JPH09322459A - Terminal wire connecting method for motor and motor stator coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to safely perform the connection of terminal wires of such as motor stator at a low cost and reliably by employing a connecting and wiring strip having a plurality of acute angle lugs at the places of contact with terminal wires for connecting the terminal wires of stator coils of a motor. SOLUTION: A connecting and wiring strip of a conducting material is made by providing many folded acute angle lugs by press-punching and inserting wires to the lugs, and they are welded by resistance welding by means of a control in response to a film destroying time, a film vaporization time, a current applied during conductor melting time, and a pressuring force, and a material of conducting member to be jointed. By doing this, the welding can be performed by fully satisfying electric conductivity and high reliability on the mechanical strength. Also, by neatly arranging terminal wires 4, the stator can be made more compact and also the man-hours and costs can be reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to terminal wire connection of coils such as home appliance coil, induction motor stator, DC motor armature coil, and connection of conductive material and circuit.

[0002]

2. Description of the Related Art The number of terminal wires of an AC motor stator coil is twice as many as the number of coils, and the position of the wire after winding may be unstable. Wired by hand. Moreover, the connection method is that a person styles each wire and connects them by soldering. This method is very labor intensive,
Also, there were many problems such as requiring skill. As means for solving such a problem, Japanese Patent Laid-Open No. 62-27
No. 7041, Japanese Patent Application Laid-Open No. 3-245760, Japanese Patent Application Laid-Open No. 4-58751, Japanese Patent Application Laid-Open No. 5-308742, Japanese Patent Application Laid-Open No. 6-233483, etc., a method of connecting terminal lines by a wiring board. Is being done.

[0003]

All of the above wiring board connections have a structure in which a terminal wire is inserted into a through hole of a wiring board and joined by soldering or crimping. Among these methods, soldering is an unfavorable manufacturing method because it contains lead in the solder, which is said to adversely affect the human body and adversely affect the natural environment. In addition, since the solder has a low melting point, the insulation film of the terminal wire is heat resistant, for example, if it is an AIW film, the predetermined electrical conductivity cannot be obtained only by soldering. This requires a process and increases the manufacturing cost. In addition, the caulking crimping method has a problem in that the reliability in terms of electrical characteristics when a heat cycle is applied is low, and the resistance value varies due to variations in the conductor connection cross-sectional area in the connection portion. Further, with respect to the insulating film having a high mechanical strength, the insulating film may be stretched and kept in an insulating state even when pressure is applied, and the bonding may not be performed. Further, since these wiring boards have a three-dimensional shape, there is a problem that the shape is complicated, the manufacturing method thereof is complicated, and the cost is high. An object of the present invention is to inexpensively, reliably and safely connect a terminal wire such as a motor stator by a connecting plate manufactured by a simple method.

[0004]

The basic principle of the present invention, which was created to achieve the above object, is that a wire rod is punched out by a press or the like, and a wire rod is provided with a large number of acute-angled projections. The terminal wire is sandwiched between the conductor material of the folded structure, and the resistance of the resistance coating causes the film breakage time, the film vaporization time, the conducting current during the conductor melting time, and the applied pressure to be applied to the film.
By connecting the terminal wires such as the motor stator by a simple method by controlling the connection according to the material of the conductive material to be connected, the connection plate is inexpensive, reliable, and safe.

[0005]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows an end wire processing wiring board of an AC motor stator winding coil according to an embodiment of the present invention. FIG. 2 shows the structure of the terminal line connecting portion. The number of terminal wires of the AC motor stator coil is twice as many as the number of coils.Since the position of the wire rod is unstable after winding, it is difficult to automate the connection and most of the wires are manually wired. ing. Moreover, the connection method is that a person styles each wire and connects them by soldering. This method has many problems such as requiring a lot of man-hours and requiring skill. In the present invention, as shown in FIG. 1, the terminal wires 4 rising vertically from the stator coil 3 are collectively connected to the wiring board 1 so that the wiring is rationalized. As shown in FIG. 2, the shape of the connecting portion has a shape in which the central portion of a strip-shaped conductive metal plate is turned over, and the portion in contact with the terminal wire 4 has a flat knurled shape having a large number of sharp corners. . This makes it easier for the acute-angled portion to break the wire rod coating when joining the wire rods, and thus facilitates welding. FIG. 3 shows a joining method. FIG. 4 shows the joining conditions. The wiring board 1 and the terminal wire 4 are connected by a resistance welding method. Resistance welding is a method in which a current is applied between the electrodes while applying pressure to the electrodes 5, and the heat generated by the current melts and joins the conductors.

In this embodiment, electrodes are placed on the terminal wires 4 sandwiched between the wiring boards 1 as shown in the figure, and a current from a transformer is passed between the electrodes to join the conductors. As for the relationship between the current value and the pressing force at that time, as shown in FIG. 4, first, the pressing force and the current are rapidly applied during the time t1. The oxide film of the wiring board 1 and the insulating film of the terminal wire 4 are destroyed by this sudden pressing force and current. Next, for t2 hours, a pressure and an electric current are applied to set the temperature between the electrodes to a temperature higher than the vaporization temperature of the coating, and the insulating coating of the terminal wire 4 is melted and vaporized to remove the coating. Next, during t3 hours, an electric current and a pressing force are further applied to set the temperature between the electrodes to be equal to or higher than the melting temperature of the conductor material to join the conductors together. t
After the completion of energization for 3 hours, the applied pressure is delayed and lowered, and pressure is applied until the temperature is lowered and the solidified again.

Next, a method of manufacturing the wiring board 1 will be described with reference to FIGS.
Shown in The wiring board 1 is manufactured from the hoop-shaped material 11 by a progressive press die. After the hoop-shaped material 1 is fed by the material feeding mechanism 16 in order, the upper die 12 and the lower die 13 of the progressive die are hydraulically or pneumatically pressured.
The pressing operation is performed according to the guide 15 by the reference numeral 4.
The hoop material is subjected to knurling at the point, punched at, the punched part is raised at the point to turn over, and the hoop material is processed into the shape of the wiring board 1. After processing, the wiring board 1 is cut into a required length unit and shaped into an annular shape as shown in FIG. 6 to obtain the shape of the wiring board 1.

FIG. 7 shows a coil arrangement of a 48-slot 4-pole AC motor stator, and FIG. 8 shows a connection diagram. The stator coil 3 has four slots in the core 2 with four sets of U-phase large and small coils 3u indicated by solid lines, V-phase large and small coils 3v indicated by alternate long and short dash lines, and W-phase large and small coils 3w indicated by dotted lines, each set at 30 degrees. They are arranged offset. The connection is shown in Figure 8.
As shown, the U-phase, V-phase, and W-phase coils are connected in one side to form a star-shaped connection. Therefore, as shown in FIG. 7, the connection of the entire stator coil is made by first assembling one end (black circle) of all the coils as a neutral wire and then connecting one end of the U-phase coil (white circle) and one end of the V-phase coil (white circle). The locations marked with triangles) and the ends of the W-phase coils (locations marked with X) are collectively connected. In the delta connection method, there is no neutral wire as shown in (b) and only the U, V, and W phases are connected.

9 and 10 show the structure of the wiring board 1 for collectively connecting the stator coil terminal wires. The structure is a quadruple structure in which a wiring board 1c for connecting a neutral wire, a wiring board 1u for U phase connection, a wiring board 1v for V phase connection, and a wiring board 1w for W phase connection are arranged in an overlapping manner. Insulator 9 between wiring boards
Has a structure that is insulated by. Further, as shown in FIG. 10, each connecting portion is provided with a hole into which a resistance welding electrode is inserted, and only the wiring board of each connecting portion is exposed.

With this, resistance welding can be performed at each location, and the connection can be performed at once.

[0012]

According to the present invention, the connection of the terminal wires such as the motor stator is manufactured by a simple method such as progressive press punching, so that the electrical conductivity is sufficiently satisfied and the mechanical strength is also improved. It is possible to connect with high reliability. Moreover, by compacting the terminal wire connection, which has been very complicated in the past, the size of the stator can be reduced, and the man-hours can be greatly reduced and the cost can be reduced.
Further, since the solder is not used, the decomposability is improved, and there is an effect that the product structure does not have an adverse effect on the natural environment.

[Brief description of drawings]

FIG. 1 shows a terminal wire processing wiring board of a motor stator winding coil of the present invention.

FIG. 2 shows a structure of a terminal line connecting portion.

FIG. 3 shows a resistance welding connection

FIG. 4 is a diagram showing welding connection conditions.

FIG. 5 shows a method for manufacturing a wiring board.

FIG. 6 shows a circuit board annular shaping.

FIG. 7 shows a stator coil layout.

FIG. 8 shows a stator coil wiring diagram.

FIG. 9 shows a stator coil wiring board structure.

FIG. 10 is a detailed view showing a stator coil wiring board.

[Explanation of symbols]

1 ... Wiring board, 2 ... Stator core, 3 ... Stator coil, 4 ...
Terminal wire 5 ... Resistance welding electrode, 6 ... Transformer, 9 ... Insulating material,
11 ... Hoop-shaped conductive material, 12 ... Progressive press upper die, 13
… Progressive press lower mold, 14… Cylinder, 15… Guide, 1
6 ... Hoop feeding mechanism

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Suetaro Shibukawa 2520 Takaba, Hitachinaka City, Ibaraki Stock Company Hitachi Automotive Systems Division (72) Inventor Go Omata 7-1, Higashi Narashino, Narashino, Chiba Ceremony Hitachi Industrial Equipment Division

Claims (2)

[Claims] 1. A motor according to claim 1, wherein a structure of a connection wiring board for connecting a terminal wire of a stator coil of the motor is provided with a plurality of acute-angled projections at a position in contact with the terminal wire. 2. A method for connecting a stator coil terminal wire for a motor, wherein a terminal wire is welded to a connection plate for connecting the terminal wire of a motor stator coil, wherein a current flowing at a film breaking time, a film vaporizing time and a conductor melting time of a wire rod. And a method of connecting a stator coil terminal wire of a motor, which is characterized by changing a pressing force.