WO2006063551A1 - Fabrication d'un enroulement de pièce usinée - Google Patents

Fabrication d'un enroulement de pièce usinée Download PDF

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Publication number
WO2006063551A1
WO2006063551A1 PCT/DE2005/002135 DE2005002135W WO2006063551A1 WO 2006063551 A1 WO2006063551 A1 WO 2006063551A1 DE 2005002135 W DE2005002135 W DE 2005002135W WO 2006063551 A1 WO2006063551 A1 WO 2006063551A1
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WO
WIPO (PCT)
Prior art keywords
soldering
solder
electrodes
winding
layer
Prior art date
Application number
PCT/DE2005/002135
Other languages
German (de)
English (en)
Inventor
Werner Fürguth
Original Assignee
Temic Automotive Electric Motors Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Temic Automotive Electric Motors Gmbh filed Critical Temic Automotive Electric Motors Gmbh
Priority to DE112005002560T priority Critical patent/DE112005002560A5/de
Publication of WO2006063551A1 publication Critical patent/WO2006063551A1/fr

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Classifications

    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • 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
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0004—Resistance soldering
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056—Manufacturing winding connections
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056—Manufacturing winding connections
    • H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081—Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/06—Embedding prefabricated windings in machines
    • H02K15/062—Windings in slots; salient pole windings
    • H02K15/064—Windings consisting of separate segments, e.g. hairpin windings
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • B23K2101/38—Conductors

Definitions

  • the present invention relates generally to the F ⁇ rmteüwicHungsher ein, and for example, a method 'for producing a winding of an electrical machine by. Soldered by the insulating layer of insulated moldings.
  • the stator and / or rotor is generally equipped with a winding.
  • a multiphase machine asynchronous or synchronous machine
  • the current flowing through the stator winding generates a magnetic rotating field which applies torque to the rotor.
  • the winding is composed of wound wire coils. These run in the region of the so-called coil sides in grooves of the stator body. Because of the generally circular cross-section of the wires, the five-stroke in the generally rectangular grooves is usually less than 50%.
  • WO 01/95462 A1 a method for producing a similar shaped part winding is known, in which first all shaped parts of the winding are joined, and only then are all produced electrical connections of one or both sides winding in one operation by SchwaHlöten or dip soldering produced.
  • DE 197 41 557 C.1 it is known, using the Widerstanäslötvons to solder differently shaped, electrically conductive, electro-mechanical components, in particular to tin, and to raise funds deposits on just mentioned workpieces. Resistance soldering is done by attaching two electrodes, one from above and one from below, to the workpiece to be tinned or soldered.
  • solder To be melted solder is located either on the lower electrode and the "workpiece directly above and on the workpiece, the second electrode, or vice versa, the current flows therefore through the workpiece and the solder which is heated by its electrical resistance and melt.
  • the temperature of the solder is controlled by the current and time of the current flow, which allows the solder to have different degrees of melting, which also allows for the attachment of small solder deposits to the workpiece.
  • a resistance soldering method in which a soldering part to be connected is contacted on its opposite sides by a respective soldering electrode. The soldering current thus flows through the gap between the parts to be soldered.
  • the FR 2808938 Al discloses a method for producing a molded coil, are assembled in the molded parts by Verl ⁇ t ⁇ ng "into a coil.
  • the open ends of the mold parts are two by placing electrodes, the other soldered one to the one mold part to a different mold part
  • the two electrodes press from opposite directions onto parts to be soldered, the heating current flows over the interface to be soldered between the molded parts.
  • the invention relates to a method for producing a winding of an electrical machine from winding moldings having an insulated top surface and non-insulated bonding surfaces for soldering.
  • the method comprises. Placing a molding on an already constructed layer of already soldered together Porm puzzle such that at one to. soldered connection point come to lie a connecting surface of a molded part of the already constructed layer and a Verbi ⁇ - tion surface of the considered applied molded part with Lot located therebetween on each other; Setting up at least two soldering electrode finishes. on the insulated upper side of the upper of the molded parts to be joined in the region of the solder joint to be soldered and voltage loading of the solder electrodes, wherein the insulating layer is penetrated by the solder joints.
  • Another aspect relates to: a method for manufacturing an electric machine having a stator and a rotor, wherein the stator is equipped with a shaping coil according to the above method, and the stator equipped with the winding is assembled with the rotor of an electric machine.
  • Fig. 5 illustrates a soldering process by a cross-sectional view of winding layers with soldering electrodes applied to a soldering material on a molding of the uppermost winding layer
  • Fig. 2 is a flow chart of the soldering process
  • Fig. 3 shows an exemplary winding diagram of a multi-stranded winding with overlapping coils
  • Fig. 4 illustrates two different exemplary molding types in perspective and cross-sectional views
  • Fig. 5 is a perspective view of a winding layer under construction
  • Fig. 6 is a perspective view of a support of an electrical machine with a preform being developed
  • Fig. 7 is a partial perspective view of a stator fully loaded with the winding;
  • Fig. 8 schematically illustrates a starter-generator with such a winding.
  • Fig. 9, the attachment and manufacture of a particular. Show quantity of soldering material to a workpiece;
  • Fig. 10 is a flow chart of the vinning process
  • Fig. 1 illustrates a soldering process by a C ⁇ cutaway view of winding layers and on a molding of the uppermost Wickhrngslage patch soldering electrodes.
  • the moldings to be joined are soldered together, that is, connected to one another by melting a metal introduced into the air gap.
  • the heat causing the melting of the solder is sercludermung generated.
  • the parts to be soldered are - apart from the joints to be soldered - isolated, so that the introduction of the resistive heating-providing current in the molded part by, an initially still uninterrupted insulating layer is carried out.
  • the working temperature is in such a soldering typically below 450 0 C, and correspond 5.
  • ckend is (Sn and / or Pb-based, for example, on) is used which melts ia a solder at a temperature below 450 ° C.
  • a typical insulating layer such as insulating varnish based on synthetic resin (epoxy resin) also melts and / or burns.
  • solder pad solder pad
  • two solder electrodes are placed on the exposed insulated upper side of the upper of the molded parts to be joined in the region of the solder joint and voltage applied. They penetrate the insulating layer, so that a Lötstrom flows through the upper mold part and the associated resistance heating causes a soldering of the moldings.
  • the insulating layer may be penetrated by the solder electrodes in various ways. If the soldering electrodes are placed on the insulating layer opposite the connecting surface, the soldering electrodes can, for example, mechanically penetrate the insulating layer if the contact pressure is suitable (for example with a contact pressure F between 0.1 kN and 0.3 kN). In other embodiments, hot solder electrodes are placed on the insulating layer *, resulting in thermal penetration of the insulating layer. The solder electrodes are still hot in some embodiments due to the previous soldering process. That is, the residual heat of the soldering electrodes existing after the previous soldering operation is used.
  • the soldering electrodes are additionally heated, for example by a bridge circuit.
  • the insulating layer is burned or melted away at the location of the solder electrodes.
  • the resulting (combustion) scrubstajide are then removed, for example, with a cloth or a polishing pad.
  • the insulating layer is pierced by a combination of thermal and mechanical dovetailing.
  • the mechanical action on the insulating layer still form a relative movement of the soldering electrodes or of the molded part, in order to more easily penetrate the insulating layer.
  • the insulating layer can burn or melt in the area of the applied solder electrodes due to the resistance heating associated with the voltage application, the insulating layer is only punctually injured and, for example, approximately 90% of the insulation layer is retained. After soldering, the absence of insulation at these locations on the top of the moldings is no longer essential. Theoretically, the lack of or damaged by the solder electrodes insulation on the molding tops is a weak point, since the next mold part is placed on these tops.
  • soldering electrodes does not have to take place in the above-mentioned sequence. Rather, the Spannrrngsbeetzhausung for example, already done at the moment of putting it on; In principle, it is even possible to apply soldering electrodes that have already been charged with the bath to the molding process.
  • all soldering electrodes used for soldering a viewing junction are placed on the upper of the molded part to be connected in the region of the connection point. This causes the soldering current to flow substantially only in the upper mold part. At most a small portion of the stream will take a current path that traverses twice the interface to be soldered and covers part of the path in the lower molding. As a result, virtually only the upper of the moldings will heat directly through the ohmic losses, while the other mold will only be heated indirectly by heat conduction across the interface.
  • the Lötelektxodenkraft when pressing several L ⁇ telektroden at the junction is used in some embodiments, not only the contact mediation between the electrode and Formteü, but also the compression of the molded part and their Verbi ⁇ ungsfizzen.
  • no further mechanism is provided for compressing the molded part at the joint; the compression thus takes place solely by the soldering electrodes.
  • the pressure of the soldering electrodes is maintained at least until the solidification of the solder after completion of thematsbeunterschlagung.
  • solder effecting the solder joint is e.g. even before the resistance heating between the connecting surfaces is heated together with the molded parts to be joined.
  • one of the mold pieces or both moldings is plated (tinned) with a defined amount of solder material ("solder pad") at the bond surface before the moldings are installed and soldered.
  • solder pad a defined amount of solder material
  • kan ⁇ may be applied to the connecting surfaces and a flux.
  • the solder (optionally with flux) e.g. applied as soldering powder or solder paste during or before installation and before the resistance heating on the kaus.
  • the layer-wise construction of the winding then takes place from outside to inside, to the axis, so that the respectively accessible Fo ⁇ nteilseite is the axis facing side (the accessible side is in this Description also called the "upper side").
  • the soldering of the individual moldings takes place in each case when the connection points are still accessible at the top; For example, it is also done in layers or by the order of parts. It is possible, always alternately set all the moldings of a new layer or partial layer on an already built up position, and then produce the belonging to this layer electrical connections. Alternatively, it is also possible to place only parts of a layer or partial layer (for example, in each case only a single molded part) on the already constructed layer and then immediately produce the associated soldering.
  • each molding has at its two ends in each case a connecting surface.
  • the mold parts are L-shaped, thus comprising a groove bar to be inserted into a groove of the stator and, at right angles to it, a connecting conductor section which extends tangentially outside the stator and the connection to the other coil side of the coil in question serves.
  • two such L-shaped moldings thus form a turn of a coil; a coil in turn is formed by helical superimposition of several such turns.
  • the two groove rods of a winding are at the same height, i. ia the same radial distance to the axis of the machine.
  • connection there are two different types of connections: the first type connects the relevant molded part with the underneath or overlying winding, the second type connects the two molded parts of a turn.
  • the totality of all windings at the same height forms a winding layer (also called “mold part layer").
  • L-shaped moldings are used, for example, stretched moldings ("I-shaped parts"), which form, for example, each only the groove bars or the connecting conductors. Accordingly, twice as many electrical connections are to be made here as in a winding produced from L-shaped molded parts. To build the winding, the slot bars are inserted in layers in the grooves of the stator; then an ignition conductor is soldered to each two inserted slot bars. Possible are z. 'B. also U-shaped moldings, wherein used is inserted the base of the "U” in the stator slots, and the legs of the "U” with the U-legs of the other mold parts areraitgel ⁇ tei for forming the connecting conductors.
  • L-shaped part windings also apply to such I- and U-form wound windings, for example as regards the layered construction of the winding and the covering of the joints by overlying layers.
  • the connecting conductors overlap of three coils ⁇ ie height is of a single connecting conductor about a third of the height of the slot bar, so that in kausleiterb 'e- rich as many conductors as can be layered in the slot bar above the other in each case three times.
  • the connecting conductors are correspondingly wider, for example three times as wide as the slot bars. So that the connections to be produced between the individual molded parts do not apply, the molded parts have reduced heights in the region of the connecting points.
  • the groove bars have flattened tongues at their ends projecting from the grooves; the two-dimensional connecting conductors each have a depression which receives this flattened tongue tongue without projection.
  • the connecting conductor thus has a lower height than that
  • connection conductor is thus "more planar" than the slot bar.
  • the winding is constructed so that the surface area at the joint molding each lower and the lower surface is above. The electrodes thus press the less flat shaped part onto the surface, which results in a more favorable distribution of the electrode forces to the underlying layer and thus a reduction in the danger of a violation of the electrical insulation to this layer.
  • the upper mold part is melted over the joint by the laser beam.
  • the thickness of the molding over the joint is, for example, 0.4 mm in the laser welding process.
  • significantly thicker molded parts can be joined together than with the abovementioned laser welding method, which melts the upper film part at the connection point.
  • the thickness of the upper molding at the joint is at least 0.65 mm, in other embodiments at least 0.9 mm; in still further embodiments even at least 1.2 mm or even at least 1.5 mm.
  • the thickness of the upper molded part at the joint is related to the height of the grooved bar.
  • the connecting conductor may be made shallower than the grooved bar in order to bypass the pass-through conductors of the other coils enable.
  • the height of the connecting conductor is approximately one third of Nu ⁇ stab blocks.
  • the two parts to be joined stand at the connection point together only the connecting conductor height available; that is, the two mold parts divide the Verbindnngsleiterière. Divide the height, for example, in equal parts, so the slot bar, for example, by a factor of 6 higher than the upper molding at the junction.
  • the said factor is 7.5.
  • the thickness of the upper molding at the joint is 0.5 mm
  • the groove rod height is 3 mm.
  • the grooves have a total height of 12 mm, then four turns of coil are needed to fill the slots with current-carrying conductor.
  • the slot bars have a square cross-sectional shape, in some embodiments even a rectangular cross-sectional shape, with the longer rectangle side extending in the depth direction of the slot (ie, generally in the radial direction of the electric machine).
  • the soldering current is measured during the soldering process, and it is concluded therefrom that the quality of the solder joint. For example, an excessively high contact resistance between the soldering electrode and the molded part in an individual case may result in the flowing soldering current being too low to cause a complete melting and fusing of the solder of the two molded part surfaces.
  • the soldering current can be measured, for example, by measuring the magnitude of a voltage drop in the soldering current source or by measuring a magnetic field generated by the soldering current flow. Too low a soldering current may be detected, for example, by the fact that the soldering current integrated in a soldering current does not exceed a predetermined threshold, or in that the instantaneous current value has not been above a predetermined minimum value for at least a predetermined minimum time.
  • the pairs of molded parts to be soldered are soldered, one after another, by means of a single-hole device.
  • the Lötvorrichrung stationary and the stator with the winding to be produced in contrast can be arranged rotatably.
  • each corresponding to a double groove spacing so step by step, a newly inserted winding part position can be soldered.
  • a multiple soldering device is used, mii simultaneously several or all joints of a layer or partial layer of Fo ⁇ n ⁇ eilen in here be soldered described manner.
  • the produced winding is intended for an electric machine, which is designed as a starter-generator of a motor vehicle.
  • this is a so-called Kufbelwelle starter generator, so ran an elekrri- see machine, which sits without its own bearing on the crankshaft or KurbelweUverliernernng the internal combustion engine.
  • the rotor of the electric machine is non-rotatably coupled to the crankshaft, i. on the other hand, it alternates between the crankshaft and the rotor of the electric machine, a clutch or a reduction or reduction gear (for example in the form of a planetary gear).
  • Such a Kuxbelwelle starter generator is generally disc-shaped, i.
  • the diameter of the rotor is greater than the axial length.
  • the starter-generator is equipped with its own storage and arranged at a suitable point in the drive train or coupled to the drive train auxiliary drive train.
  • the named electric machine with its own bearing can also have the disc shape defined above.
  • the continuous power of such starter generators is generally in the range between 4 kW and 50 kW.
  • the electric machine also serves as a booster in some embodiments, which supports the engine when driving the vehicle , as the sole drive motor when driving without an internal combustion engine, and / or as a recuperation brake for the vehicle, which converts mechanical braking energy into electrical energy to be stored.
  • Such electrical machines are particularly stressed due to the diversity of the operating requirements and the harsh environmental conditions, for example compared to conventional stationary drives.
  • FIG. 1 this illustrates the soldering operation of moldings to show a cross-sectional view of a portion of a coil 1 under construction, which is shown here for ease of understanding.
  • the winding 1 is constructed of individual molded parts 2, which will be explained in more detail with reference to an exemplary winding below in connection with FIGS. 3 to 7.
  • the structure of the winding 1 takes place in layers; in the illustration of FIG. 1, two such winding layers 3.1, 3.2 already assembled and soldered, while a third winding layer 3.3 is currently under construction. In this position 3.3 are two molded parts 2 ', 2 "joined together so that they lie at a junction 4, each with a connecting surface 5', 5" to each other.
  • connection surfaces 5 1 , 5 are pre-tinned with a solder pad 11 (however, both connection surfaces may also be pre-tinned)
  • solder pad 11 both connection surfaces may also be pre-tinned
  • the two soldering electrodes 7 are pressed onto the region 6 of the upper part 2 "at the joint 4, each with a force F.
  • the Ernzel electrode force F is 0.05 kN up to 0.2 kN per electrode, for example 0.1 kN, this force is sufficient to penetrate common insulations of winding moldings with the aid of the soldering electrodes 7.
  • the upper mold part 2 " is pressed onto the lower mold part T by the force (with a total force of 0.1 kN to 0.4 kN, for example 0.2 kN), and this in turn is pressed onto the underlying, already constructed molding sections 3.1
  • the pressure force finally becomes at the lowest mold part 3.1, for example, from the stand in which the layers 3 are inserted, alternatively, it is also possible to support the lower mold part 3.1 at its parts projecting from the stator laterally on a support
  • the pressing of the soldering electrodes 7 and the reaction force counteracted by the already formed molding layer 3.1, the molded parts 2 ', 2 "to be joined are thus compressed at the connection point 4. For very large pressure forces, the solder between the parts to be soldered could be pressed out during the soldering process.
  • soldering electrodes 7 are soldered by means of a soldering generator 8 with a suitable one.
  • Soldering chip so that an electric current flows essentially in the upper molded part 2 "in the region of the connection point 4.
  • This can be, for example, direct current, alternating current or half-wave current means the transported charge) in a simple way, by specifying the number of full or half waves per soldering process at a fixed voltage amplitude.
  • the current flowing in the upper mold part 2 '' heats this directly.With heat conduction through the solder gap, it also indirectly heats the lower one Form part 2 'in the region of the connection point so that the solder applied by the previously described priming melts on the joints.
  • the insulating layer 50 at the locations where the solder electrodes 7 are placed in the area 6 burned or it melts - depending after duration and S TRENGTH theberichteinwrrkuiig and texture: the insulating layer 50.
  • Insulating for example, based on epoxy resin, temperarures keep the 200 0 C only briefly stood. The soot residues and other residues produced during combustion and / or melting are removed with a cloth or a polishing pad. After a so-called aging time, the soldering current is switched off. The solder electrodes 7 are further pressed until the solder is frozen again. Subsequently, the Löttelroroden 7 are lifted and converted to the next to be soldered joint, where see the process described repeated. After the soldering process, approximately 90% of the insulating layer 50 is still intact. The residual heat of the soldering electrodes 7 is used in some Ausu ⁇ ingsformen to easily penetrate the insulating layer 50 in the subsequent soldering.
  • the penetration of the insulating layer when placing the soldering electrodes 7 can be done only partially in some embodiments.
  • the insulating layer 50 is only slightly damaged during placement of the soldering electrodes 7, so that the contact made between the soldering electrodes 7 and mold part 2 is not sufficient to flow around the soldering current through the mold part 2 can be, but • rather only one (not yet the whole Elektrodenaufsetz -Face comprehensive) Initialtitle ist, the only one (because of the greater contact resistance lower) initial current passes, is produced.
  • This initial current leads to a local heating at the contact point, which only (by melting / burning the insulation at the entire contact point) creates a sufficient contact for the flow of the entire soldering.
  • the soldering generator 8 is equipped with a Lötstromanalysator 9, which - as explained above - measures the current flowing during the soldering current, the measured current optionally over the. Soldering summed up, and from this on the quality of the soldering closes.
  • this soldering stress analysis has only one monitoring function, that is to say in the case of detection of an improper stir flow, for example, a corresponding indication is sent to an operator monitoring the soldering process.
  • the soldering current analyzer 9 is coupled to a control unit 10 of the soldering generator 8 in such a way that, if necessary, a corrective intervention takes place in the course of the soldering operation.
  • the soldering is usually carried out with a preset number of n half-waves (for example 6 half-waves), then in the case of a detection of an insufficient current flow during these n half-cycles, the soldering process can be continued by up to m further half-worlds (for example by a further 3 Half-waves), depending on the result of the solder current analysis during the respective soldering process.
  • n half-waves for example 6 half-waves
  • m further half-worlds for example by a further 3 Half-waves
  • this part can, for example, be every second molded part of a layer, for example those molded parts which are to be soldered to moldings of the layer already soldered underneath are.
  • the soldering electrodes are pressed from above (that is, from the accessible side) to the insulation of the upper mold part of a pair of mold members to be joined, and the pressure is applied to the insulating layer (S2).
  • the solder electrodes are charged with electrical soldering voltage (S3).
  • S3 electrical soldering voltage
  • the now flowing Lötstrom brings the solder 11 between the kauert the two mold parts for melting and the insulating layer for burning or / and melting.
  • the voltage application is terminated (S4).
  • FIGS. 3-7 show in detail the structure of an exemplary molded part wrapping using the method described above.
  • Fig. 3 shows a winding diagram of such an exemplary winding 1, which is designed to be three-stranded.
  • the winding scheme repeats all twelve slots of the stator ( Figure 6).
  • the coils 12u, 12v, 12w belonging to the different strands U, V, W are arranged overlapping.
  • Each coil 12 has in two grooves oppositely extending Porterabschitte (so-called coil sides) and this connecting, running outside on the stator connecting conductor 13.
  • the winding 1 is formed so that the connecting conductor 13 of a maximum of three coils 12 are guided past each other, wherein between the coil sides of a coil 12, for example, four coil sides of coils 12 of other strands.
  • the structure of the wiggle 1 is made of L-shaped shaped parts 2, each having a slot bar 14 and a connecting conductor 13 adjoining at a right angle thereto and having a soldering pad 11 on a connection point 5 '(and / or also 5
  • the winding 1 can be essentially made up of only two different types of moldings 2, of which one type (2a) is shown in Fig. 4a and the other (2b) in Fig. 4b
  • the first type 2a is a partial turn connected to the underlying turn of the coil;
  • Type 2b is a partial turn belonging to the same winding as the first part turn.
  • connection conductors 13 are made flatter and wider than the slot bars 14, as illustrated by the cross-sectional views of FIG. 4c. And 2war the groove bars 14 have a height H and a width B, the latter, for example, is selected so that the groove bar 14 in the width fills a groove.
  • the height h of the connecting conductor 13 is, for example, one third of the height H of the slot bar 14, while conversely, the width b of the connecting conductor 13 is about three times as large as the width B of the slot bar 14. The conductor cross-section is thus in the slot bar 14 and connecting conductor 13 about the same.
  • the undersides of the grooved bar 14 and connecting conductor 13 lie on one level, but the top of the grooved bar 14 is higher than the top of the connecting conductor 13 according to the difference Hh.
  • thicker moldings than in the prior art are used Technology commonly used, so that the groove bars 15, for example, have a rectangular cross-section with the longer rectangle side in the groove direction (radial direction), as illustrated in Fig. 4c by dashed lines.
  • the mold parts 2 each have a flattened tongue 15 whose thickness is first in a neck region 16 about the height h of the connecting conductor 13 and in an adjoining connecting portion 17 "only a fraction of the height h, eg In the case of the first molded part type 2 a shown in FIG.
  • the attachment region 16 a of the tongue 15 a lies at the same height as the connecting conductor 13, that is to say at the lower side of the ignition rod 14
  • the transition between the regions 16 and 17 "takes place through a step which lies on the underside of the tongue 15 in both partial types Connecting region 17 '' thus leaves on the underside opposite the neck region 16 in each case a space in the amount of about one sixth of the Nutstabdicke free in each case the connecting surface 5 "of the upper part 2 at the connection point", which is soldered in the manner explained in FIGS. 1 and 2 with the complementary connecting surface 5 'of the lower Fo ⁇ nteils T same winding layer 3 or an underlying or overlying layer.
  • the connecting conductors 13 each have a connecting region 17 ', in which the height of the connecting conductor 13 in the region of the upper side is reduced for example to half or 0, 6 times the height h of the connecting conductor 13.
  • the top of this connection region 17 'or a part of it forms the connection surface 5'.
  • the sum of the thicknesses of the connecting region 17 "on the tongue 15 of the slot bar 14 and of the connecting region 17 'on the connecting conductor 13 is thus selected such that it corresponds approximately to the connecting conductor height h
  • the molded parts 2 have an insulating surface, formed for example by an insulating lacquer layer However, no insulating surface has the bonding surfaces 5 'and 5 ".
  • 5 illustrates the layered structure of the exemplary winding with overlapping coils from the mold parts according to FIG. 4 with the soldering method according to FIGS. 1 and 2.
  • the view marked "I - I" in FIG. 5 corresponds to the sectional view of the uppermost mold layer 3.3 and the soldering electrodes 7 of Fig. 1.
  • the moldings 2 are here - as in Figure 1 - shown for simplicity, without stand body and lying on a flat surface. in a support body of a radial field machine, on the other hand, they are arranged on the inside wall surface of a cylinder (FIG. 6).
  • a molding of the two-type 2b is used.
  • the molded part 2b is oriented so that it is rotated in relation to the illustration in Fig. 4b in the plane spanned by the Formte ⁇ l by 180 degrees.
  • the insertion takes place in turn so that now lie on the other end face of the stand connecting conductor 13b overlap like scales.
  • the overlapping direction is opposite to that of the overlap of the first type mold 2a (for example, the overlap of the mold of the first type 2a in Fig.
  • Shaped parts of the second type 2b now come to lie with their connecting surfaces 5 "on the connection surfaces 5 'of the first type 2a which have been freely accessible and have soldering pads 11.
  • this is shown by way of example for a molded part of the second type 2b
  • the adjoining connecting surfaces 5 ⁇ 5 are in turn soldered together by the electrode electrodes 7 according to the soldering method described above, as illustrated in Fig. 5.
  • the two molded parts 2a and 2b are connected to each other are, incidentally, therefore, in spite of the in Figs. 4a and 4b height offset shown the tongues 15a, 15b relative to the Verbin ⁇ ungslei- tera 13a, 13b at a height in the winding I 3 as the connection conductor through, the scarf en shame arrangement have a Schrägstelmng which is just compensated by said height offset.
  • the two mold parts 2a, 2b connected to one another thus form a, 360 "convolution lying in a plane of a coil 12, which overlap with other coils 12th of 'moldings is carried out by placing and soldering of other layers of the further structure of the overlapping each other coils 12th
  • Fig. 6 shows a perspective view of a section of the stator 19 of an electrical
  • FIG. 6 shows a processing state, in which of the lowermost winding layer 3.1, all moldings of the first type 2a and three moldings of the second
  • Type 2b are inserted in grooves 21 of the stator 19 (the latter are for better visibility with hatched surface shown).
  • FIG. 6 no longer shows the idealization of a planar development, but rather a curved construction of the winder, as is the case for example in a radial field machine of an internal rotor type. Thus, the actual winding is better visible, only the two end faces of the stand 19 are located.
  • the stator 19 is, however, generally a package of axially stacked sheets; the illustrated end faces of the stator 19 thus correspond approximately to the outermost plate of the laminated core.
  • the Lötvomchtung 20 has for this purpose a plurality of pairs of horrensetelektroden 7, which are arranged at a distance from each other, which corresponds to the distance of the solder joints 4, and their arrangement also optionally the krriii ⁇ mten arrangement of the connection points 4 follows.
  • the multiple-soldering device 20 includes three correspondingly arranged pairs of 'resistance soldering. 7 Accordingly, the multiple soldering apparatus 20 becomes with its soldering electrodes. 7 simultaneously placed on three contact points 4 on the contact surfaces; After the process described in FIGS. 1 and 2, three solder joints are thus produced in one operation.
  • the multiple soldering process is designed to solder a larger number of pairs of molds simultaneously, for example, to solder all pairs of moldings on one side of the stator 19.
  • the soldering electrodes are then arranged approximately on a circular line, for example, and are suitably (as seen from the circle center ) extendable to the outside, so that the soldering device 20 after.
  • Type of a ring with a smaller diameter than the stator 19 is retracted in the ring formed by the connecting conductors 13, the soldering electrodes 7 are then moved radially outward against the contact surfaces thereon, and thus the simultaneous soldering takes place. This allows, for example, the soldering of a winding with four winding layers in only eight such soldering operations.
  • Fig. 7 shows an embodiment of a portion of a stator 19 with ready-built winding 1.
  • Visible groove heads 22 which together form the air gap of the electric machine limiting stator surface, and behind which extend the filled with the mold parts grooves 21 radially outward ,
  • the connection conductors 13 of the molded parts 2 soldered to one another form a connecting conductor package 24 which extends annularly on each end face of the stator 19.
  • the electric machine whose winding is produced by the described method, it is, for example, a combined starter-generator of a motor vehicle with an internal combustion engine.
  • the starter-generator is a so-called crank-shaft starter generator, the rotor directly on the crankshaft or a crankshaft extension of the
  • FIG. 8 illustrates a power train drive system having a crankshaft ignition starter manufactured by the present soldering method. Namely, it has an internal combustion engine 26 that outputs torque to the drive wheels of the vehicle via a drive shaft 27 (eg, the crankshaft), a clutch 28, and other torque transmitting parts of a powertrain.
  • a drive shaft 27 eg, the crankshaft
  • a clutch 28 e.g., the clutch
  • the working as a starter and generator electric machine 29 sits, for example, a Asyncbron-Drehstromrmschine or equipped with permanent magnets synchronous three-phase machine.
  • the winding 1 of the stator 19 is fed, for example, by a polyphase inverter (in the case of a three-phase winding, for example, a three-phase inverter) with electric currents and voltages of freely adjustable amplitude, phase and frequency. Now returning to the winding moldings is still the process of pre-tinning of
  • Shaped or generally isolated workpieces which are isolated on the opposite surface of the connecting surface. 9 shows a device for pre-tinning a workpiece 2 and for simplification several exemplary embodiments in a representation.
  • the aim is to attach a certain amount of soldering material 11 to the junction 4 of a workpiece 2 with an insulation 50.
  • the workpiece 2 need not be insulated at the top and bottom, it may also be completely stripped or insulated only at the back.
  • Variously isolated workpieces 2 can be found, for example, in the case of molded parts which serve to construct an electrical machine. Such Forrnmaschine are shown for example in Figs. 1, 4 and 5.
  • the specific amount of soldering material is, for example, a soldering pad 11, which is already prefabricated on the connecting surface 4.
  • the Lotaufbringungselektroden 100 are placed after placing the solder pad 11 on the solder or attached to the solder pad 11.
  • the force with which the Lofaufbrr ⁇ gungs- lektroden 100 are placed depends on the intended effect. If the solder pad 11 is only to be fused, then it is sufficient to set up the solder application electrodes 100 with little force. However, if the solder deposition electrodes 100 are to additionally clamp the solder pad 11 to the workpiece 2, a higher seating force of the solder deposition electrodes 100 is necessary.
  • this mix is subjected to a suitable soldering voltage.
  • the heating current is for example
  • the power is supplied from a heater power generator 101 which includes a heater power analyzer 102 and a control unit 103.
  • the heating current flows after applying the voltage in the upper part of the solder pad 11. This heats up the ohmic resistance losses.
  • the solder charging electrodes 100 heat up and apply this heat to the soldering pad 11. Thereby, the soldering pad 11 softens and it becomes, depending on the flowed. Amount of current in corresponding phases of the reflow process.
  • the soldering current is analyzed by the soldering current analyzer 1Q2 and controlled by the control unit 103 so as to have the desired effect - ie just attaching the soldering pad U to the workpiece 2 or complete melting or all intervening forms of melting and softening be achieved.
  • the heating current is turned off and the solder application electrodes 100 are immediately removed from the solder pad 11, or held at the set position until the solder pad 11 solidifies.
  • IJI other exemplary embodiments Icomnat the solder material required for Vorverzinnung example in strand form of a Lötzi ⁇ nspule UO.
  • soldering strand is then pressed flat by two embossing rollers 112, and a corresponding soldering strip 115 is obtained.
  • the soldering tin coil 110, together with the embossing rollers 112, is operated in such a way that it is possible to forward and return the soldering strip 115.
  • the flat rolling of the Lötzinnspule coming Lötstranges is required for example in solder material in a round design. In other embodiments, already finish rolled solder material is used.
  • the end of the Lötstranges 115 is placed on the kauKe 4 of the workpiece 2, so that an electrical contact between the end of the Lötstranges 115 and the workpiece 2 is made at the junction 4.
  • the end of the soldering strand 115 is placed on the joint 4, there are various Ausföhiungsformen to produce the solder pad 11 and to attach.
  • a separate cutting device 120 is used, which separates the desired amount of Lötr ⁇ aterials VO ⁇ the soldering strand 115 and thus produces the solder pad 11.
  • the solder pad 11 is made by the solder application electrodes 100 during the above-described tacking operation.
  • the soldering electrodes 100 are controlled so as to be the end of the
  • soldering strand 115 soften or melt. Then, the soldering strand 115 is retracted by changing the rotational direction of the embossing rollers 112 and 110, as indicated by the arrow in FIG. 1. This has the consequence that a certain amount of solder material is separated from the soldering strand 115 and thereby the solder pad 11 is formed and at the same time adhered to the workpiece 2.
  • the controlled pre- and jerk thrust of Lötzinnspule 110 and the refgewaizen 112 also ensures the compensation of an erosion of the Lotaufbringungselektroden 100 occurs in the continuous operation.
  • solder deposition electrodes 100 When the solder deposition electrodes 100 are burned off by the use, the heated amount of soldering material and also the position of the solder deposition electrodes 100 on the end of the soldering strand 115 change, resulting in a change in the size of the resulting soldering pad 11.
  • This effect is achieved by changing the feed rate of the solder bobbin 110 and / or the embossing rollers 112, that is to say the length of the applied end of the soldering strand 115 onto the connection point. 4-, taken into account.
  • the solder pad 11 is made by merely melting the solder strand 115.
  • the control of the forward and backward movement of the soldering tin coil 110 and the embossing rolls 112 compensates for the burning off of the solder deposition electrodes 100 and thus also ensures that always the same amount of soldering material, ie the same size of the soldering pad to the workpiece 2 is attached.
  • the solder deposition electrodes 100 are formed to have a cutting action.
  • a certain amount of soldering material is separated from the soldering strand 115.
  • This type of trimming is simplified when the solder deposition electrodes 100 are additionally stressed, since this additionally leads to softening of the soldering material to be cut off.
  • Combinations of all execution forms outlined above are also realized.
  • the cutting of the solder material can be achieved by a combination of heating the solder deposition electrodes 100, cutting action of the solder deposition electrodes 100, and pushing back the solder strand 115.
  • solder application electrodes 100 to the soldering material 11 is to be understood as relative movement in all embodiments, since in some embodiments the workpiece 2 with the applied soldering material is applied to the solder application electrodes 100.
  • the embodiments differ in the timing of the voltage application of the solder deposition electrodes 100.
  • the solder application electrodes 100 are subjected to stress before or after the piecing operation.
  • the embodiments differ in terms of timing before or during removal of the solder application electrodes 100 to cease the voltage application.
  • the heating generator 101 is equipped with a heating current analyzer 102 which, as explained above, measures the current flowing during the pre-tin-plating, optionally smelting the measured current via the soldering process, and from this concludes the quality of the tin-plating.
  • this heating current analysis has only one monitoring function, that is to say in the case of the detection of an improper current flow, for example, there is a corresponding indication to an operator supervising the tinning process.
  • the Schumanlysator 102 is coupled to a control unit 103 of the soldering generator 101, that in the course of the Verzrn Vietnamesesvorgangs optionally takes place a corrective intervention.
  • the tinning is usually carried out with a preset number of n half-waves (for example 6 half-waves), then in the case of detection of insufficient current flow during these n half-worlds the soldering process can be continued by up to m further half-waves (for example at another 3 half waves), depending on the result of the Schustror ⁇ analyse the respective Verzkra ⁇ gs- or attachment process.
  • n half-waves for example 6 half-waves
  • FIG. 10 The process described above is shown in FIG. 10 in the form of a flow chart.
  • a workpiece to be pre-tinned is provided (SlO).
  • the solder material is positioned on a joint of the workpiece (Sil).
  • the Lota ⁇ irbringu.ngselektroden be attached to the solder material (S 12) andcipbeauf- scblagt (S 13).
  • the now flowing soldering flux causes the soldering material to melt or soften.
  • the saving operation is ended (S 14).
  • the solder deposition electrodes are lifted off (S15). The sequence Sil to S15 is repeated until all connection points of said.
  • the pre-tinned workpieces may be, for example, fo ⁇ nmaschine that serve to build an electrical machine.
  • the described embodiments allow a simple production of molded part winding hangings and electrical machines equipped with such windings.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

L'invention concerne un procédé pour fabriquer un enroulement (1) pour une machine électrique (29) à partir de pièces usinées (2) pour enroulements pourvues d'une face supérieure (6) isolée et de surfaces de raccordement (5) non isolées à braser. Le procédé consiste à placer une pièce usinée (2) sur un socle (3) prémonté de pièces usinées (2) assemblées par brasage, de sorte que, sur un point de jonction (4) à braser, sont superposées une surface de raccordement (5) d'une pièce usinée (2) du socle (3) prémonté et une surface de raccordement (5) de la pièce usinée (2) posée, avec une soudure intermédiaire. Selon l'invention, au moins deux électrodes (7) de soudure sont placées sur la face supérieure (6) isolée de la pièce supérieure (2') parmi les pièces usinées à raccorder, dans la zone du point de jonction (4) à braser, ces électrodes (7) de soudure étant ensuite mises sous tension. La couche isolante des électrodes (7) de soudure est alors traversée, de sorte qu'un courant de brasage passe dans la pièce usinée supérieure (2'), le réchauffement dû à la résistance provoquant ainsi le brasage des pièces usinées (2', 2') au point de jonction (4).
PCT/DE2005/002135 2004-12-16 2005-11-26 Fabrication d'un enroulement de pièce usinée WO2006063551A1 (fr)

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Publication number Priority date Publication date Assignee Title
US20200287446A1 (en) * 2013-12-18 2020-09-10 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same
US11955850B2 (en) 2013-12-18 2024-04-09 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007014852B4 (de) * 2007-03-28 2012-09-06 Audi Ag Verfahren zur Herstellung einer nahtförmigen Lötverbindung und Vorrichtung zur Durchführung des Verfahrens

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JPS5272345A (en) * 1975-12-13 1977-06-16 Sato Ryoda Resistance welding machine
DD136466A1 (de) * 1978-05-11 1979-07-11 Manfred Heerdt Verfahren zum widerstandsschweissen von blechen
JPS60240389A (ja) * 1984-05-15 1985-11-29 Yashima Denki Kk スポツト溶接方法
JPH05114450A (ja) * 1991-10-21 1993-05-07 Hitachi Ltd 絶縁被覆導線の接合方法及び接合体
WO2001095461A1 (fr) * 2000-06-08 2001-12-13 Continental Isad Electronic Systems Gmbh & Co. Ohg Enroulement a pieces moulees, procede et ensemble de pieces moulees pour machines electriques
EP1328044A2 (fr) * 2002-01-15 2003-07-16 Hitachi, Ltd. Stucture de connexion et son procédé, machine rotative et générateur à courant alternative avec cette structure et cette méthode

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Publication number Priority date Publication date Assignee Title
JPS5272345A (en) * 1975-12-13 1977-06-16 Sato Ryoda Resistance welding machine
DD136466A1 (de) * 1978-05-11 1979-07-11 Manfred Heerdt Verfahren zum widerstandsschweissen von blechen
JPS60240389A (ja) * 1984-05-15 1985-11-29 Yashima Denki Kk スポツト溶接方法
JPH05114450A (ja) * 1991-10-21 1993-05-07 Hitachi Ltd 絶縁被覆導線の接合方法及び接合体
WO2001095461A1 (fr) * 2000-06-08 2001-12-13 Continental Isad Electronic Systems Gmbh & Co. Ohg Enroulement a pieces moulees, procede et ensemble de pieces moulees pour machines electriques
EP1328044A2 (fr) * 2002-01-15 2003-07-16 Hitachi, Ltd. Stucture de connexion et son procédé, machine rotative et générateur à courant alternative avec cette structure et cette méthode

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PATENT ABSTRACTS OF JAPAN vol. 017, no. 473 (E - 1423) 27 August 1993 (1993-08-27) *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200287446A1 (en) * 2013-12-18 2020-09-10 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same
US11804757B2 (en) * 2013-12-18 2023-10-31 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same
US11955850B2 (en) 2013-12-18 2024-04-09 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same
US12088158B2 (en) 2013-12-18 2024-09-10 Aster Co., Ltd. Cold pressure welding apparatus, coil manufacturing apparatus, coil, and method of manufacturing the same

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