JP2015053853A - Stator of motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent disconnection at the joint of an aluminum wire to be caulked due to corrosion, while facilitating external connection.SOLUTION: Each coil end of an aluminum wire is thermally caulked, respectively, to a plurality of terminals 8A of the stator of a motor. A plurality of terminal housing sections 14 having a wall surrounding the circumference of the plurality of terminals 8A, respectively, are provided in a terminal block 7. The inside of the plurality of terminal housing sections 14 is coated or filled with an aluminum protective agent 15 for protecting the parts of the aluminum wire thermally caulked, respectively. The plurality of terminals 8A has one end side, where a hook-shaped portion 9 for thermally caulking each coil end of the aluminum wire is formed, respectively, the one end side covered with the aluminum protective agent 15, and the other end side having such a shape as projecting from the terminal housing section 14.

Description

  The present invention relates to a stator of a motor using an aluminum wire as a magnet wire wound around a stator core in a coil shape.

  In order to reduce the cost of the motor, aluminum wires that are cheaper than copper wires are used as the coil windings of the stator. However, when aluminum is exposed and its surface is exposed to air, aluminum is immediately covered with a strong oxide film. Aluminum oxide has a very high electrical resistance and is difficult to join. In order to cope with this, a method has been proposed in which a tin-plated aluminum plate terminal is folded back into a bowl shape, and an aluminum wire is sandwiched inside the bowl-shaped folded portion and heat caulked (see, for example, Patent Document 1).

JP 2011-34879 A (FIG. 2)

  However, since aluminum is a base metal that has a high corrosion rate and low proof stress against salt and is a base metal with a large ionization tendency, corrosion countermeasures are important. Even in the heat crimped aluminum wire of Patent Document 1, the vicinity of the heat crimped portion where the insulating film is melted is particularly susceptible to corrosion, and since nickel or copper is generally used for the tin plating base applied to the aluminum plate terminal, Disconnection due to galvanic corrosion becomes a problem.

  The present invention has been made to solve the above-described problems, and it is an object of the present invention to protect a joint portion of an aluminum wire that is heat caulked to an aluminum plate terminal to prevent disconnection due to corrosion. .

  The stator of the motor according to the present invention is formed of an aluminum wire, and a stator core in which an aluminum wire with an insulating film applied to the outer periphery of a conductor whose main conductor is aluminum is wound as a magnet wire in a plurality of coils. A terminal block installed in the vicinity of the coil end portion of the plurality of coils, and a plurality of terminals that are formed of an aluminum plate and are provided on the terminal block so as to correspond to the plurality of coils. Each coil end portion of the aluminum wire is heat squeezed, and the terminal block is provided with a plurality of terminal storage portions each having a wall surrounding each of the plurality of terminals, and the walls of the plurality of terminal storage portions The height of each wire is set to be higher than the heat-crimped part of the aluminum wire, and an aluminum wire protective agent that protects the heat-crimped part of the aluminum wire is applied inside each terminal housing if The terminals of each of the plurality of terminals are each formed with a hook-shaped portion that heat-seals each coil end portion of the aluminum wire and covered with an aluminum wire protective agent, and the other end side is a terminal housing portion. It has the shape which protruded from.

  According to the present invention, each of the plurality of terminals is formed with a hook-shaped portion on one end side that heat-squeezes each coil end portion of the aluminum wire and covered with the aluminum wire protective agent, and the other end side is a terminal storage portion. By having a shape protruding from the terminal, the aluminum wire joint that is thermally crimped on one end side of the terminal is protected by an aluminum wire protective agent to prevent disconnection due to corrosion, and on the other end side of the terminal Connection to the outside can be easily performed.

It is a perspective view which shows the stator of the motor which concerns on Embodiment 1 of this invention. It is sectional drawing of the aluminum wire used as a magnet wire of the stator of the motor which concerns on Embodiment 1 of this invention. It is a perspective view which shows an example of the connection aspect of the mountain-shaped terminal used for the stator of the motor which concerns on Embodiment 1 of this invention, an aluminum wire, and a lead wire. It is a perspective view which shows the other example of the connection aspect of the mountain-shaped terminal used for the stator of the motor which concerns on Embodiment 1 of this invention, an aluminum wire, and a lead wire. It is a longitudinal cross-sectional view which expands and shows the terminal accommodating part filled with the aluminum wire protective agent (sealant) of the stator of the motor which concerns on Embodiment 1 of this invention. It is a perspective view which shows an example of the connection aspect of the groove-shaped terminal used for the stator of the motor which concerns on Embodiment 2 of this invention, an aluminum wire, and a lead wire. It is a perspective view which shows the other example of the connection aspect of the groove-shaped terminal used for the stator of the motor which concerns on Embodiment 2 of this invention, an aluminum wire, and a lead wire. It is a perspective view which shows the stator of the motor which concerns on Embodiment 3 of this invention. It is explanatory drawing of the filling method of the aluminum wire protective agent (insulation varnish) to the terminal accommodating part of the stator of the motor which concerns on Embodiment 3 of this invention.

  Below, the stator of the motor which concerns on this invention with illustration embodiment is demonstrated. In addition, this invention is not limited by the following embodiment.

Embodiment 1. FIG.
FIG. 1 is a perspective view showing a stator of a motor according to Embodiment 1 of the present invention. FIG. 2 is a sectional view of an aluminum wire used as a magnet wire of the stator of the motor according to the first embodiment of the present invention. FIG. 3 is a perspective view showing an example of a connection mode of a mountain-shaped terminal, an aluminum wire, and a lead wire used in the stator of the motor according to the first embodiment of the present invention.
In general, a motor has a housing formed by press-molding a sheet metal, a rotating shaft supported rotatably at the center of the housing, a rotor supported by the rotating shaft, and a coil wound around a tooth held in the housing. A stator, a terminal block disposed on one side of the stator, and a terminal fixed on the terminal block are provided. Here, only the stator 100, which is a feature of the present invention, is illustrated, and other configurations, that is, the housing, the rotating shaft, and the rotor are omitted.

  The stator of the motor according to the first embodiment of the present invention includes a stator core 1 in which a stator 100 is formed by laminating a plurality of electromagnetic steel plates as shown in FIG. The stator core 1 is formed with a plurality of axially penetrating slots 2, and a coil 6 is provided between the two slots 2 by winding a plurality of turns of a magnet wire composed of an aluminum wire 5. The coil 6 is installed at a plurality of locations in the circumferential direction. The aluminum wire 5 is obtained by baking an insulating film, for example, an enamel insulating film 4, on the outer periphery of a conductor 3 whose main conductor is aluminum as shown in FIG.

  A ring-shaped terminal block 7 is installed in the vicinity of the coil end portion of the coil 6, that is, on the upper surface of the coil 6, as shown in FIG. The terminal block 7 is provided with a plurality of terminals 8A formed of an aluminum plate.

  The terminals 8A have a conductor whose main component is aluminum and tin plating with nickel or copper as a base. Further, as shown in FIG. 3, these terminals 8A are entirely bent in a chevron shape, and a hook-shaped portion 9 is formed on one end side by folding back partly in a hook shape on the inner corner side. Inside the bowl-shaped portion 9, the aluminum wire 5 of the coil end portion is sandwiched and heat caulked (fused). The heat caulking is conducted by sandwiching the hook 9 of the terminal 8A between the welding electrodes, heating the hook 9 to destroy and remove the oxide film on the surface of the aluminum wire 5, and the aluminum wire 5 and the terminal 8A. These tin-plated surfaces are joined by resistance welding and caulking. The enamel insulating film 4 of the aluminum wire 5 is melted and electrically connected by heat caulking.

  Further, the lead wire (copper wire) 10 of the power supply wire is soldered to the other end of the terminal 8A bent in a mountain shape, that is, the end opposite to the portion where the aluminum wire 5 is thermally crimped, as shown in FIG. 11 is connected. The lead wire 10 and the terminal 8A may be connected via a connector. This will be described with reference to FIG.

FIG. 4 is a perspective view showing another example of a connection mode of a mountain-shaped terminal, an aluminum wire, and a lead wire used in the stator of the motor according to the first embodiment of the present invention.
As shown in FIG. 4, the end of the other end of the terminal 8A is dropped to form a male connector 12, and a female connector 13 is attached to the lead wire 10 by caulking. Thereby, the lead wire 10 and the terminal 8A can be connected by inserting the male connector 12 into the female connector 13, and the lead wire 10 and the terminal 8A can be more easily connected. .

  The enamel insulating film 4 of the aluminum wire 5 shown in FIG. 2 has a melting point of 450 ° C. or less, and the enamel insulating film 4 is melted without melting the terminal 8A mainly composed of aluminum by heat caulking.

FIG. 5 is an enlarged longitudinal sectional view showing a terminal accommodating portion filled with an aluminum wire protective agent (sealant) of the stator of the motor according to the first embodiment of the present invention.
As shown in FIGS. 1 and 5, the terminal block 7 is provided with a plurality of terminal accommodating portions 14 having walls 17 surrounding each of the terminals 8A. The height of each wall 17 is an aluminum wire. It is set higher than 5 heat-caulked parts. The inside of each terminal housing 14 is filled with an aluminum wire protective agent that protects a portion of the aluminum wire 5 that has been crimped by heat, for example, a sealant 15 mainly composed of silicon. As a result, the portion of the aluminum wire 5 where the enamel insulating film 4 is melted by the heat caulking and the substrate is exposed is protected by the sealant 15. Since the wall 17 of the terminal accommodating portion 14 is higher than the portion where the aluminum wire 5 is caulked, that is, the upper surface of the sealing agent 15, the filled sealing agent 15 does not sag. Moreover, since the terminal accommodating part 14 is provided for every terminal 8A, it is not necessary to fill the sealing agent 15 more than necessary.

Next, a method for manufacturing the stator of the motor according to the first embodiment of the present invention will be described.
First, an aluminum wire 5 having an insulating film 4 applied to the outer periphery of a conductor 3 whose main conductor is aluminum as shown in FIG. 2 is wound around the stator core 1 in a plurality of coils as a magnet wire as shown in FIG. Next, a terminal block including a plurality of terminal storage portions 14 corresponding to the coil end portions of the respective coils 6 is installed in the vicinity of the coil end portions of the respective coils 6 formed of the aluminum wires 5.
Next, each coil end portion of the aluminum wire 5 is sandwiched between the respective hook-shaped portions 9 of the plurality of terminals 8A formed of an aluminum plate as shown in FIG. 3 or FIG. 4, and the hook-shaped portions 9 are further welded. Heating is performed by energizing the electrode with electrodes. Next, the lead wire 10 of the power supply line is connected to the other end of each of the plurality of terminals 8A by solder 11 as shown in FIG. 3 or via a connector as shown in FIG.
Thereafter, the plurality of terminals 8A on which the aluminum wires 5 have been crimped by heat are accommodated in the corresponding terminal accommodating portions 14, and inside these terminal accommodating portions 14, respectively, as shown in FIG. 1 and FIG. A sealant 15 mainly composed of silicon for protecting the formed portion is applied or filled. In this way, the stator 100 is created.

  As described above, the motor stator 100 according to the first embodiment of the present invention includes a plurality of terminals 8 </ b> A formed of an aluminum plate, after each of the coil end portions of the aluminum wire is thermally crimped. 8A is accommodated in each of the corresponding terminal accommodating portions 14, and a sealant 15 mainly composed of silicon for protecting the heat-crimped portion of the aluminum wire 5 is applied to the inside of the plurality of terminal accommodating portions 14, respectively. Alternatively, since the filling is performed, the joint portion of the aluminum wire 5 that is thermally crimped to the terminal 8A is protected by the sealant 15, and disconnection due to corrosion is prevented.

  The conductor 3 of the aluminum wire 5 only needs to have aluminum as a main component. For example, an aluminum alloy containing copper, magnesium, iron, zirconium, or the like can provide the same effect.

Embodiment 2. FIG.
FIG. 6 is a perspective view showing an example of a connection mode between a groove-shaped terminal, an aluminum wire, and a lead wire used in the stator of the motor according to the second embodiment of the present invention. The parts corresponding to are given the same reference numerals. In the description, reference is made to FIG. 1, FIG. 2, and FIG.
In the motor stator according to the second embodiment of the present invention, the terminal 8B is entirely bent into a groove shape as shown in FIG. 6, and a part of the terminal 8B is folded back to the inner corner side in a hook shape. A bowl-shaped portion 9 is formed. Inside the bowl-shaped portion 9, the aluminum wire 5 of the coil end portion is sandwiched and crimped by heat.

  Further, at the other end of the terminal 8B bent into the groove shape, that is, at the end opposite to the portion where the aluminum wire 5 is thermally crimped, the lead wire (copper wire) 10 of the power supply line is provided as shown in FIG. They are connected by solder 11. The connection between the lead wire 10 and the terminal 8B may be made via a connector. This will be described with reference to FIG.

FIG. 7 is a perspective view showing another example of a connection form of a groove-shaped terminal, an aluminum wire, and a lead wire used in the stator of the motor according to the second embodiment of the present invention.
As shown in FIG. 7, the end of the other end of the groove-shaped terminal 8B is dropped into a male connector 12, and a female connector 13 is attached to the lead wire 10 by caulking. Thereby, the lead wire 10 and the terminal 8B can be connected by inserting the male connector 12 into the female connector 13, and the connection between the lead wire 10 and the terminal 8B can be performed more easily. .

  6 and FIG. 7, when mounted on the stator 100 of FIG. 1, the lead wire 10 is connected from the outside in the radial direction when mounted on the stator 100 of FIG. Can be taken widely. For this reason, work efficiency improves.

Embodiment 3. FIG.
FIG. 8 is a perspective view showing a stator of a motor according to Embodiment 3 of the present invention. FIG. 9 is an explanatory diagram of a method of filling an aluminum wire protective agent (insulating varnish) into the terminal accommodating portion of the stator of the motor according to the third embodiment of the present invention. In each figure, the same reference numerals are given to the portions corresponding to the first embodiment. In the description, reference is made to FIGS.
The stator 100 of the motor according to the third embodiment of the present invention uses the mountain-shaped terminal 8A described in the first embodiment as shown in FIGS. However, the groove-shaped terminal 8B described in the second embodiment can be used as the terminal.
The stator 100 of the motor according to the third embodiment of the present invention fixes the coil 6 as an aluminum wire protective agent in place of the sealant 15 (FIG. 5) mainly composed of silicon described in the first embodiment. The varnish 16 used in the process is used, and this varnish 16 is filled or applied to each terminal accommodating portion 14. Other configurations are the same as those of the first embodiment.

Next, a method for manufacturing the stator of the motor according to the third embodiment of the present invention will be described. The procedure other than filling or applying the varnish 16 to each terminal accommodating portion 14 will be described in the first embodiment. Therefore, the description will be simplified, and a method of filling or applying the varnish 16 to the terminal accommodating portion 14 or the coil 6 will be mainly described.
First, the aluminum wire 5 (FIG. 2) is wound around the stator core 1 in a plurality of coils as a magnet wire as shown in FIG. Next, a terminal block having a plurality of terminal storage portions 14 is installed in the vicinity of the coil end portion of each coil 6 formed of the aluminum wire 5.
Next, each coil end part of the aluminum wire 5 is pinched | interposed into each bowl-shaped part 9 of the some terminal 8A formed with the aluminum plate, respectively, and it heat-seats. Next, the lead wire 10 of the power supply line is connected to the other end of each of the plurality of terminals 8A by solder 11 as shown in FIG. 3 or via a connector as shown in FIG. To be stored in the terminal storage section 14.
Thereafter, the coil 6 is temporarily submerged in the varnish tank to a position higher than the terminal accommodating portion 14 as shown in FIG. 9, and the varnish 16 is spread in each terminal accommodating portion 14. Next, when the varnish 16 has spread in each terminal storage part 14, the coil 6 is taken out from the varnish tank, and the varnish 16 is thermally cured while maintaining the posture with the terminal block 7 up. In this way, the stator 100 is created.

  As described above, the motor stator 100 according to the third embodiment of the present invention uses the varnish 16 used when fixing the coil 6 as the aluminum wire protective agent, and the varnish 16 is connected to each terminal storage portion 14. Therefore, the joint portion of the aluminum wire 5 that is thermally crimped to the terminal 8A is protected by the varnish 16, and disconnection due to corrosion is prevented.

  Further, when the coil 6 is impregnated with the varnish 16, the terminal storage portions 14 can be filled with the varnish 16 at the same time, so that the working efficiency is improved.

  INDUSTRIAL APPLICABILITY The present invention can be applied to all devices in which an aluminum wire is wound as a magnet wire in a coil shape and the terminal portion is exposed to air, and is particularly useful for devices installed in salt damage areas and humid places.

  1 Stator Core, 2 Slots, 3 Conductors, 4 Enamel Insulating Film (Insulating Film), 5 Aluminum Wire, 6 Coil, 7 Terminal Block, 8A, 8B Terminal, 9 Cage, 10 Lead Wire, 11 Solder, 12 Male Connector, 13 female connector, 14 terminal housing, 15 sealant (aluminum wire protectant), 16 varnish (aluminum wire protector), 17 wall, 100 stator.

Claims (4)

A stator core in which an aluminum wire with an insulating film on the outer periphery of a conductor whose main conductor is aluminum is wound as a magnet wire in a plurality of coils;
A terminal block installed in the vicinity of coil end portions of the plurality of coils formed of the aluminum wire;
A plurality of terminals formed by an aluminum plate and corresponding to the plurality of coils on the terminal block;
Each of the coil ends of the aluminum wire is thermally crimped to the plurality of terminals,
The terminal block is provided with a plurality of terminal storage portions each having a wall surrounding each of the plurality of terminals,
The heights of the walls of the plurality of terminal storage portions are set higher than the thermally crimped portions of the aluminum wires, respectively.
Inside each of the plurality of terminal storage portions, an aluminum wire protective agent that protects the thermally crimped portion of the aluminum wire is applied or filled,
Each of the plurality of terminals has one end side formed with a hook-shaped portion that heat-squeezes each coil end portion of the aluminum wire and is covered with the aluminum wire protective agent, and the other end side from the terminal storage portion A stator for a motor having a protruding shape.   The motor stator according to claim 1, wherein a lead wire of a power supply line is connected to the other end side of the plurality of terminals by solder or a connector, respectively.   3. The motor stator according to claim 1, wherein each of the plurality of terminals is bent so that the other end side is positioned on the terminal storage portion, and has a groove shape. 4.   4. The motor stator according to claim 3, wherein a lead wire of a power supply line is soldered to the upper surface of the other end of each of the plurality of terminals that is bent.

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