Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
  • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K13/00—Structural associations of current collectors with motors or generators, e.g. brush mounting plates or connections to windings; Disposition of current collectors in motors or generators; Arrangements for improving commutation
  • H02K13/04—Connections between commutator segments and windings

Definitions

• the present invention relates to, for example, the case where an armature coil of a starter motor, which is a starting device of an internal combustion engine, is subjected to ultrasonic welding with a commutator segment.
• the present invention relates to a connection method that can prevent the breakage of an amateur coil that occurs in the above.
• FIGS. 1 (a) and 1 (b) are an external view and a cross-sectional view, respectively, showing a conventional amateur.
• (1) is an amateur
• (2) is a shaft
• ( 3) ) Is a gear formed on the end of the shaft (by rolling or cutting, etc.)
• (4) is a commutator
• (5) is a combimeter ( 4 )
• the segment, ( 6 ) is a mold material to which this segment ( 5 ) is fixed
• (7) is an armature coil
• (7a) and (7) 7b) is the outlet of the armature coil, which is to be ultrasonically welded to the segment ( 5 ).
• (8) is a slot formed in the core of the armature (1), into which the above-mentioned armature coil is inserted and wound.
• Fig. 2 shows the armature of Fig. 1 connected by welding.
• na is a coil
• u is a magnetostrictive element that converts ultrasonic power to mechanical energy
• Is a horn for concentrating the vibrating energy of the magnetostrictive element d3 ⁇ 4, and is a chip.
• the outlets (7a) and (7b) of the above coil Are vibrated and these spigots are welded to the surface of the segment ( 5 ).
• Fig. 3 shows one circuit of the coil (7) wound around the armature (1), and was excited by the ultrasonic welding method shown in Fig. 2.
• FIG. 4 is a model diagram showing the condition where the coil (7) is subjected to the vibrating force of the amplitude by the ultrasonic welder. Bending vibration is applied to the coil 2 at a radius equal to the coil length L, with the input end (l) as a fulcrum. In this case, the applied ultrasonic vibration reaches a maximum of 20 to 30 (KHZ), and even if the vibration is applied for several seconds to several tens of seconds, tens of thousands to hundreds of thousands of bending bends are applied.
• KHZ 20 to 30
• Fig. 1 (a) is an outline drawing showing an armature manufactured by the conventional ultrasonic welding method
• Fig. 1 (b) is a sectional view taken along the line A-A in Fig. 1 (a).
• Fig. 2 is a configuration diagram for explaining the conventional method of ultrasonic welding of an amateur coil and a commutator segment.
• Fig. 3 is an armature.
• Fig. 4 is an external view showing one circuit of the coil wound on the coil
• Fig. 4 is a model diagram showing the state of being subjected to the exciting force by the ultrasonic welding device
• Fig. 5 is a diagram showing the conventional method. Bending Enlarged view showing the bent part of the armature coil
• Fig. 6 is an outline drawing showing an armature manufactured by the conventional ultrasonic welding method
• Fig. 1 (b) is a sectional view taken along the line A-A in Fig. 1 (a).
• Fig. 2 is a configuration diagram for explaining the conventional method of ultra
• FIGS. 6 (a) and 6 (b) are diagrams for explaining the method according to the present invention, and show an armature coil that is d.
• an angle bending process with an inner radius R and a radius of curvature is performed to form a shape required for the armature winding.
• ( ⁇ is the armature coil
• (15a) is the outlet of the armature coil
• the segment of the commutator (4) 15
• the part corresponding to the insertion end (14a) of the slot (8) of the amateur core is shown in (15b), which is made of epoxy resin.
• the elongation at this time should be set within the permissible elongation specific to each material type, such as copper or aluminum used for the armature coil.
• each material type such as copper or aluminum used for the armature coil.
• the radius of curvature R is about 1.5 times as large as the diameter of a wire with a diameter of 2 (4) as an example. It was found that setting to ⁇ ⁇ would not cause conventional harmful cracks or breakage for ultrasonic welding to the segment. Therefore, the armature coil is bent from the slot insertion end so that it has a radius of curvature approximately 1.5 times that of the armature coil. By connecting the coil outlet and the segment by ultrasonic welding, cracking by the conventional method described above is prevented. be able to .
• the round wire was used for the armature coil, based on the consideration of the example round wire and the experimental results, but it is not limited to the round wire.
• the cross-sectional shape is short It goes without saying that the same effect can be obtained even when using a line having a cross section of another polygon or a complex shape.
• the present invention relates to a method in which an outlet of an armature coil is connected to a segment of a commutator by ultrasonic welding.
• the bending shape from the core slot end of the armature coil should have a radius of curvature that is approximately 1.5 times the cross-sectional diameter or thickness of the coil. Since ultrasonic welding is performed without any problems, it is possible to effectively prevent cracks and breakage of the coil generated during ultrasonic welding. .
• the present invention is not limited to the connection of an armature coil of a rotating electric machine, but is also applicable to the connection of conductors of other electric devices.

Landscapes

• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Power Engineering (AREA)
• Motor Or Generator Current Collectors (AREA)
• Manufacture Of Motors, Generators (AREA)

Priority Applications (1)

Applications Claiming Priority (2)

Publications (1)

Family

ID=13035524

Family Applications (1)

Country Status (4)

Cited By (1)

Families Citing this family (10)

Citations (1)

Family Cites Families (6)

• 1979
  • 1979-05-04 JP JP5672779A patent/JPS55147952A/ja active Granted
• 1980
  • 1980-04-30 WO PCT/JP1980/000092 patent/WO1980002479A1/ja active IP Right Grant
  • 1980-04-30 DE DE8080900792T patent/DE3069492D1/de not_active Expired
  • 1980-11-17 EP EP80900792A patent/EP0028264B1/en not_active Expired

Patent Citations (1)

Also Published As

Similar Documents

Legal Events