KR102272514B1 - Manufacturing method for hairpin - Google Patents

Abstract

The present invention relates to a method of manufacturing such a concave-convex copper wire while at the same time forming irregularities on the surface of a copper wire that can be used in a high-efficiency BLDC motor, etc.
A prismatic copper wire having high frequency and high magnetic permeability according to the present invention and a method for manufacturing the same are for a copper wire having high frequency and high permeability, which is cut to a certain length and has one or more irregularities on the surface, and has a circular cross section An intermediate material having a rectangular cross section by pressing both sides of the material that has undergone the vertical pressing step (S100) and the vertical pressing step (S100) of pressing the material (M) up and down to form a flat plate having a certain thickness (S100) A side pressing step (S110) of generating M ') and a four-way pressing step (S120) of simultaneously pressing the upper and lower sides and sides of the intermediate (M') that has undergone the vertical pressing step (S100) and the side pressing step (S110) ), a chamfering step (S130) of performing chamfering by pressing or processing the edge of the intermediate material (M′) that has undergone the four-way pressing step (S120), and the intermediate material (M′) that has undergone the chamfering step (S130). ) is composed of a concave-convex forming step (S140) and the like for manufacturing a angular copper wire (H) by forming concavities and convexities on the surface. According to the present invention as described above, there is an advantage that the performance of the motor is doubled.

Description

Rectangular copper wire manufacturing method with high frequency and high permeability {Manufacturing method for hairpin}

The present invention relates to a method for manufacturing a copper wire having high frequency and high magnetic permeability, and more particularly, to form irregularities on the surface of each copper wire that can be used in a high-efficiency BLDC motor or a transformer, and at the same time, such irregularities (凹凸). ) relates to a method of manufacturing a square copper wire.

In general, a technology that uses an electric motor as a kind of automobile-related parts to exert a driving force is being developed, and for this, the production technology of the motor as well as the operation efficiency of the motor is required.

And, the motor (motor) refers to a power machine that rotates by receiving electric power and generates a rotational force on its shaft, and there are direct current or single-phase alternating current and three-phase alternating current depending on the method of electricity supplied.

The motor is provided with a stator, and a coil is wound around the stator. As such a coil, a circular coil having a circular cross section has been used in the prior art.

When a circular copper wire is used as the coil of the motor, it is relatively easy to form the shape of the coil, but there is a disadvantage in that the space factor, which is the ratio of the overall cross-sectional area of the coil compared to the cross-sectional area of the conductor constituting the coil, is low.

In addition, using an inverter with high-speed switching to drive such a motor, the frequency is increased to implement various speed control and torque control algorithms, and there is a disadvantage in that the loss increases due to this.

Therefore, in recent years, a technique for increasing the space factor by using a flat copper wire as a coil of a motor has been disclosed. However, in the case of such a flat copper wire, it is difficult to implement a complicated shape for the connection, and since the height of the connection part may increase, a method for easily forming the shape of the flat copper wire is required.

In addition, in the case of a flat copper wire, there is an advantage in that the surface area is widened compared to the conventional circular coil, but there is still a problem of low efficiency.

Korean Patent Registration No. 10-1743742

Accordingly, an object of the present invention is to solve the problems of the prior art as described above, and to provide a angular copper wire having high frequency and high magnetic permeability in which irregularities are formed on the surface.

Another object of the present invention is to provide a method for manufacturing a angular copper wire so that irregularities are formed on the surface of a circular coil through a square shape by a plurality of processes.

According to the features of the present invention for achieving the above object, the angular copper wire having high frequency and high magnetic permeability according to the present invention is cut to a predetermined length, and one or more irregularities are formed on the surface. .

In addition, the method for manufacturing a angular copper wire having a high frequency and high magnetic permeability according to the present invention comprises: a vertical pressing step (S100) of pressing the material (M) having a circular cross section up and down to form a flat plate having a predetermined thickness; a side pressing step (S110) of pressing both sides of the material that has undergone the vertical pressing step (S100) to generate an intermediate (M′) having a rectangular cross section; a four-way pressing step (S120) of simultaneously pressing the top and bottom and sides of the intermediate material (M') that has undergone the vertical pressing step (S100) and the side pressing step (S110); a chamfering step (S130) of performing chamfering by pressing or processing the edge of the intermediate material (M') that has undergone the four-way pressing step (S120); It characterized in that it comprises a concave-convex forming step (S140) of manufacturing the angular copper wire (H) by molding the concavo-convex on the surface of the intermediate (M') that has undergone the chamfering step (S130).

The concave-convex forming step (S140) is characterized in that it is a process of simultaneously or sequentially pressing the upper and lower and side surfaces of the intermediate material M' to form irregularities on the surface of the intermediate material M'. .

The chamfering step (S130) is a process for allowing the intermediate material (M') to pass between a pair of chamfering rollers 40 formed so that the chamfering grooves 42 are recessed inwardly on the surface; The radius of curvature (R) of the chamfered groove (42) is characterized in that it corresponds to the upper and lower sizes of the intermediate material (M').

After the concave-convex forming step (S140), the cutting step (S150) of delivering the angular copper wire (H) to a predetermined size, and the angular copper wire (H) cut by the cutting step (S150) into a 'U' shape A twisting step (S170) of bending the bending step (S160), twisting the central portion of the angular copper wire (H) that has undergone the bending step (S160) to form a hairpin shape (S170), and the angle passing through the twisting step (S170) It is characterized in that it comprises a coating step (S180) of coating the surface of the copper wire (H).

An angular copper wire having high frequency and high magnetic permeability according to the present invention and a method for manufacturing the same have the following effects.

First, in the present invention, irregularities are formed on the surface of each copper wire. Therefore, since the surface area is increased, there is an advantage in that the performance of the motor or the transformer is increased despite the skin effect. In addition to the advantage of improving the motor performance due to the increase in current density due to these irregularities, a gap is formed between each copper wire to increase the cooling effect, so there is an advantage in that overheating or heat generation of the motor is reduced.

And, in the present invention, the edge of each copper wire is removed by the chamfering step. Therefore, since the sharp edge is removed, there is an advantage in that the risk of spark generation due to this part is reduced.

In addition, in the present invention, after performing vertical pressure and side pressure, further pressurizing up, down, left and right at the same time to manufacture a square copper wire having a rectangular cross section, which is again formed with irregularities on the surface. Therefore, since pressing is performed in stages, there is also an advantage that efficient molding is possible compared to pressing at once.

In addition, in the present invention, each copper wire is cut to a predetermined size, then bending and twisting are performed, and finally, a coating operation is performed. Therefore, compared to the case of pre-coating, peeling of the coating is prevented, so that the quality is improved.

1 is a block diagram showing the configuration of a preferred embodiment of a method for manufacturing a angular copper wire having high frequency and high magnetic permeability according to the present invention.
Figure 2 is a perspective view showing the configuration of a material used in the method for manufacturing a angular copper wire having a high frequency and high permeability according to the present invention.
Figure 3 is a partial cross-sectional view showing an embodiment of the vertical pressing step constituting the embodiment of the present invention.
Figure 4 is a partial cross-sectional view showing an embodiment of the side pressing step constituting the embodiment of the present invention.
5 is a partial cross-sectional view showing an embodiment of the four-way pressing step constituting the embodiment of the present invention.
Figure 6 is a partial cross-sectional view showing an embodiment of the chamfering step constituting the embodiment of the present invention.
Figure 7 is a partial cross-sectional view showing an embodiment of the step of forming the unevenness constituting the embodiment of the present invention.
8 is a perspective view showing a state in which each copper wire is changed by the bending step and the twisting step constituting the embodiment of the present invention.

Hereinafter, a method for manufacturing an angular copper wire having high frequency and high magnetic permeability according to the present invention will be described in detail with reference to the accompanying drawings.

1 to 8 show the configuration of an embodiment of a method for manufacturing a angular copper wire having high frequency and high magnetic permeability according to the present invention. That is, in FIG. 1, the configuration of an embodiment of a method for manufacturing a angular copper wire having high frequency and high permeability according to the present invention is shown as a whole in a block diagram, and in FIGS. 2 to 8 , each copper wire having high frequency and high magnetic permeability according to the present invention is shown in FIGS. The construction of one embodiment of the manufacturing method is partially shown for each step.

As shown in these figures, the method for manufacturing a angular copper wire having a high frequency and high permeability according to the present invention presses the material (M) having a circular cross section up and down to form a flat plate having a predetermined thickness ( S100), the side pressing step (S110) of generating an intermediate material (M') having a rectangular cross section by pressing both sides of the material that has undergone the vertical pressing step (S100), and the vertical pressing step (S100) and The four-way pressing step (S120) of simultaneously pressing the upper and lower and side surfaces of the intermediate (M') that has undergone the side-pressing step (S110), and the corner of the intermediate (M') that has undergone the four-way pressing step (S120) A chamfering step (S130) of performing chamfering by pressing or processing, and a concave-convex forming step of manufacturing the angular copper wire (H) by molding the unevenness (凹凸) on the surface of the intermediate material (M') that has undergone the chamfering step (S130) (S140), a cutting step (S150) of delivering the angular copper wire (H) that has undergone the uneven forming step (S140) to a predetermined size, and the angular copper wire (H) cut by the cutting step (S150) is 'U' 'Bending step (S160) of bending into a shape, twisting step (S170) of twisting the central part of the angular copper wire (H) that has passed through the bending step (S160) to form a hairpin shape (S170), and the twisting step (S170) It consists of a coating step (S180) and the like of coating the surface of the angular copper wire (H) that has been subjected to.

First, a circular material M is prepared as shown in FIG. 2 . That is, a material having a circular cross section is input, and the material M is preferably made of aluminum or copper.

In general, the electrical conductivity of metals is excellent in the order of silver (Ag) > copper (Cu) > aluminum (Al) > zinc (Zn) > nickel (Ni) > iron (Fe), but silver (Ag) is relatively expensive. Therefore, it is preferable to use a copper (Cu) material having an excellent electrical conductivity while being cheaper than silver (Ag) due to a high economic cost burden.

In addition, aluminum (Al) has excellent electrical conductivity after copper (Cu), but has a disadvantage in that the amount of current is lower than that of copper (Cu) by less than 60%.

However, the specific gravity of copper (Ag) is 89, which is relatively heavy, whereas the specific gravity of aluminum is 27, which is much lighter than copper. Therefore, in the case of using an aluminum material, since the overall weight of the motor is reduced, the aluminum material may be advantageous in a place where work is performed at a high place or where movement is frequent.

In this way, when each copper wire (H), which will be described below, is manufactured using a copper (Cu) material, the magnetic permeability is increased, and consequently, the performance of the motor is improved.

The vertical pressing step (S100) is a process of making flat by pressing the cylindrical material (M) up and down as described above. Therefore, at this time, as shown in FIG. 3, the upper and lower rollers 10 and 12 are used to press the upper and lower portions of the material M. As shown in FIG.

As such, a press may be used to pressurize the material M, but the use of a roller is convenient for continuous operation. That is, it is easier to work more easily to flatten the material M by pressing it up and down using a press, but in order to continue the continuous operation step by step, the material M continues to flow in one direction using a roller Because it is convenient to work on the go.

As described above, when the material M is pressed using the upper roller 10 and the lower roller 12, the material M flows while the upper roller 10 and the lower roller 12 rotate in opposite directions. have to make a shop. That is, the material M is moved and pressed up and down at the same time.

It is preferable that the lower roller 12 is fixed, and the upper roller 10 is installed to be movable up and down to press the material M. Accordingly, although not shown, the upper roller 10 is installed to be movable up and down by a cylinder or the like.

And, at least one of the lower roller 12 and the upper roller 10 should rotate at a predetermined speed. That is, in order to pressurize the material M while moving, the lower roller 12 and the upper roller 10 must simultaneously rotate at the same speed or at least one must rotate. Accordingly, although not shown, a motor for rotating the lower roller 12 is preferably provided on the side surface of the lower roller 12 .

After the material (M) is pressed up and down by the process as described above, the material (M) is pressed up and down and has a flattened cross section as shown in (b) of FIG. 3 .

In this state, the side pressing step (S110) proceeds.

The side pressing step (S110) is a process of pressing the material M by the side rollers 20 formed in pairs on the left and right as shown in FIG. 4 .

The left side roller 20 or the right side roller 20 has a shape corresponding to each other and presses the material M while being spaced apart by a predetermined distance. Accordingly, at least one of the pair of side rollers 20 is installed to be able to flow from side to side.

As described above, although not shown, a motor, a cylinder, and the like should be further provided for rotation and movement of the side roller 20 .

After the side of the material (M) is pressed by the above process, the intermediate (M') as shown in FIG. 4(b) is molded. That is, as shown, the intermediate material M' having a rectangular cross-section is generated.

However, since the intermediate material M' is sequentially subjected to up-and-down pressurization and left-right pressurization, the corners of the intermediate material M' protrude up and down and have a dented rectangular cross-section.

In this state, the four-way pressing step (S120) proceeds.

The four-way pressing step (S120) is a process of simultaneously pressing the upper and lower sides and sides of the intermediate material M' that has undergone the vertical pressing step (S100) and the side pressing step (S110), and is pressurized with a roller in four directions.

Specifically, as shown in FIG. 5 ( a ), rollers are provided on the upper, lower, left, and right sides of the intermediate material M' to press each other. That is, up and down, the upper roller 30 and the lower roller 32 are installed to be spaced apart by a predetermined distance, respectively, and operate to approach each other, and left and right, the left roller 34 and the right roller 36 are provided to approach each other. It works.

When the pressurization is made by this process, the upper and lower surfaces, and the left and right sides of the intermediate material M' are simultaneously pressed to have a square or rectangular cross section as shown in (b) of FIG. 5 .

In this way, after the four-way pressing step (S120) is performed, the intermediate material M' has a rectangular cross section, but residues such as burs exist in a protruding state or have a sharp shape at the corners. .

Therefore, it is necessary to smooth the edges of the intermediate (M'), and this process is the chamfering step (S130).

The chamfering step (S130) is a process of performing chamfering by pressing or processing the edge of the intermediate material (M') that has undergone the four-way pressing step (S120). It is preferably made by a chamfering roller (40).

The chamfering step (S130) is a process for allowing the intermediate material M' to pass between a pair of chamfering rollers 40 formed to have a chamfering groove 42 recessed inward on the surface. That is, as shown, the side surfaces of the pair of chamfering rollers 40 are collided inward to form a chamfered groove 42 , and the edge of the intermediate material M' is pressed into the chamfered groove 42 . do.

The radius of curvature R of the chamfer 42 preferably corresponds to the upper and lower sizes of the intermediate M'. That is, the chamfered groove 42 is formed to have a predetermined curvature as shown. The radius of curvature R of the chamfered groove 42 is at least 1/2 of the vertical height of the intermediate material M'. should be made larger.

And, if the radius of curvature R of the chamfering groove 42 is too large, the chamfering effect is reduced, so an appropriate radius of curvature is required.

Of course, instead of pressing the chamfering step (S130) using a pair of chamfering rollers 40 as described above, cutting the edge of the intermediate material M' by processing or blunting the edge by other methods It will also be possible

After the chamfering step (S130) is performed by the above process, an intermediate (M') having a shape as shown in (b) of FIG. 6 is generated. That is, the intermediate material M' is formed so that the corners of the rectangle have a predetermined curvature.

In this way, the smoothing of the edge of the intermediate material M' through the chamfering step S130 is to prevent partial discharge or sparks. That is, when the edge of the intermediate material M' is sharp, partial discharge or sparks are likely to occur through the sharp edge during operation of a finished motor product.

After the chamfering step (S130) is performed, the concavo-convex forming step (S140) is performed next.

The concave-convex forming step (S140) is a process of manufacturing the angular copper wire (H) by forming the concavo-convex on the surface of the intermediate material (M') that has been subjected to the chamfering step (S130).

In this concave-convex forming step (S140), concavities and convexities are formed on the upper surface, lower surface, and side surfaces of the intermediate material M'. Therefore, as shown in (a) of FIG. 7 , the upper and lower rollers 52 and the left and opposite rollers 54 and 56 are provided, respectively, so that the intermediate material in four directions is provided. (M') is pressurized.

After the concavo-convex forming step (S140) as described above is completed, the angular copper wire (H) having concavities and convexities formed on the upper and lower sides and the side, respectively, as in FIG. 7(b) is formed.

Of course, the step of forming the unevenness ( S140 ) as described above may be performed by a number of processes. That is, the upper concave-convex roller 50 and the lower concave-convex roller 52, the left concave-convex roller 54 and the right concave-convex roller 56 simultaneously press the intermediate material M' in four directions and pressurize it step by step. It can also be configured.

Specifically, as in the upper and lower pressing step (S100) and the side pressing step (S110), the intermediate (M') is first pressed with the upper and lower rollers 50 and 52 to form the intermediate (M). ') to form concavities and convexities on the upper and lower surfaces, respectively, and then press the side using the left concave-convex roller 54 and the right concave-convex roller 56 so that concavities and convexities are formed on the side. It will also be possible

As such, the uneven formation step ( S140 ) is a process of simultaneously or sequentially pressing the upper and lower sides and sides of the intermediate material M' to form irregularities on the surface of the intermediate material M'.

After the concavo-convex forming step (S140) as described above is performed, a copper wire (H) as shown in (b) of FIG. 7 is generated, and the shape forming of the copper wire (H) is completed.

Next, a transformation process for inserting the continuous angular copper wire (H) as described above into the stator of the motor is performed.

In detail, first, the cutting step (S150) is performed, which is a process of transferring the long angular copper wire (H) that has undergone the uneven formation step (S140) to a predetermined size. The length of each copper wire (H) cut in the cutting step (S150) may vary depending on the size of the motor.

After the angular copper wire (H) is cut to a predetermined size by the cutting step (S150), the bending step (S160) proceeds. The bending step (S160) is a process of bending the angular copper wire (H) into a 'U' shape.

A state in which the angular copper wire (H) is bent by this process is shown in (b) of FIG. 8 .

After the bending step (S160) as described above, the twisting step (S170) proceeds.

The twisting step (S170) is a process of twisting the central portion of the angular copper wire (H) that has undergone the bending step (S160) to form a hairpin shape.

After the twisting step (S170) as described above is performed, the coating step (S180) proceeds.

The coating step (S180) is a process of coating the surface of the angular copper wire (H) that has undergone the torsion step (S170).

At this time, the coating material used in the coating step (S180) may be variously configured. For example, the coating may be made on the surface of the angular copper wire (H) with a metal material or may be coated with another material.

Preferably, it is preferable to form a metal coating layer by coating the surface of the copper wire (H) with a metal powder having a relatively higher conductivity than the material of the copper wire (H). For example, it may be made of any one of a material having relatively high conductivity compared to copper, aluminum, or an aluminum alloy, silver, or gold.

In addition, in the coating step (S180) as described above, in addition to coating the entire copper wire (H), it will be possible to coat only a part (end, etc.).

When the above steps are completed, the manufacture of each copper wire (H) is completed and assembly is made.

The angular copper wire (H) according to the present invention generated by the process as described above is a angular copper wire for high frequency and high permeability. That is, since the surface of the angular copper wire H according to the present invention is configured to have irregularities, the surface area is increased and the performance of the motor is increased by the skin effect.

Specifically, the skin effect refers to the tendency of the current density to increase toward the outer part of the wire when passing through the wire in alternating current (AC) with frequency. That is, as the frequency increases, current tends to flow outward of the conductor or electromagnetic waves propagate only along the surface of the conductor medium.

The reason for such a skin effect is that the more the center within the cross-sectional area of the wire is, the larger the flux chaining increases and the inductance increases, so the current does not flow well in the center and tends to flow to the surface.

When alternating current (AC) like direct current flows through the cross-sectional area of a wire, power loss is greater. The effective AC resistance is the average power loss in the wire divided by the average value of the square of the current. .

The skin effect resistance ratio increases as the cross-sectional area of the wire increases as the frequency increases. This means that the cross-sectional area of the wire cannot be used efficiently and effectively.

Therefore, examples of using the skin effect include a hollow cable (CABLE) with an increased surface area by making the inside empty, a cable with an oil pipe in the middle of the electric wire, or a method using a cable of a power transmission line as a corridor or multi-conductor, etc. There is this.

And, as is known, the dependence of the skin depth (δ) in the conductor varies depending on the frequency (f), the magnetic permeability (μ), the conductivity (σ), and the like. That is, the higher the frequency, the greater the permeability (larger conductivity), the smaller the skin depth.

As a result, the skin effect reduces the cross-sectional area of a conductor through which current flows, and thus increases the resistance, which in turn affects the loss of the transmission cable. In addition, the usable frequency band is limited.

However, since the surface area of each copper wire (H) according to the present invention is increased, it is possible to prevent power loss despite such a skin effect. That is, as the frequency increases, the penetration depth decreases, but in the present invention, since the surface area is large, current can flow even if the frequency is increased.

The scope of the present invention is not limited to the embodiments illustrated above, and many other modifications based on the present invention will be possible for those skilled in the art within the above technical scope.

10. Upper roller 12. Lower roller
20. Side roller 30. Top roller
32. Lower roller 34. Left roller
36. Woo roller 40. Chamfer roller
42. Chamfered groove 50. Concave-convex roller
52. Concave-convex roller 54. Concave-convex left roller
56. Concave-convex roller M. Material
M'. Intermediate H. copper wire

Claims (5)

A vertical pressing step (S100) of pressing the material (M) having a circular cross section up and down to form a flat plate having a certain thickness, and pressing both sides of the material that has undergone the vertical pressing step (S100) to form a rectangular cross section Four directions of simultaneously pressing the upper and lower sides and sides of the intermediate material M' that has undergone a side pressing step (S110) of generating an intermediate material (M′) with branches, and the vertical pressing step (S100) and the side pressing step (S110) The pressing step (S120), the chamfering step (S130) of performing chamfering by pressing or processing the edge of the intermediate material (M') that has been subjected to the four-way pressing step (S120), and the middle of the chamfering step (S130). A concave-convex forming step (S140) of manufacturing the angular copper wire (H) by molding the uneven (凹凸) on the surface of the water (M '), and a cutting step (S150) of delivering the angular copper wire (H) to a certain size; A bending step (S160) of bending the angular copper wire (H) cut by the cutting step (S150) into a 'U' shape, and twisting the center of the angular copper wire (H) that has undergone the bending step (S160) to form a hairpin (hairpin) ) includes a twisting step (S170) of forming a shape, and a coating step (S180) of coating the surface of the angular copper wire (H) that has undergone the twisting step (S170);
The concavo-convex forming step (S140) is,
The chamfering step (S130) is performed by pressing the intermediate material M' in four directions with an upper concave-convex roller 50, a lower concave-convex roller 52, and a left concave-convex roller 54 and a right concave-convex roller 56. It is a process of forming irregularities on both the upper surface, the lower surface, and the side of the rough intermediate (M');
The chamfering step (S130) is,
It is a process of allowing the intermediate material (M') to pass between a pair of chamfering rollers (40) having a chamfering groove (42) recessed inwardly on the surface;
The radius of curvature (R) of the chamfered groove (42) is,
A method of manufacturing a angular copper wire having high frequency and high magnetic permeability, characterized in that it has a size larger than 1/2 of the upper and lower heights of the intermediate material (M') and smaller than the upper and lower heights of the intermediate material (M'). delete delete delete delete

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