JP5903580B2 - Winding peeling method of electric motor - Google Patents

Description

  The present invention relates to a technique in which an insulating coating at a tip end portion of an insulating coating-coated electric wire whose core wire is covered with at least one layer of insulating coating is peeled off so that the core wire is exposed and joined to another component by soldering. In particular, the present invention relates to a method for peeling a winding wound around a stator or the like of an electric motor.

  Until now, copper wire has been mainly selected as a conductor of electric wires used in motors (electric motors). However, recent increases in copper wires and improvements in the weight of motors have advanced, and the use of conductors for electric wires other than copper wires has increased.

  Since electric wires other than copper wires, such as aluminum wires, have a strong aluminum oxide layer on their surfaces, soldering connections with terminals and lead wires are extremely difficult unless the insulating coating and the aluminum oxide layer are removed. It was difficult. Further, since the aluminum conductor has a lower strength than the copper wire, there has been a problem that many disconnections occur when the insulating coating and the aluminum oxide layer are peeled off while rotating the cutting blade.

  Therefore, in order to deal with such problems, a technique for removing an oxide film by ultrasonic waves (for example, see Patent Document 1) and a technique for preventing or removing oxidation using a reducing gas (for example, a patent) Document 2), a technique for joining by using ultrasonic waves and zinc-based solder together (for example, see Patent Document 3), a technique for peeling an insulating film in a flux (for example, see Patent Document 4), and the like have been proposed. .

Japanese Patent Laid-Open No. 2-54947 JP 2004-323977 A Japanese Patent Laid-Open No. 9-239531 JP 2009-148053 A

  However, although the removal of the aluminum oxide layer as described in the patent literature is an important issue, no measures have been taken for wire breakage or insulation coating residue when the insulation coating is peeled off from the previous process. Deterioration of the defective rate during the production of electric motors and deterioration of soldering quality have been issues. Especially for thin wires, it was a big problem.

  The present invention solves the problems as described above, and provides an insulating film peeling method for an insulating coated electric wire that does not require large-scale equipment and can increase the bonding reliability with other parts at low cost. The purpose is to do.

  In order to solve the above-described conventional problems, a winding stripping method for an electric motor according to the present invention is a method for stripping an insulating film at a winding end of a winding wound around a magnetic pole of a stator, It is characterized in that the insulating coating is peeled by moving the insulating coating peeling device in which the cutting blade rotates by pulling the wire end portion and applying tension.

Thereby, an insulating film can be peeled without disconnecting an electric wire. In other words, by rotating a plurality of cutting blades to cut the insulating film, it can be peeled uniformly and in a short time, and by applying tension to the end of the winding and peeling, preventing disconnection Can do. And, by applying tension, it corrects the distortion and bending of the electric wire and prevents the electric wire from sagging when it is peeled off by the cutting blade. This can prevent disconnection.

  According to the winding peeling method of the electric motor of the present invention, the insulating coating is peeled off while rotating a plurality of cutting blades and applying tension to the end of the winding, so that the insulation can be performed without disconnecting the electric wire. The coating can be peeled off.

Explanatory drawing of the winding peeling method which concerns on embodiment of this invention Partial sectional drawing of the electric motor in embodiment of this invention Configuration diagram of the stator of the same motor Sectional drawing of the electric wire which concerns on embodiment of this invention

  The present invention relates to a method for peeling off an insulating film at a winding end of a winding wound around a magnetic pole of a stator, wherein the winding end is pulled to be in a tensioned state, and a cutting blade rotates. The insulating film peeling apparatus is moved to move the insulating film to separate the insulating film. Thereby, an insulating film can be peeled without disconnecting an electric wire. Even when aluminum having a strength lower than that of a copper wire or an iron wire is adopted as a conductor of the winding, disconnection when the insulating coating is peeled can be prevented.

  Further, if the moving direction of the insulating film peeling device is the same as the direction in which the tension is applied, it is possible to easily prevent the sag of the electric wire that occurs when peeling with the cutting blade.

  The tension is desirably 5 MPa or more and 50 MPa or less with respect to the conductor. If the pressure is less than 5 MPa, it is not possible to correct the distortion or bending of the electric wire or to prevent the electric wire from sagging when it is peeled off by the cutting blade. In addition, the electric wire may be disconnected at a tension greater than 50 MPa.

  The conductor of the winding is preferably 0.15 mm or more and 0.5 or less. If the thickness is less than 0.15 mm, the insulation film is peeled off when the cutting blade is rotated because the wire is thin, and if the wire is larger than 0.5 mm, the distortion of the wire due to the tension and the correction of the bending wrinkles cannot be performed.

  Further, when peeling off the insulating film of the winding, it is desirable to peel off the conductor of the winding simultaneously at 0.001 mm or more and 0.005 mm or less. When the conductor part of the winding is peeled off at less than 0.001 mm, the aluminum oxide layer is not completely removed, so that the soldering connection between the conductor part and the terminal or the lead wire cannot be easily performed. Moreover, when the conductor part of a coil | winding is simultaneously peeled larger than 0.005 mm, the amount of biting of a cutting blade may become large and may cause a disconnection.

  In addition, when peeling the conductor part of a coil | winding larger than 0.005 mm simultaneously, it is more preferable to carry out by dividing the frequency | count of peeling into multiple times.

(Embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 2 is a structural diagram showing a cross section of the electric motor according to the embodiment of the present invention. FIG. 3 is a view showing a specific configuration example of a winding completed product (finished stator product) 17 of the same motor. In the present embodiment, an example of an electric motor that is mounted for an air conditioner as an electric device and that is a brushless motor for driving a blower fan will be described. In the present embodiment, an example of soldering connection between a wire conductor and a terminal will be described.

  2 and 3, the stator 13 is formed by molding the stator core 1 around which the winding 3 is wound with an insulating resin 7 which is a molding material for integrally molding the mold. . An insulator 2 that insulates the stator core 1 is interposed between the stator core 1 and the winding 3. Further, the winding start line or the winding end line (hereinafter referred to as the winding end 4) is peeled off the insulating coating, applied with soldering flux, and soldered to the terminals 6.

  The rotor 12 is inserted inside the stator 13 through a gap. The rotor 12 includes a disk-shaped rotating body 11 including the rotor core 8 and a shaft 10 to which the rotating body 11 is fastened so as to penetrate the center of the rotating body 11. The rotor core 8 holds a plurality of permanent magnets 9 in the circumferential direction facing the inner peripheral side of the stator 13. Two bearings 14 that support the shaft 10 are attached to the shaft 10 of the rotor 12. One of the two bearings 14 is fixed to an insulating resin 7 that is integrally molded with the mold, and the other is fixed to a metal bracket 15. Further, the brushless motor incorporates a printed circuit board 16 on which a drive circuit is mounted. After this printed circuit board 16 is electrically joined to the terminal 6, the bracket 15 is press-fitted into the stator 13 to form a brushless motor.

  FIG. 4 is a cross-sectional view of the electric wire 20 used as a winding. Here, the electric wire 20 may have a configuration in which the conductor 18 is covered with the insulating coating 19, and the insulating coating 19 may have a configuration in which the conductor 18 is covered with one or two layers of insulating coating. Furthermore, the structure covered with the multilayer insulation film of three or more layers may be sufficient. When the insulating coating 19 is a multilayer, the withstand voltage can be improved, which is advantageous for further miniaturization. Moreover, as the electric wire 20, although the conductor 18 is covered with the at least 1 layer of insulating film 19, the oxide film produced | generated by the manufacturing process of an electric wire, for example, an aluminum oxide layer exists in the conductor surface.

  In the present embodiment, as the electric wire 20, an aluminum conductor 18 covered with two layers of insulating coating 19 made of polyester and nylon (so-called PEWN electric wire) is used. However, it is not restricted to this electric wire 20, You may use what is comprised with another material. The material of the insulating coating 19 may be any of urethane, polyester, and polyimide.

  FIG. 1 is an explanatory diagram of a winding peeling method according to an embodiment of the present invention. In FIG. 1, the winding end 4 is enlarged and shown in comparison with the finished winding product 17. The insulating film peeling device 108 includes a cutting blade 101, a cutting blade rotating device 102, a cutting blade moving device 103, and a tension applying device 104.

  First, the winding end 4 is passed through the centers of the three cutting blades 101, the cutting blade rotating device 102, and the cutting blade moving device 103, and the tip 5 of the winding end is connected to the tension applying device 104. A tension is applied to the conductor 18 of the electric wire 20 with a force of 5 MPa or more and 50 MPa or less in the tension application direction indicated by.

  Next, the cutting blade 101 is rotated by the cutting blade rotating device 102, the cutting blade moving device 103 is moved in the direction of the arrow 105 which is the same direction as the tension application direction, and the insulating coating 19 is peeled off. Then, the conductor 107 after the insulating film is peeled is processed.

At this time, the conductor 18 of the electric wire 20 is preferably 0.15 mm or more and 0.5 mm or less. Also,
The insulating coating 19 has a thickness of approximately 0.01 mm to 0.03 mm. Further, when the insulating film 19 is peeled off, it is preferable that the conductor 18 is peeled off at 0.001 mm or more and 0.005 mm or less on one side at the same time to form the conductor 107 after peeling off the insulating film. The cutting blade 101 is structured to bite into the electric wire 20 when rotated, and the amount of peeling can be adjusted by adjusting the biting stopper.

  Next, the portion where the insulating film 19 remains (the portion that has not been peeled off) near the tip 5 of the winding end is cut. Next, a flux is applied to the conductor 107 after the insulating coating is peeled off, soldered to the terminals 6, and molded with the insulating resin 7 to form the stator 13. In this embodiment, a flux having a solid content of 15%, a viscosity of 4 mPa, and a halogen content of 0.08 ± 0.02% is used, and the solder is Sn-3Ag-0.5Cu. did. Next, the rotor 12, the printed circuit board 16, and the bracket 15 were assembled into an electric motor.

(Example 1)
In the content described in the embodiment, the electric wire 20 was used in which the conductor material was aluminum, the conductor diameter was 0.3 mm, the insulating coating 19 was PEWN, and the insulating coating thickness was 0.012 mm. Further, a tension of 30 MPa was applied to the conductor of the electric wire in the direction of the tension applied to the winding end 4, the cutting blade 101 was rotated at a rotational speed of 1500 r / min, and the insulating coating 19 was peeled off. At this time, the direction 105 in which the cutting blade moves is the same as the tension applying direction, and the direction 106 in which the cutting blade rotates is set so that the winding end 4 is pulled into the cutting blade in the same direction as the tension applying direction. Further, the biting prevention stopper of the cutting blade 101 was adjusted so that the conductor 18 was peeled off simultaneously by 0.002 mm on one side. Production of 1000 electric motors was performed under such conditions, and the disconnection failure rate at the time of insulation film peeling, the insulation film remaining failure rate after peeling, and the soldering connection failure rate with the terminals 6 were confirmed.

(Comparative Example 1)
As a conventional insulating film peeling method, the winding end 4 is passed through the center of the three cutting blades 101, the cutting blade 101 is rotated by the cutting blade rotating device 102, moved by the cutting blade moving device 103, and insulated. The film 19 is peeled, and the conductor 107 after the insulating film is peeled is processed. Also in the comparative example, the electric wire 20 was used in which the conductor material was aluminum, the conductor diameter was 0.3 mm, the insulating coating 19 was made of PEWN, and the insulating coating thickness was 0.012 mm.

  Moreover, the rotation speed of the cutting blade 101 was set to 1500 r / min, and the biting prevention stopper of the cutting blade 101 was adjusted so that the conductor 18 was simultaneously peeled off by 0.002 mm on one side. Production of 1000 electric motors was performed under such conditions, and the disconnection failure rate at the time of insulation film peeling, the insulation film remaining failure rate after peeling, and the soldering connection failure rate with the terminals 6 were confirmed.

  Table 1 shows the results of confirmation between Example 1 and Comparative Example 1.

  As is apparent from Table 1, when the method of the present invention is used, the insulating coating 19 can be peeled without breaking even with a thin aluminum wire having a conductor diameter of 0.3 mm. Furthermore, since the aluminum oxide layer produced | generated on the conductor surface can also be removed simultaneously, the soldering connection with the terminal 6 can also be implemented easily. By applying tension, this corrects the distortion and bending of the wire, and prevents the wire from sagging when it is peeled off by the cutting blade, thereby preventing uneven cutting of the cutting blade into the wire. Because it is.

  In general, the aluminum oxide layer is said to be 0.0005 mm or less. By peeling off the aluminum oxide layer at the same time as peeling off the insulating film 19, soldering with the terminal 6 while improving the productivity is achieved. Wiring defects can be reduced.

  In the method of Comparative Example 1, the tip end side of the winding end 4 moves or loosens / sags at the same time as the cutting blade 101 rotates, making it difficult for the cutting blade to bite in evenly, causing disconnection, or peeling. An insulating film remains later, and aluminum oxide cannot be removed, so that a problem occurs in the soldering connection with the terminal 6.

  Therefore, according to the winding peeling method for an electric motor of the present invention, it is possible to provide an insulating film peeling method for an electric wire that can increase the reliability of joining to other components at low cost while improving productivity.

  As described above, the winding separation method for an electric motor of the present invention can be applied to an electric motor such as an air conditioner, and can also be applied to other electric motors.

DESCRIPTION OF SYMBOLS 1 Stator iron core 2 Insulator 3 Winding 4 Winding end part 5 End of winding end 6 Terminal 7 Insulating resin 10 Shaft 12 Rotor 13 Stator 16 Printed circuit board 17 Finished winding product 18 Conductor 19 Insulating film 20 Electric wire 101 Cutting blade 102 Cutting blade rotating device 103 Cutting blade moving device 104 Tension applying device 107 Conductor after stripping the insulating coating 108 Insulating coating stripping device

Claims (5)

A method for separating the winding ends of the windings wound on the stator core, before Kimakisen is wire coated aluminum conductor with an insulating coating was applied tension to said winding end A winding stripping method for an electric motor , in which the insulating coating stripping device in which the cutting blade rotates is moved to strip the insulating coating and the oxide coating of the aluminum conductor simultaneously . The method for peeling a winding of an electric motor according to claim 1 , wherein the moving direction of the insulating film peeling device is the same as the direction in which the tension is applied. The winding separation method for an electric motor according to claim 1, wherein the tension is 5 MPa or more and 50 MPa or less with respect to the aluminum conductor. 4. The method according to claim 1, wherein a conductor diameter of the aluminum conductor is 0.15 mm or more and 0.5 mm or less. 5. The method according to claim 1 , wherein the aluminum conductor is separated by 0.001 mm or more and 0.005 mm or less.