JP2012164535A - Connection method of wire material and strand and rotary electric machine using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide connection structure which connects the end of a wire material wound around the core of a rotary electric machine to a strand as a crossover efficiently at a low cost by using an ultrasonic bonding method, and to provide a method thereof.SOLUTION: An insulating connection having a groove, on the bottom surface of which an uneven shape is formed, is provided. The end of a wire material wound around the core of a rotary electric machine and a strand for connection are arranged to overlap in the groove of the connection. Ultrasonic excitation is then performed while pressing the overlapping part of the wire material and the strand through an excitation tool. After they are connected integrally, at least the inside of the groove is covered with an insulating resin.

Description

  The present invention relates to a method for connecting a wire and a stranded wire, and a rotating electric machine using the method, and more particularly to a structure of an electric motor or a generator.

  Motors and generators typified by motors and alternators (hereinafter, both are collectively referred to as rotating electrical machines) are wound around a rotor or stator core as a wire, for example, a single wire made of a copper material with low electrical resistance, A magnetic field is generated by passing an electric current through the wire. In the case where the winding of the wire is performed by dividing it into a plurality of locations in one rotating electrical machine, a stranded wire is often used as a connecting wire in order to connect these wires. Since a stranded wire is composed of a plurality of thin core wires, it is highly flexible and can be easily handled in a rotating electric machine, so that it is generally used.

  One method for connecting the end of the wire and the stranded wire is to use a crimped terminal. This method has a merit that the caulking terminal portion is caulked and connected after inserting the stranded wire and the end of the wire into the caulking terminal, and the connection work can be easily performed. However, since the crimping terminal surrounds the periphery of the wire and the stranded wire with the crimping member, there is a disadvantage that the connecting portion becomes large.

  In recent years, rotating electrical machines have been in the trend of miniaturization and high output, and there is a strong demand for reducing the size of the rotating electrical machine including the connecting portion of the wire. Therefore, there is an ultrasonic bonding method as another connection method that replaces the crimping terminal. This ultrasonic bonding method uses an apparatus composed of a vibration tool that oscillates ultrasonically and an anvil that fixes a member (wire and stranded wire). By applying vibration, diffusion bonding is generated at the interface between the two bonding members (wire material and stranded wire). The ultrasonic bonding method does not require the addition of caulking terminals or the like as in the caulking method, and is effective for reducing the size and space of the connecting portion.

  Patent Documents 1 and 2 disclose a method for ultrasonically joining a stranded wire and a connecting member. Patent Document 1 uses a variable-width anvil to preliminarily consolidate a stranded wire so as to have a predetermined width by ultrasonic bonding, and further ultrasonically bond the integrated stranded wire and a connection terminal as a connecting member. To do. In Patent Document 2, the tip of the vibration tool and the anvil are formed into a concave and convex shape that matches each other, and a stranded wire and a foil-like conductor as a connecting member are sandwiched between them to perform ultrasonic bonding. In either case, an anvil for firmly holding the stranded wire and the connecting member is installed on the cradle of the ultrasonic bonding apparatus to perform bonding.

JP 2003-94293 A JP 2003-333669 A

  However, many problems occur when the techniques disclosed in Patent Documents 1 and 2 are applied to the connection between a wire rod and a stranded wire of a rotating electrical machine. That is, when connecting and linking motor wires that have been separately wound to twisted wires that are connecting wires, the anvil holding the twisted wires and the wires is attached to and detached from the rotating electrical machine every time it is connected to all connection points. It is necessary, and productivity increases when the number of connection points is large. Moreover, in a thin rotary electric machine, there may be no room for attaching an anvil.

  The present invention has been made in view of such circumstances, and is a highly productive connection method in a wire connection method for connecting and connecting a wire of a rotary electric machine that has been separately wound to a stranded wire that is a crossover. Another object of the present invention is to provide a small, high-output rotating electrical machine in which a wire and a stranded wire are connected by the connection method.

  In order to solve the above problems, when connecting the wire of the rotating electrical machine and a stranded wire having a plurality of core wires, an uneven surface is formed at the bottom to regulate the width when the stranded wire is integrated. A connecting portion having a plurality of grooves is provided on the rotating electrical machine side, the wire rod and the stranded wire are installed in the groove of the connecting portion, and the stranded wire is integrated by ultrasonically exciting the oscillating tool under pressure. And connected to the wire.

  According to the present invention, by providing a connecting portion for connecting a wire and a stranded wire as a component of a rotating electrical machine, it is possible to connect efficiently, and as a result, an inexpensive small-sized, high-output rotating electrical machine. Can be produced.

It is the schematic for demonstrating the connection method which is the 1st thru | or 3rd embodiment of this invention. FIG. 4A is a plan view showing the whole of the stator, and FIG. 4B is an A-A ′ sectional view thereof. It is the schematic for demonstrating the connection method which is the 1st Embodiment of this invention. 1A is an enlarged plan view showing the connecting portion in FIG. 1, and FIG. 1B is a sectional view taken along the line B-B ′. BRIEF DESCRIPTION OF THE DRAWINGS It is a figure for demonstrating the connection procedure in the connection method which is the 1st Embodiment of this invention, Comprising: (a) is sectional drawing showing the state before pressurizing and vibrating with a vibration tool, (b) Is a cross-sectional view showing a state in which the stranded wires are integrated and connection with the wire is completed, and (c) is a cross-sectional view showing a state when the connecting portion is resin-sealed. It is a figure for demonstrating the connection procedure in the connection method which is the 2nd Embodiment of this invention, Comprising: (a) is sectional drawing showing the state when installing a strand wire in the groove | channel of a connection part, (b) ) Is a cross-sectional view showing a state when the stranded wire is integrated, (c) a cross-sectional view showing a state when the vibration tool is retracted, and (d) is a wire placed on the integrated stranded wire (E) is a cross-sectional view showing a state when the wire rod is pressed and vibrated with a vibration tool and the connection with the stranded wire is completed, and (f) is a resin-sealed connection portion. It is sectional drawing showing a state when it stops. It is a figure for demonstrating the connection procedure in the connection method which is the 3rd Embodiment of this invention, Comprising: (a) is sectional drawing showing the state when installing a strand wire on an anvil, (b) is a twist. Sectional drawing showing the state when the wires are integrated, (c) is a sectional view showing the state when the integrated stranded wire is installed in the groove of the connecting portion, and (d) shows the wire placed on it (E) is a cross-sectional view showing a state when the wire rod is pressed and vibrated with a vibration tool and the connection with the stranded wire is completed, and (f) is a resin connection portion. It is sectional drawing showing a state when sealed. It is a figure for demonstrating the 3rd Embodiment of this invention, Comprising: It is a figure which shows one Example of the grip pattern of an anvil and a connection part.

  Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings.

A first embodiment of the present invention will be described with reference to FIGS.
FIG. 1 is a view showing a process of manufacturing a stator of a three-phase induction motor by the connection method of the present invention, wherein (a) is a plan view showing the whole of the stator, and (b) is a sectional view taken along line AA ′. It is. A plurality of wire rods 1 are wound around the core 10 of the stator 9 in a divided manner. An annular connection plate 11 is provided on the upper portion of the stator 9, and the connection plate 11 has a connection portion 11 a for connecting the wire 1 and the stranded wire 2 on the upper surface thereof in the same number as the number of divided windings. . The plurality of wires 1 are in charge of the U phase, the V phase, and the W phase, respectively, and one end of the winding wire of each phase wire 1 is connected to the three stranded wires 2 corresponding to each phase at the connection portion 11a. And connect. On the other hand, the other ends of the windings of the wire 1 are separately connected to each other as neutral points. (Not shown)
2A and 2B are diagrams showing details of the connecting portion 11a, in which FIG. 2A is a plan view and FIG. 2B is a cross-sectional view along the line BB ′. In the same figure (a), the stranded wire 2 is installed as a stranded wire 2a in a state where the insulation coating is peeled off at the portion of the connecting portion 11a covering the groove 11b. In FIG. 5B, the holding plate 12 at the bottom of the groove 11b is formed with a concavo-convex grip pattern 12ga on the top surface and a first concavo-convex grip pattern 12gb on the bottom of the groove 12b. The wire 1 is placed on the grip pattern 12bg, and the stranded wire 2a that is exposed by peeling off the coating of the stranded wire 2 is further placed thereon. The stranded wire 2a is composed of a plurality of core wires 2b.

  The connecting plate 11, the connecting portion 11a integrated with the connecting plate 11 and the groove 11b are made of electrically insulating resin, and the holding plate 12 is made of metal. The holding plate 12 is fixed to the bottom of the groove 11b by adhesion, or is fixed by insert molding when the connection plate 11, the connection portion 11a, and the groove 11b are manufactured by resin molding. Both the connection plate 11 and the holding plate 12 are components of a rotating electrical machine.

  FIG. 3 is a diagram for explaining the subsequent connection procedure. FIG. 2A shows a state where vibration is applied from above the stranded wire 2a while being pressurized with the vibration tool 3. FIG. A grip pattern 3g having a third uneven shape is formed at the bottom of the vibration tool 3, and thereby ultrasonic vibration in a direction perpendicular to the paper surface of the drawing is applied to the upper surface of the stranded wire 2a.

  The ultrasonic vibration is transmitted to the inside of the stranded wire 2a and the wire 1 and the wire 1 is restrained by the grip pattern 12gb so as to receive the vibration. Due to the pressurization and vibration of the vibration tool 3, the twisted wire 2 a is integrated so that the core wires 2 b are joined to each other from the upper part in contact with the vibration tool 3 while the core wire 2 b moves and the cross-sectional shape thereof changes. proceed.

  FIG. 2B shows a state where the connection between the integrated stranded wire 2aa and the wire 1 is completed. A contact portion between the plurality of core wires 2b of the stranded wire 2aa and the wire 1 forms a bonding interface 120 by diffusion bonding. FIG. 3C shows a state when the entire connecting portion is sealed with the sealing resin 21 thereafter. The sealing resin 21 is an electrically insulating resin, and is dropped onto the connection portion 11a of the connection plate 11 in a molten state, and is cured to fix the stranded wire 2aa and the wire 1 to the connection portion 11a.

  As described above, according to the first embodiment, the grip pattern is formed on the metal holding plate 12 to receive the ultrasonic vibration, and therefore, the holding equivalent to the anvil against the large vibration energy when the stranded wires are integrated. An effect can be obtained. Therefore, it is not necessary to attach and detach a receiving jig such as an anvil every time it is connected, and since the connection between the wire and the stranded wire can be obtained by performing pressure and vibration with the vibration tool 3 only once. A connection method with low man-hours and high productivity can be obtained.

  In addition, since the insulation and fixing process after connection is performed by sealing with an electrically insulating resin, the connection method requires less member costs and manufacturing man-hours than the insulation and fixing method using an insulating tape and a heat-shrinkable tube. be able to. Therefore, an inexpensive electric motor and generator can be provided.

A second embodiment of the present invention will be described with reference to FIG.
FIG. 4 is a cross-sectional view illustrating the details of the connecting portion 11a and the connecting procedure in the present embodiment. In FIG. 6A, the holding plate 13 at the bottom of the groove 11b is formed with a grip pattern 13g having a first concavo-convex shape on the upper surface thereof. The stranded wire 2a exposed by peeling off the coating of the stranded wire 2 is placed thereon. The stranded wire 2a is composed of a plurality of core wires 2b.

  The connecting plate 11, the connecting portion 11a integral with the connecting plate 11 and the groove 11b are electrically insulating resin, and the holding plate 13 is metal. The holding plate 13 is fixed to the bottom of the groove 11b by bonding, or is fixed by insert molding when the connecting plate 11, the connecting portion 11a, and the groove 11b are manufactured by resin molding. Both the connection plate 11 and the holding plate 13 are components of a rotating electrical machine.

  FIG. 2B shows a state where the stranded wire 2a is integrated into a stranded wire 2aa by pressurization and vibration of the vibration tool 3. Ultrasonic vibration in a direction perpendicular to the paper surface of the drawing is applied to the upper surface of the stranded wire 2a by the grip pattern 3g which is the third uneven shape at the bottom of the vibration tool 3, and the stranded wire 2a is applied by the grip pattern 13g. It is restrained so as to receive the ultrasonic vibration transmitted to the inside. FIG. 2C shows a state in which the vibration tool 3 is temporarily retracted. And in the figure (d), the wire 1 is installed on the strand wire 2aa.

  FIG. 4E shows a state where the connection between the integrated stranded wire 2aa and the wire 1 is completed. By pressurization and vibration of the vibration tool 3, the wire 1 is deformed to become a wire 1b, and a contact portion between the upper surface of the stranded wire 2aa and the wire 1b forms a bonding interface 121 by diffusion bonding. The vibration direction of the vibration tool 3 when connecting the wire 1 is also a direction perpendicular to the paper surface. The pressure and vibration conditions are the pressure when the stranded wire 2a is integrated in FIG. This is different from the excitation condition.

  In order to connect a plurality of wires 1 to a single stranded wire 2, the stranded wire 2a has a larger conductor cross-sectional area than the wire 1, so the pressure and vibration conditions when connecting the wire 1 are the same as those of the stranded wire 2a. This is a condition where the input energy is less than the condition for integration. Therefore, in the same figure (b) and the same figure (e), it joins by switching the apparatus conditions of an ultrasonic bonding apparatus.

  FIG. 5F shows a state when the entire connecting portion is sealed with the sealing resin 21 thereafter. The sealing resin 21 is an electrically insulating resin, and is dropped onto the connection portion 11a of the connection plate 11 in a molten state, and is cured to fix the stranded wire 2aa and the wire 1 to the connection portion 11a.

  As described above, according to the second embodiment, the grip pattern is formed on the metal holding plate 13 to receive the ultrasonic vibration, and therefore, the holding equivalent to the anvil against the large vibration energy when the stranded wires are integrated. An effect can be obtained. Therefore, it is not necessary to attach or detach a receiving jig such as an anvil every time it is connected, and a connection method with a small number of manufacturing steps can be achieved.

  Moreover, when plating, such as Sn, is given to the core wire 2b of the stranded wire 2a, in the process of integrating the stranded wire 2a, the plating scatters from the upper surface where the vibration tool 3 contacts, and the core wire 2b Since the Cu portion is exposed, a strong diffusion bonding is obtained at the bonding interface 121 with the wire 1 which is also Cu, and a highly reliable connection method can be obtained.

  In addition, since the insulation and fixing process after connection is performed by sealing with an electrically insulating resin, the connection method requires less member costs and manufacturing man-hours than the insulation and fixing method using an insulating tape and a heat-shrinkable tube. be able to. Thereby, an inexpensive electric motor and generator can be provided.

A third embodiment of the present invention will be described with reference to FIGS.
FIG. 5 is a cross-sectional view for explaining the details of the connecting portion 11a and the connecting procedure in this embodiment. The connecting method of the wire of a present Example has the 1st process of integrating a strand wire using an anvil, and the 2nd process of connecting the integrated strand wire to the wire of an electric motor.

  FIGS. 4A and 4B are diagrams for explaining the first step. In FIG. 2A, the stranded wire 2 a exposed by peeling off the coating of the stranded wire 2 is installed in the groove 4 b of the anvil 4. A grip pattern 4g having a second uneven shape is formed at the bottom of the groove 4b. FIG. 2B shows a state where the stranded wire 2a is integrated into a stranded wire 2aa by pressurization and vibration of the vibration tool 3. An uneven grip pattern 4g of the anvil 4 is transferred to the bottom of the stranded wire 2aa to form an uneven shape.

  FIGS. 7C to 7F are diagrams for explaining the second step. In FIG. 2C, the integrated stranded wire 2aa is placed in the groove 11b of the connection portion 11a of the connection plate 11 which is a constituent member of the rotating electrical machine, with the bottom where the uneven shape is formed facing down. A grip pattern 11g having a first uneven shape is formed at the bottom of the groove 11b. The grip pattern 11g is formed by a molding die in the same manner as other shapes when the connection plate 11, the connection portion 11a, and the groove 11b are manufactured by resin molding.

  In FIG. 4D, the wire 1 is installed on the stranded wire 2aa. And (e) of the same figure shows the state which the connection of the integrated strand wire 2aa and the wire 1 was completed. The ultrasonic vibration applied from the vibration tool 3 is received by the grip pattern 11g, and the stranded wire 2aa is restrained. By pressurization and vibration of the vibration tool 3, the wire 1 is deformed to become a wire 1b, and a contact portion between the upper surface of the stranded wire 2aa and the wire 1b forms a bonding interface 121 by diffusion bonding.

  The pressure and vibration conditions of the vibration tool 3 are different from the pressure and vibration conditions when the stranded wire 2a is integrated in FIG. In order to connect a plurality of wires 1 to a single stranded wire 2, the stranded wire 2a has a larger conductor cross-sectional area than the wire 1, so the pressure and vibration conditions when connecting the wire 1 are the same as those of the stranded wire 2a. This is a condition where the input energy is less than the condition for integration. Therefore, even if the grip pattern 11g is made of a resin, reliable bonding can be obtained without being melted or worn by ultrasonic vibration.

  FIG. 5F shows a state when the entire connecting portion is sealed with the sealing resin 21 thereafter. The sealing resin 21 is an electrically insulating resin, and is dropped onto the connection portion 11a of the connection plate 11 in a molten state, and is cured to fix the stranded wire 2aa and the wire 1 to the connection portion 11a.

  FIG. 6 shows an embodiment of the grip pattern 4g which is the second uneven shape of the anvil 4 and the grip pattern 11g which is the first uneven shape of the connecting portion 11a. For the stranded wire 2 and the stranded wire 2 a, ultrasonic vibration by the vibration tool is applied in the direction of the vibration direction 30. The grip pattern 4g has a shape having a plurality of parallel grooves in a direction orthogonal to the vibration direction 30, and this pattern is transferred to the integrated stranded wire 2aa. The grip pattern 11g has the same shape as this, and the ultrasonic vibration is reliably received by engaging with the transfer pattern of the stranded wire 2aa.

  As described above, according to the third embodiment, since the connection portion of the electrically insulating resin for connecting the wire and the stranded wire can be formed without adding another metal member, the connection method with low manufacturing cost and can do.

  In addition, when the core wire 2b of the stranded wire 2a is plated with Sn or the like, in the process of integrating the stranded wire 2a, the plating scatters from the upper surface with which the vibration tool 3 contacts, and the core wire 2b Since the Cu portion is exposed, a strong diffusion bonding is obtained at the bonding interface 121 with the wire 1 which is also Cu, and a highly reliable connection method can be obtained.

  In addition, since the insulation and fixing process after connection is performed by sealing with an electrically insulating resin, the connection method requires less member costs and manufacturing man-hours than the insulation and fixing method using an insulating tape and a heat-shrinkable tube. be able to. Thereby, an inexpensive electric motor and generator can be provided.

  As described above, the present invention has been specifically described based on the embodiment. However, the connection plate having the plurality of connection portions is not an annular integral part, but may be configured by combining parts divided according to ease of manufacture and assembly. Good. Moreover, although demonstrated using the example in case the cross-sectional shape of the strand wire and wire before integration is circular, the same effect can be acquired also in the case of other cross-sectional shapes. That is, the present invention is not limited to the embodiment of the present invention, and it goes without saying that the ultrasonic bonding of the stranded wire and the wire can be changed without departing from the gist thereof.

DESCRIPTION OF SYMBOLS 1 ... Wire rod, 1b ... Wire rod, 2 ... Stranded wire, 2a ... Stranded wire, 2b ... Core wire, 2aa ... Stranded wire, 3 ... Excitation tool, 3g ... Grip pattern, 4 ... anvil, 4b ... groove, 4g ... grip pattern, 9 ... stator, 10 ... core, 11 ... connecting plate, 11a ... connecting portion, 11b ... Groove, 11g ... Grip pattern, 12 ... Holding plate, 12b ... Groove, 12ga ... Grip pattern, 12gb ... Grip pattern, 13 ... Holding plate, 13g ... Grip pattern, 21 ... sealing resin, 30 ... vibration direction, 120 ... bonding interface, 121 ... bonding interface

Claims (15)

  A method of connecting a wire and a stranded wire having a plurality of core wires, wherein the wire is disposed in the groove of an insulating connecting portion having a groove having a first uneven shape formed on the bottom surface, and the wire The stranded wire is placed on top of the stranded wire, and a pressing force and ultrasonic vibration are applied to the stranded wire and the wire from the stranded wire side via a vibration tool to connect the wire and the stranded wire. A method for connecting a wire and a stranded wire, characterized in that:   2. A wire rod and a twist according to claim 1, wherein a metal holding plate is disposed at the bottom of the groove, and a first concavo-convex shape is formed on a surface of the metal holding plate in contact with the wire. How to connect to the line.   A method of connecting a wire and a stranded wire having a plurality of core wires, wherein the stranded wire is disposed in the groove of an insulating connecting portion including a groove having a first concavo-convex shape formed on the bottom surface, After press-shaping the stranded wire via an oscillating tool placed on the stranded wire side, the wire is placed on top of the stranded wire, and the stranded wire and the wire from the wire side via the oscillating tool A method of connecting a wire and a stranded wire, wherein a pressing force and ultrasonic vibration are applied to the wire to connect the wire and the stranded wire.   4. A wire rod and a twist according to claim 3, wherein a metal holding plate is disposed at the bottom of the groove, and a first concavo-convex shape is formed on the surface of the metal holding plate on the side in contact with the wire. How to connect to the line.   A method of connecting a wire and a stranded wire having a plurality of core wires, wherein the stranded wire is disposed in the groove of a metal anvil having a groove provided with a second concavo-convex shape at the bottom, and from the stranded wire side A first step of pressing and shaping the stranded wire via a vibration tool, and the groove of the insulating connecting portion provided with a groove having a first concavo-convex shape formed on the bottom surface of the pressed and shaped strand wire After placing in the wire, the wire is placed on top of the press-shaped twisted wire, and pressing force and ultrasonic waves are applied to the wire and the press-shaped twisted wire from the wire side through the vibration tool. A method of connecting a wire and a stranded wire, comprising: a second step of applying vibration to connect the wire and the press-shaped twisted wire.   The first and second concavo-convex shapes are parallel grooves having the same shape orthogonal to the longitudinal direction of the stranded wire, and the direction in which ultrasonic vibration is applied is a direction orthogonal to the parallel grooves. The method for connecting the wire according to claim 5 and a stranded wire.   6. After the connection between the wire and the stranded wire is finished, an insulating resin is applied so as to fill the groove, and the wire and the stranded wire according to claim 1, Connection method.   The connection between the wire and the stranded wire is performed through a third concavo-convex shape formed on the surface of the vibration tool on the side in contact with the wire or the stranded wire. Or the connection method of the wire in any one of 5, and a strand wire.   A rotating electrical machine comprising a core, a wire rod distributed around the core, and a connection plate for connecting a plurality of wire rods and a crossover wire composed of stranded wires at the end of the wire rod, An insulative connecting portion having a groove having a first concavo-convex shape is formed at the bottom, and the rotating electrical machine is connected within the groove so that the end of the wire and the crossover wire overlap each other .   A metal holding plate having a first concavo-convex shape formed on the surface in contact with the wire or the connecting wire is disposed between the bottom of the groove and the wire or the connecting wire. The rotating electrical machine according to claim 9.   A rotating electrical machine comprising a core, a wire rod distributed around the core, and a connection plate for connecting a plurality of wire rods and a crossover wire composed of stranded wires at the end of the wire rod, An insulating connecting portion having a groove having a first uneven shape at the bottom is formed, and is made of a metal having an end of the wire and the twisted wire, the groove having a second uneven shape at the bottom. The stranded wire is disposed in the groove of the anvil, and the stranded wire is connected in the groove so as to overlap with the stranded wire formed by pressing and shaping the stranded wire from the side of the stranded wire through a vibration tool. Rotating electric machine.   12. The rotating electrical machine according to claim 11, wherein the first and second uneven shapes are parallel grooves having the same shape orthogonal to the longitudinal direction of the stranded wire.   The rotating electrical machine according to claim 9, wherein the rotating electrical machine is sealed with an insulating resin so as to cover at least an upper portion of the insulating connecting portion including the inside of the groove.   The rotating electrical machine according to claim 9, wherein the connection plate on which the insulating connection portion is formed has an annular shape or a shape divided into two or more parts.   The rotating electrical machine according to claim 9, wherein the rotating electrical machine is an electric motor or a generator.

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