JP6090045B2 - Manufacturing method of collective conducting wire - Google Patents

Description

The present invention relates to a method for manufacturing a collective conducting wire composed of a plurality of strands.

  The stator constituting the motor is formed of a stator core formed by laminating an annular yoke, a plurality of teeth projecting radially inward from the yoke, and a steel plate having a slot formed between adjacent teeth. The stator is formed by being wound between the teeth while the coil is inserted into the slot. The coil winding has an insulating coating formed around the conductors to insulate the conductors in the coil, and an insulator such as an insulating bobbin or insulating paper is disposed between the teeth and the coil. Thus, insulation between the core and the coil is achieved. Further, for example, in a distributed winding type winding form, interphase insulation between different-phase coils is achieved by an insulator such as insulating paper.

  For example, a conventional coil forming winding is made by dissolving a thermosetting enamel resin in a solvent and applying it to a thickness of several μm around a copper conductor, and heat-treating it to harden the coating layer. The winding is manufactured by forming the enamel film having a desired thickness by repeating the process. In general, an amidoimide resin, a urethane resin, an esterimide resin, a polyimide resin, an oxide film, or the like is used as a material for the enamel coating. In addition to the winding having a circular cross section, a rectangular wire capable of increasing the coil space factor is applied.

  By the way, for example, when applying the above-described circular winding or rectangular wire as a winding for a coil constituting a drive motor of a hybrid vehicle or an electric vehicle, for the purpose of further improving the coil space factor and improving torque. Although the cross-sectional area of the winding tends to increase, eddy current loss increases as the cross-sectional area increases.

  As a countermeasure against this eddy current loss, the conductor cross-section is divided into small cross sections, an insulation coating is formed around the small cross-section conductors to form small cross-section strands, and the bundle formed by bundling these strands Attention has been focused on the method of applying conducting wires.

  For example, Patent Document 1 discloses a flat litz wire formed by twisting and rolling strands having a circular cross section (enameled wire).

  In the production of the assembly conductor described above, a plurality of strands are bundled and integrated, but during this processing, there is a fear that the insulating coating such as enamel coating around the conducting wire may be broken, and there is a concern about foaming during welding. . Further, in order to obtain a sufficient loss reduction effect with the enamel coating, a thickness of at least about 10 μm is required, and thus the thickness of the enamel coating is a factor of a decrease in the coil space factor.

JP 2000-90747 A

The present invention has been made in view of the problems described above, and relates to a method of manufacturing an assembly conductor in which a plurality of strands having a circular cross section are bundled into a rectangular wire to manufacture an assembly conductor. It is an object of the present invention to provide a method of manufacturing a collective conducting wire that has no problem of breaking the surrounding insulating coating, has an excellent eddy current loss reduction effect, and has a high coil space factor.

In order to achieve the above object, a method of manufacturing a collective conducting wire according to the present invention includes a copper conductor having a circular cross section and a nonmagnetic insulating coating having a higher electrical resistance than copper disposed around the conducting wire. A wire comprising an insulating coating composed of a metal coating;
A plurality of wires each having a circular copper cross section and not having an insulating coating,
Adjacent a wire having the insulating film and a wire not having the insulating film, and bundling the element wire having the insulating film and the wire not having the insulating film in a staggered arrangement on the left and right and top and bottom,
A plurality of bundled strands are accommodated in dies or rolls, and the strands of each strand are converted into a flat wire and integrated, and a flat rectangular wire having an insulating coating and a bare rectangular strand not having an insulating coating are obtained. The assembly conductors are arranged in a staggered arrangement on the top and bottom and on the left and right .

The method for producing a collective conducting wire of the present invention is a metal coating (such as an aluminum clad coating) having a higher electrical resistance than a copper-based conducting wire such as aluminum or an alloy thereof instead of an enamel coating around the strands and a non-magnetic material. Is applied.

  Here, regarding a plurality of cross-sectional strands constituting the assembly conductor, all strands have a metal coating around them, and one of adjacent strands in a bundled posture has a metal coating. However, even if the other side does not have a metal coating (a configuration in which a strand having a metal coating and a strand having no metal coating are in a staggered arrangement), each strand can be insulated.

  By applying a non-magnetic metal coating, there is no problem of breaking the metal coating when bundling multiple strands of copper material with a circular cross section, and foaming problems during welding Since it does not occur, it becomes a collective conducting wire excellent in workability and weldability.

  In addition, a sufficient loss reduction effect can be obtained with a metal coating, and a thickness of about several hundreds of nanometers is sufficient to form a coating with a uniform thickness. In comparison, the coil space factor is significantly improved.

As can be understood from the above description, according to the collective conducting wire manufacturing method of the present invention, a nonmagnetic metal film having a higher electrical resistance than copper is formed around all or part of the strands. As a result, the problem of breakage of the insulating coating and firing during welding can be solved, the loss reduction effect is excellent, and the coil space factor can be increased.

(A) is the figure explaining the manufacturing method of the collective conducting wire of this invention, (b) is the schematic diagram which showed Embodiment 1 of the collective conducting wire of this invention while explaining a manufacturing method following (a) It is. It is the schematic diagram which showed Embodiment 2 of the assembly conducting wire of this invention.

  Hereinafter, embodiments of the collective conducting wire of the present invention will be described with reference to the drawings. Needless to say, the number of wires constituting the assembly conducting wire is not limited to the illustrated example.

(Embodiment 1 of collective conducting wire)
FIG. 1a is a diagram for explaining a method for manufacturing a collective conducting wire according to the present invention, and FIG. 1b is a schematic diagram for explaining the manufacturing method following FIG. 1a and showing Embodiment 1 of the collective conducting wire according to the present invention.

  First, a plurality of strands 3 having a circular cross section and having a nonmagnetic metal coating 2 having a higher electrical resistance than copper and around a copper conductive wire 1 are prepared.

  Here, as the material of the metal coating 2, aluminum, stainless steel, platinum, titanium, and alloys thereof can be applied, and each material has higher electrical resistance than copper and is non-magnetic and workable. Is good.

  As shown in FIG. 1a, a plurality of strands 3 having a circular cross section are bundled and accommodated in a die or a roll (not shown) so that the strands 3 are made into a rectangular wire and integrated, as shown in FIG. 1b. In addition, the collective conducting wire 10 is manufactured by integrating the flat rectangular wire 4 in which the substantially rectangular insulating coating 2 ′ is formed around the flat conducting wire 1 ′. In addition, in the form which bundles the some strand 3, there exist the form bundled by twisting strands, the form bundled by weaving, etc.

  Since the insulating coating 2 'is a non-magnetic metal material, a sufficient loss reduction effect can be obtained, and a thickness of about several hundreds of nanometers is sufficient to form a uniform coating. The coil space factor is remarkably improved as compared with the collective conducting wire to which the coating is applied.

  According to the collective conducting wire 10 shown in the figure, the insulating wire 2 'is broken or foamed during welding because the non-magnetic metal coating 2' is formed around the rectangular wire 4 and has a higher electrical resistance than copper. This eliminates the above problem, and is a collective conducting wire having an excellent loss reduction effect and a high coil space factor.

(Embodiment 2 of collective conducting wire)
FIG. 2 is a schematic diagram showing a second embodiment of the collective conducting wire of the present invention.

  The illustrated assembly lead wire 10A is a flat rectangular wire 4 in which one of adjacent wires in a bundled posture has an insulating coating 2 ', and the other is a bare flat rectangular wire 5 having no insulating coating, The strands 4 and 5 are arranged in a staggered manner at the top and bottom.

  Also in the collective conducting wire 10A, since insulation between the conducting wires is achieved, the collective conducting wire is excellent in loss reduction effect and has a high coil space factor.

[Experiment and results of measuring AC loss]
The inventors of the present invention prototyped the collective conductors of the following examples and comparative examples, measured the AC loss of both, and conducted an experiment to compare the loss reduction effect.

<Example>
For bare wires with a diameter of φ0.9mm made of copper material, aluminum is clad to form an insulating film to form a round cross-section wire, and a plurality of wires are bundled and accommodated in a die. It was set as the assembly conducting wire which consists of a flat wire.

<Comparative Example 1>
A plurality of strands made of bare rectangular conductors (cross-sectional dimension is 1.7 × 3.2 mm) were bundled and accommodated in a die to obtain a collective conductor made of flat strands (the same cross-sectional area as in the example).
<Comparative example 2>
A rectangular wire having the same cross-sectional area as in Example and Comparative Example 1 was used.

<Loss measurement method and measurement results>
Using an AC magnetic property test device (Epstein measuring device, made by Metron Giken), AC loss of the working wires of the examples and the rectangular wires was measured.

  Based on the measurement results of the example, the comparative example 1, and the comparative example 2, the loss reduction rate of the example and the comparative example 1 was obtained for the comparative example 2.

  As a result, the loss reduction rate of Comparative Example 1 was 60%, the loss reduction rate of the Example was 85%, and the loss reduction effect of the Example was confirmed.

  Moreover, it was confirmed by this experiment that the workability and weldability of the examples are good.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Conductive wire (cross-section conducting wire), 1 '... Flat wire, 2, 2' ... Insulating coating, 3 ... Elementary wire (round wire), 4 ... Flat wire, 5 ... Bare rectangular wire, 10, 10A ... Meeting conductor

Claims (1)

A wire comprising an insulating coating, comprising: a copper conductive wire having a circular cross section; and a metal coating that is a non-magnetic insulating coating having a higher electrical resistance than copper disposed around the conducting wire. When,
A plurality of wires each having a circular copper cross section and not having an insulating coating,
Adjacent a wire having the insulating film and a wire not having the insulating film, and bundling the element wire having the insulating film and the wire not having the insulating film in a staggered arrangement on the left and right and top and bottom,
A plurality of bundled strands are accommodated in dies or rolls, and the strands of each strand are converted into a flat wire and integrated, and a flat rectangular wire having an insulating coating and a bare rectangular strand not having an insulating coating are obtained. A method for manufacturing a collective conducting wire , wherein the collective conducting wires are arranged in a staggered arrangement in the vertical and horizontal directions .

Images