of the conducting wire 20. Further, the separating portion 18d and the locking portion 18e are set so as to protrude in the axial direction by an amount corresponding to the radius of the conducting wire 20 from the placement portion 18c. The insulators 18 are provided in a pair in the axial direction so that they can be mounted from both ends of the stator core 17 in the axial direction. The mounting portion 18c, the separation portion 18d, and the locking portion 18e are the plate portions of the center piece 21. Although it is formed on the side of 21a, the plate portion 21a is cut out so as not to face the placement portion 18c, the separation portion 18d, and the locking portion 18e.

  A winding 19 is wound in concentrated winding on each tooth portion 17b (covered by the tooth covering portion 18b) of the stator core 17 to which the insulator 18 is mounted. The wires 19 are connected to each other on the opposite side (lower side in FIG. 1) of the plate portion 21a of the center piece 21 by a crossover (not shown). Note that the winding 19 is entirely disposed in the radial direction of the stator core 17 in the tooth portion 17b by being wound around the tooth portion 17b, and has a binding force with respect to the tooth portion 17b. It is arranged like this.

  Here, each winding 19 at a position corresponding to the placement portion 18c, the separation portion 18d, and the locking portion 18e is an end winding as a partial winding which is a final winding (last winding). Except for the wire 19a (see FIG. 2), the wire is wound around the teeth portion 17b on the radially outer side of the separating portion 18d, and the radially inward movement is restricted by the separating portion 18d. The conductor connecting portion 19b which is a part of the end winding 19a is disposed on the mounting portion 18c, in other words, between the separating portion 18d and the locking portion 18e.

  The control device 14 includes a circuit (not shown) including a switching element for generating a drive current to be supplied to the winding 19 and a resin case 31 that houses the circuit. Further, the control device 14 is electrically connected to an internal circuit, extends from the resin case 31 to the outside, and is electrically connected to a part of the conductive wire 20 (conductive wire connecting portion 19b). A plurality of connection terminals 32 (only one is shown in FIG. 1) are provided. Three connection terminals 32 are provided corresponding to a part of each of the three conductors 20 (conductor connection part 19b), and the contact part 32a that is in direct contact with the conductor connection part 19b is as shown in FIG. It is formed in an arc shape having a diameter larger than that of the conductive wire 20 (conductive wire connecting portion 19b).

  And the control apparatus 14 has the resin case 31 fixed with respect to the said centerpiece 21 (stator 13), and the connection terminal 32 is a part of said conducting wire 20 (conducting wire connection part 19b) with the mounting part 18c mentioned above. ) Is sandwiched (in the axial direction) and is electrically connected to a part of the conductive wire 20 (conductive wire connecting portion 19b).

  Specifically, the conductor 20 including the conductor connecting portion 19b includes a conductor main body 20a (see FIG. 1) made of a conductive metal (copper in the present embodiment) and an insulating film covering the outer surface of the conductor main body 20a. Have. The insulating film of the present embodiment contains graphite powder (not shown) as a laser light absorbing member. In addition, the insulating film (excluding graphite powder) of the present embodiment is a material having high heat resistance (high heat resistance material) compared to urethane-based materials, for example, polyimide-based, polyamide-imide-based or polyester-imide It consists of a system material (resin). Then, the insulating film on the conductor connecting portion 19b, which is a predetermined portion of the conductor 20, is removed, and the conductor main body 20a and the connection terminal 32 exposed at the portion are irradiated with laser light LB (see the right side of FIG. 3) described later. They are joined and electrically connected (by welding). FIG. 1 schematically shows the conductor connection portion 19b from which the insulating film has been removed, that is, the conductor connection portion 19b having only the conductor body 20a. Further, FIG. 1 illustrates a state before the lead wire connecting portion 19b (the lead wire main body 20a) and the connection terminal 32 are joined (melted).

  A heat sink 33 is fixed to the control device 14 (resin case 31) of the present embodiment. In addition, a resin-made resin cover 34 that covers the conductor connection portion 19b and the connection terminal 32 that are part of the conductor 20 is fixed to the brushless motor 11 (the control device 14 and the center piece 21) of the present embodiment. ing.

  The rotor 15 includes a bottomed cylindrical yoke 41, a plurality of magnets 42 fixed to the inner peripheral surface of the yoke 41, and a rotating shaft 43 fixed to the center of the yoke 41. The rotor 15 is disposed so that the magnet 42 faces the outer periphery of the stator core 17 (the teeth portion 17b), and the rotating shaft 43 is supported by the bearing 44 held on the cylindrical portion 21b of the center piece 21 (with respect to the stator 13). E) is supported rotatably. The fan 12 is fixed to the outer peripheral surface of the yoke 41 of the present embodiment.

  Next, a method for manufacturing the brushless motor 11 (motor) configured as described above (including a method for connecting conductive wires) will be described in detail. The manufacturing method of the brushless motor 11 includes a “conductor arrangement step”, a “film removal step”, and a “conductor connection step”.

  In the “conductor arrangement step”, a part of the winding wire 19 is formed by the conductor wire 20 (that is, during the winding operation) at a position corresponding to the connection terminal 32 (in this embodiment, the mounting portion). 18c)). Specifically, in the present embodiment, when each winding 19 at a position corresponding to the placement portion 18c is configured by the conducting wire 20, each winding is a final winding (last winding) as a part of the winding. The end winding 19a (see FIG. 2) is disposed radially inward (on the mounting portion 18c) from the separating portion 18d, and the other windings except for the end winding 19a are disposed radially outside the separating portion 18d. To do. At this time, in the present embodiment, of course, the end winding 19a (see FIG. 2) is disposed radially outward (on the mounting portion 18c) from the locking portion 18e. At this time, in the present embodiment, the connecting wire (not shown) is disposed on the opposite side of the plate portion 21a of the center piece 21 (the lower side in FIG. 1 and the side on which the control device 14 is not disposed). To do.

  Next, in the “film removal step”, as shown on the left side of FIG. 3, the conductor connection portion 19 b of the conductor 20 is irradiated with the laser beam LB from the laser beam irradiation device 51 (see FIG. 4). And the conductor body 20a (see FIG. 1) is exposed.

  Specifically, the laser light irradiation device 51 includes a laser oscillator 52 for generating laser light (YAG laser in the present embodiment) and a half mirror 53 as a beam splitter for dividing the laser light from the laser oscillator 52. And a first output unit 54 for outputting one divided by the half mirror 53 and a second output unit 55 for outputting the other. The first output unit 54 is for condensing one of the parts divided by the half mirror 53 and forming it into a rectangle (see FIG. 4). The second output part 55 is divided by the half mirror 53. The other is condensed and formed into a circular shape, and each is composed of a combination of optical systems such as a condensing lens. In FIG. 4, the irradiation spot of the laser beam (rectangular laser beam) LB formed into a rectangle is schematically illustrated by a two-dot chain line.

  Then, in the “film removal step”, a rectangular shape from the first output portion 54 of the laser beam irradiation device 51 is formed on the conductor connection portion 19b in the object X1 on the left side of FIG. 3 where the control device 14 is not disposed. The irradiated laser beam (rectangular laser beam) LB is irradiated (see FIG. 4). At this time, the position of the conductor connecting portion 19b and the focal position of the laser beam LB (the distance from the condenser lens (not shown) to the conductor connecting portion 19b in the first output portion 54, and the condenser lens to the condenser lens) By shifting the distance to the specified focal point), the laser beam LB is irradiated to the conductor connection portion 19b so as to include the entire width in the direction perpendicular to the longitudinal direction of the conductor connection portion 19b (see FIG. 4). That is, the laser beam (rectangular laser beam) LB from the first output unit 54 in this example is an irradiation spot that is narrower than the full width in the longitudinal direction of the conducting wire connecting portion 19b (that is, the diameter of the conducting wire 20) at the focal position. By displacing the position of the conducting wire connecting portion 19b and the focal position of the laser beam LB, the laser beam LB is simultaneously irradiated to the full width range in the longitudinal direction of the conducting wire connecting portion 19b. Thereby, the insulating film is removed.

  Next, in the “conducting wire connecting step”, as shown on the right side of FIG. 3, first, the control device 14 is positioned (fixed) in the axial direction with respect to the stator core 17 (center piece 21). The connection terminal 32 is brought into contact (in the axial direction) with the exposed conductor main body 20a in the conductor connecting portion 19b of the conductor 20. And the laser beam LB by the laser beam irradiation device 51 is irradiated to the connection terminal 32 in the object X2 on the right side of FIG. 3 where the control device 14 is arranged, and the lead wire main body in the connection terminal 32 and the lead wire connection portion 19b. 20a is joined and electrically connected. Specifically, a laser beam (circular laser beam) formed in a circular shape from the second output unit 55 of the laser beam irradiation device 51 is connected to the connection terminal 32 of the object X2 on the right side of FIG. ) Irradiate LB. At this time, the position of the connection terminal 32 and the focal position of the laser beam LB (the distance from the condensing lens (not shown) to the connection terminal 32 in the second output unit 55, and the condensing lens to the condensing lens) are specified. The distance to the focal point) is substantially matched, and the laser beam LB is irradiated to almost one point of the connection terminal 32. Thereby, the connection terminal 32 and the conductor main body 20a in the conductor connection part 19b are joined and electrically connected. In addition, as shown on the right side of FIG. 3, this “wire connection process” is performed in a state before the resin cover 34 (see FIG. 1) is fixed to the brushless motor 11 (the control device 14 and the center piece 21). The resin cover 34 is fixed after the “conducting wire connecting step”, and the manufacture of the brushless motor 11 is completed. In the present embodiment, the “film removal step” and the “wire connection step” are simultaneously performed on different objects X1 and X2. That is, the “film removal process” is performed on the object X1 and simultaneously the “conductor connection process” is performed on the object X2, and then the “film removal process” and the “film removal process” are performed on the new object X1. The object (the brushless motor 11) is sequentially produced in large numbers (mass production) by repeating the "conducting wire connection process" using the object X1 having completed "" as the object X2.

Next, characteristic effects of the above embodiment will be described below.
(1) In the “film removal process”, the insulating film is removed by irradiating the conductive wire connecting portion 19b of the conductive wire 20 with the laser beam LB from the laser light irradiation device 51. Further, carbonization of the insulating film and remaining in the welded portion is reduced, and the conductive wire connecting portion 19b (conductive wire main body 20a) and the connection terminal 32 can be electrically connected well. Moreover, since the laser beam irradiation device 51 is used in both the “film removal process” and the “wire connection process”, for example, a blade or a special device for driving the blade tool is separately required in the “film removal process”. Rather, the facility can be small (small and low cost) as a whole. For example, when the insulating film is peeled off with a blade, a large space is required for mechanically driving (moving) the blade to peel off the insulating film, but this is not necessary. Further, for example, when the insulating film is peeled off with a blade, it is easy to dispose of the separated insulating film, but this is almost unnecessary.

  (2) In the “film removal step”, the position of the conductor connecting portion 19b and the focal position of the laser beam LB are shifted, so that the conductor connecting portion 19b includes the full width in the longitudinal direction of the conductor connecting portion 19b. Is irradiated with a laser beam LB. Therefore, for example, the laser beam LB having a reduced energy density as compared with the case where the laser beam is scanned in a state where the position of the conductor connection portion 19b and the focal position of the laser beam LB coincide with each other and the same range is irradiated. Can be easily and satisfactorily removed since the film is irradiated simultaneously over a wide area. That is, when scanning with laser light, a separate member (movable mirror or the like) is required for scanning, and the conductor main body 20a is adversely affected in that the laser light has been irradiated for a longer time than others. Although there is a risk of the effect, these can be avoided. In addition, since the position of the conducting wire connecting portion 19b and the focal position of the laser beam LB are shifted, the conducting wire connecting portion 19b is irradiated with the laser beam LB so as to include the full width in the longitudinal direction of the conducting wire connecting portion 19b. Even in the case where the diameter of the conductive wire 20 (conductive wire connecting portion 19b) is different (other motors), the same laser beam irradiation device 51 can be used (by changing the displacement).

  (3) In the “film removal step”, a laser beam (rectangular laser beam) LB, one of which is divided by the half mirror 53 and formed into a rectangular shape, is irradiated to the conductor connecting portion 19b. The energy loss can be reduced as compared with the case where the laser beam shaped into a circle is irradiated onto the conductor connecting portion 19b. In addition, for example, compared to the case where the laser beam shaped into a circle is irradiated onto the conductor connecting portion 19b, the portion other than the insulating film is irradiated with the laser light, and the portion other than the insulating film is adversely affected. Effect is reduced.

  (4) Since the laser beam (circular laser beam) LB in which the other divided by the half mirror 53 is formed into a circular shape is irradiated to the connection terminal 32 in the “conducting wire connection process” (compared to the rectangular laser beam) Thus, the energy can be concentrated and the connection terminal 32 and the conductor connection portion 19b (conductor body 20a) can be electrically connected to each other in an even better time. In addition, since the “conducting wire connection process” of the present embodiment is performed with the position of the connection terminal 32 and the focal position of the laser beam LB substantially matched, the connection terminal 32 (compared to the case where the position is shifted). And the conductor connecting portion 19b (conductor main body 20a) can be connected in a shorter time.

  (5) Since the “film removal process” and the “conductor connection process” are performed simultaneously on different objects X1 and X2, waste when producing a large number (mass) of the objects (brushless motor 11) is reduced. The

  (6) In the process of forming the winding wire 19 by the conducting wire 20 in the “lead wire arranging step” (that is, during the winding operation), a part of the winding wire 19 is placed on the mounting portion 18c corresponding to the connection terminal 32. Be placed. In other words, in the “conductor arrangement step”, the operation of winding the lead wire 20 around the connection terminal 32 that is not the same as the process of forming the winding or the connecting wire by the lead wire 20 is performed, and the winding is simply performed. In a series of processes constituting 19, a part thereof is arranged at a position corresponding to the connection terminal 32. Therefore, the manufacturing process can be simplified as compared with a method including a process of winding (bending) the conductive wire 20 around the connection terminal 32 or the like.

  (7) Since the insulating film contains graphite powder as a laser beam absorbing member, the laser beam LB is absorbed by the graphite powder during the “film removal process” in which the insulating film is removed by irradiating the laser beam LB. In other words, the transmission and reflection of the laser beam LB are reduced by the graphite powder, and the insulating film can be removed by the low-power laser beam LB. Therefore, for example, high efficiency and low cost can be achieved when the insulating film is removed. Further, since the insulating film can be removed with the low-power laser beam LB, it is possible to reduce, for example, damage to the conductor body 20a.

The above embodiment may be modified as follows.
In the “film removal step” in the above embodiment, one of the parts divided by the half mirror 53 is formed into a rectangle by the first output unit 54, and the laser beam (rectangular laser beam) is irradiated to the conductor connection unit 19b. However, as long as the laser beam is irradiated by the laser beam irradiation apparatus common to the “conducting wire connection step”, the method may be changed to another method.

  For example, as a laser beam irradiation device having only the second output unit 55 without the half mirror 53 and the first output unit 54, the insulating film is removed by irradiating the conducting wire connection unit 19b with the laser beam LB formed in a circular shape. You may make it do. In this way, the beam splitter (half mirror 53) and the two output units of the laser beam irradiation apparatus and the two output units are not necessary (only the second output unit 55 is required), compared with the above embodiment, and the laser beam irradiation apparatus is simplified. It can be configured. In this case, for example, by shifting the position of the conductor connection portion 19b and the focal position of the laser beam LB, as shown in FIG. Furthermore, it is desirable to irradiate the laser beam LB to the conductor connecting portion 19b (so as to include the same width in the longitudinal direction as in the above embodiment). Furthermore, if the laser beam LB shown by a two-dot chain line in FIG. 5 is changed to a laser beam (rectangular laser beam) LB as shown in FIG. 4 by using a mask (thin metal plate), the laser beam is applied to a portion other than the insulating film. Irradiation is reduced, and adverse effects on portions other than the insulating film are reduced. Of course, in this example (method in which the half mirror 53 and the first output unit 54 are not used) and the above-described embodiment, the laser is kept in a state where the position of the conductor connecting portion 19b and the focal position of the laser beam LB are substantially matched. The insulating film may be removed by scanning light and irradiating the same range. In addition, a condensing lens or the like that irradiates the first output unit 54 in advance at a focal position in a range similar to the range (see FIG. 4) of the embodiment of the conductor connection unit 19b (formation of an irradiation spot). It is possible to irradiate a range similar to the range of the embodiment (see FIG. 4) by substantially matching the position of the conductor connecting portion 19b and the focal position of the laser beam LB. .

  In the “film removal step” of the above-described embodiment, the laser beam (rectangular laser beam) LB formed into a rectangle by the first output unit 54 is irradiated to the conductive wire connecting unit 19b. It is good also as what changed the shape and shape | molded the laser beam irradiated to the conducting wire connection part 19b in the ellipse (it is a shape close | similar to the said rectangle) (elliptical laser beam). Even if it does in this way, the effect similar to the effect of the said embodiment (when irradiating the laser beam (rectangular laser beam) shape | molded in the rectangle) can be acquired.

  In the above embodiment, the “film removal step” and the “wire connection step” are performed simultaneously on different objects X1 and X2. However, the present invention is not limited to this, and may not be performed simultaneously. . For example, in the case of manufacturing with a laser beam irradiation apparatus having only the second output unit 55 without the half mirror 53 and the first output unit 54 as in the above-described another example, of course, the “film removal step” The “conductor connection process” cannot be performed at the same time, and they are performed separately.

  In the above embodiment, the conductor connecting portion 19b of the conductor 20 constituting the winding 19 in the armature constituting the stator 13 and the connection terminal 32 of the control device 14 for supplying a driving current to the winding 19 are provided. Although the invention is embodied in the method for manufacturing the brushless motor 11 that is electrically connected, the present invention is not limited to this. For example, the method may be embodied in a method for manufacturing a DC motor with a commutator.

  That is, as shown in FIGS. 6 and 7, in the armature that constitutes the rotor 60, a conductor connecting portion 62a that is a part of the conductor 62 that constitutes the winding 61, and a segment 64 of the commutator 63 (see FIG. 7). You may embody in the manufacturing method of the DC motor with a commutator which electrically connects with the commutator connection piece 65 as a conductor member extended from. In the “conductor connection process” of this example, the commutator connecting piece 65 is provided with a through hole 65a in advance, and the first opening of the through hole 65a is disposed so as to be closed by the conductor connecting portion 62a. The laser beam LB from the output unit 55 is irradiated around the second opening of the through hole 65a in the commutator connecting piece 65 and is also applied to the conducting wire connecting unit 62a through the through hole 65a. If it does in this way, commutator connecting piece 65 and conducting wire connecting part 62a (its conducting wire main part) will each receive the energy of laser beam LB directly. Further, a part of the laser beam LB irradiated to the conductive wire connecting part 62a is reflected, but a part of the reflected laser beam is irradiated to the inner surface of the through hole 65a, and the inner surface receives the energy of the laser beam. become. From these things, the commutator connection piece 65 and the conducting wire connecting portion 62a (the conducting wire main body) can be favorably joined with low energy. In the “film removal step” of this example, the laser beam (rectangular laser beam) LB from the first output unit 54 (the position of the conductive wire connecting portion 62a and the focal position of the laser beam LB are compared with the above embodiment). The lead wire connection portion 62a is irradiated with a shift.

  In the above embodiment, the laser beam irradiation device 51 has the half mirror 53 that divides the laser beam from the laser oscillator 52 into approximately half (the intensity of reflected light and transmitted light is approximately 1: 1). However, the present invention is not limited to this, and the beam splitter may be changed to another beam splitter, and the others may be implemented by the same method as in the above embodiment.

  In the above embodiment, the insulating film contains graphite powder as a laser light absorbing member. However, the present invention is not limited to this and may be changed to another insulating film. For example, a laser light absorbing paint (for example, black) ink or the like is applied in advance (at least before the “film removal step”) to the outer surface of the insulating film that does not contain a laser light absorbing member (graphite powder). Also good. Even in this case, during the “film removal process” in which the insulating film is removed by irradiating the laser light, the laser light is absorbed by the laser light absorbing paint, and the insulating film is applied by the low-power laser light. Can be removed. Further, for example, a fluororesin as a low refractive index member (a member having a refractive index lower than that of the insulating film) may be provided (coated) on the outer surface of the insulating film that does not contain the laser light absorbing member (graphite powder). ) Good. Even in this case, in the “film removal process” in which the insulating film is removed by irradiating the laser beam, the laser beam that has passed through the inside from the low refractive index member is difficult to escape to the outside, and the low-power laser beam is used. The insulating film can be removed.

  In the above embodiment, the laser oscillator 52 of the laser beam irradiation device 51 is for generating a YAG laser (wavelength: 1.06 μm), but of course, other laser beams (for example, carbon dioxide laser) A laser oscillator for generating (a wavelength is 10.6 μm) or a semiconductor laser (a wavelength is 0.946 μm) may be used.

  In the above embodiment, the present invention is embodied in the method for manufacturing the brushless motor 11 in the electric fan device 1 for engine cooling, but may be changed to the method for manufacturing the brushless motor in other devices. Further, the present invention is not limited to motors such as the brushless motor 11 and the DC motor with commutators (FIGS. 6 and 7), and other conductors that electrically connect other conductors (not constituting the winding) to other conductor members. A connection method may be embodied.

The technical idea that can be grasped from the above embodiments will be described below together with the effects thereof.
(A) In the method for connecting conductive wires according to claim 2, in the conductive wire connecting step, the laser light from the output part of the laser light irradiation device, which is the same as the film removing step, is used as the conductive wire main body and the conductive member. And irradiating at least one of the focal point position of the laser beam and at least one position of the conductor main body and the conductor member.

  In this case, for example, compared with the case where one of the parts divided by the beam splitter is used in the film removing process and the other part of the divided part is used in the wire connection process (the above embodiment), the beam splitter (half The mirror 53) and the two output units (first or second output units 54 and 55) are not required, and the laser beam irradiation apparatus can be simplified. Also, in the lead wire connecting step, the focal position of the laser beam and at least one position of the lead wire main body and the conductor member are substantially matched, so that the energy is concentrated and the lead wire main body and the conductor member are electrically good. Furthermore, it can connect in a short time.

(B) The method for connecting conductive wires according to claim 4, wherein the film removing step and the conductive wire connecting step are simultaneously performed on different objects.
If it does in this way, since a membrane | film | coat removal process and a wire connection process are simultaneously performed with respect to the different object, the waste at the time of producing many (mass) objects is reduced.

  (C) The method for manufacturing a motor according to claim 5, further comprising a conductor arranging step of arranging a part of the winding or the connecting wire at a position corresponding to the conductor member in the process of forming the winding or the connecting wire by the conductor. A method of manufacturing a motor characterized by the above.

  If it does in this way, the part will be arrange | positioned in the position corresponding to a conductor member in the process which comprises a coil | winding or a crossover with a conducting wire in a conducting wire arrangement | positioning process. That is, in the conductor arrangement process, the operation of winding (crossing) the conductor wire, which is a separate operation from the process of forming the winding or the junction wire with the conductor wire, is not performed, and the winding or the junction wire is simply configured. In a series of processes, a part thereof is arranged at a position corresponding to the conductor member. Therefore, the manufacturing process can be simplified.

(D) A method for connecting a conducting wire according to any one of claims 1 to 4, wherein the insulating film contains a laser light absorbing member.
In this way, in the “film removal process” in which the insulating film is removed by irradiating the laser beam, the laser light is easily absorbed by the laser light absorbing member, and the insulating film is removed with the low-power laser light. Can do. Therefore, for example, high efficiency and low cost can be achieved when the insulating film is removed. Further, for example, it is possible to reduce damage to the conductor main body.

The schematic block diagram of the electric fan apparatus in this Embodiment. The top view of the stator in this Embodiment. Explanatory drawing for demonstrating the laser beam irradiation apparatus and manufacturing method of this Embodiment. The schematic diagram for demonstrating the laser beam (rectangular laser beam) in this Embodiment. The schematic diagram for demonstrating the laser beam of the film removal process in another example. The perspective view for demonstrating the manufacturing method of the DC motor with a commutator in another example. The perspective view for demonstrating the manufacturing method of the DC motor with a commutator in another example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 13 ... Stator, 14 ... Control apparatus, 19, 61 ... Winding, 19b, 62a ... Conductor connection part (predetermined part), 20, 62 ... Conductor, 20a ... Conductor body, 32 ... Connection terminal (conductor member), 51 ... Laser beam irradiation device, 53: half mirror (beam splitter), 60: rotor, 63: commutator, 64: segment, 65: commutator connecting piece (conductor member), LB: laser beam.

Claims (7)

A conductive wire connecting method for electrically connecting a conductive wire having a conductive wire main body made of a conductive metal and an insulating film covering the conductive wire main body to a conductive member,
A film removal step of removing the insulating film by irradiating a predetermined portion of the conducting wire with a laser beam by a laser beam irradiation device;
After the film removal step, the conductive wire body exposed by removing the insulating film and the conductor member are brought into contact with each other, and at least one of them is irradiated with laser light from the laser light irradiation device. A conductive wire connecting method comprising: a conductive wire connecting step for joining and electrically connecting. In the connection method of the conducting wire according to claim 1,
In the film removing step, the laser beam is irradiated to the conductive wire so as to include the full width in the direction perpendicular to the longitudinal direction of the conductive wire by shifting the position of the conductive wire and the focal position of the laser light. How to connect the conductors. In the connection method of the conducting wire according to claim 1 or 2,
The laser beam irradiation device has a beam splitter,
In the film removal step, the conductive wire is connected by irradiating the conductive wire with a rectangular laser beam or an elliptical laser beam in which one of the beams splitter is shaped into a rectangle or an ellipse. In the connection method of the conducting wire according to claim 3,
In the conducting wire connecting step, at least one of the conducting wire main body and the conductor member is irradiated with a laser beam in which the other divided by the beam splitter is formed into a circular shape.   5. The method for manufacturing a motor according to claim 1, wherein the conducting wire is a part of a winding in the armature. In the manufacturing method of the motor according to claim 5,
The armature constitutes a stator,
The method of manufacturing a motor, wherein the conductor member is a connection terminal electrically connected to a control device for supplying a driving current to the winding. In the manufacturing method of the motor according to claim 5,
The armature constitutes a rotor,
The method for manufacturing a motor, wherein the conductor member is a commutator connecting piece extending from a commutator segment.

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