WO2019188036A1 - 接合体、回転電機、及び回転電機の製造方法 - Google Patents
接合体、回転電機、及び回転電機の製造方法 Download PDFInfo
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- WO2019188036A1 WO2019188036A1 PCT/JP2019/008568 JP2019008568W WO2019188036A1 WO 2019188036 A1 WO2019188036 A1 WO 2019188036A1 JP 2019008568 W JP2019008568 W JP 2019008568W WO 2019188036 A1 WO2019188036 A1 WO 2019188036A1
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- terminal
- mold
- coil
- joint surface
- convex portion
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- 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
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/02—Windings characterised by the conductor material
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/18—Windings for salient poles
Definitions
- the present invention relates to a joined body, a rotating electrical machine, and a method for manufacturing the rotating electrical machine.
- an aluminum wire is sometimes used for a coil wound around a stator of a rotating electrical machine. Thereby, the weight reduction and manufacturing cost of a rotary electric machine can be reduced.
- a connection terminal such as a terminal with solder.
- various techniques for joining an aluminum wire to a connection terminal such as a terminal by resistance welding have been proposed.
- resistance welding metals to be welded are overlapped, a welding location is sandwiched between electrodes, an appropriate pressure is applied to the material to be welded by this electrode, and current is supplied to the material to be welded. Then, each other is melt-bonded by Joule heat generated by the contact resistance of the welded part.
- the present invention provides a joined body, a rotating electrical machine, and a manufacturing method of the rotating electrical machine that can sufficiently ensure peel strength by resistance welding.
- the joined body overlaps the first joined surface of the first joined body and the second joined surface of the second joined body, Having a joint where the first joint surface and the second joint surface are joined by resistance welding, and at least one recess is formed on either the first joint surface or the second joint surface; At least one convex portion that fits into the concave portion is formed on one of the first joint surface and the second joint surface.
- the concave portion and the convex portion are formed in a rectangular cross section.
- the concave portion and the convex portion have a substantially rectangular cross section, so that the convex portion is not easily removed from the concave portion. For this reason, the anchor effect between a 1st to-be-joined body and a 2nd to-be-joined body increases, and the peeling strength of a 1st to-be-joined body and a 2nd to-be-joined body can be raised.
- the concave portion and the convex portion are unidirectional with respect to the first joined body and the second joined body. Are formed long and are arranged in a row in the other direction orthogonal to the one direction.
- the anchor effect between the first bonded body and the second bonded body can be reliably enhanced.
- the concave portion and the convex portion are from the normal direction of the first joint surface and the second joint surface. It is formed in an annular shape.
- the anchor effect between the first bonded body and the second bonded body can be reliably enhanced.
- the mechanical strength of the mold is increased by the amount of the recesses and projections being annular, and the molding life of the mold can be increased.
- the concave portion and the convex portion have a quadrangular shape when viewed from the normal direction of the first joint surface and the second joint surface. Is formed.
- the rotating electrical machine is a rotating electrical machine having the joined body according to any one of the first to fifth aspects of the present invention, wherein the first joined body is:
- the coil is made of an aluminum alloy wound around a stator, and the second joined body is a terminal.
- the seventh aspect of the present invention there is provided a method for manufacturing a rotating electrical machine according to the sixth aspect of the present invention, wherein the first mold and the second mold are formed from both sides in the thickness direction of the terminal in the rotating electrical machine described above. Is applied to the second joint surface to form one of the convex portion and the concave portion, and the first pressing surface of the first mold and One of the second pressing surfaces of the second mold is provided with a mold protrusion for forming the recess, and the first pressing surface of the first mold and the second pressing surface of the second mold.
- a mold concave portion for receiving the mold convex portion is provided on a surface facing the mold convex portion, and the mold convex portion and the mold concave portion have a cross section. It is formed in a rectangular shape.
- the first bonded body and the second bonded body are respectively pressed using the first mold and the second mold, so that the first bonded body of the first bonded body is processed.
- a concave portion or a convex portion having a substantially rectangular cross section can be easily and reliably formed on one joint surface.
- a method for manufacturing a rotating electrical machine wherein the first mold and the second mold are formed from both sides in the thickness direction of the terminal in the rotating electrical machine described above. Is applied to the second joint surface to form one of the convex portion and the concave portion, and the first pressing surface of the first mold and One of the second pressing surfaces of the second mold is provided with a mold protrusion for forming the recess, and the first pressing surface of the first mold and the second pressing surface of the second mold. Either one of the two pressing surfaces is a flat surface.
- the convex portion fits into the concave portion, whereby an anchor effect can be generated between the first joined body and the second joined body at the joined portion. For this reason, when the 1st to-be-joined body and the 2nd to-be-joined body are resistance-welded, the peeling strength of these two to-be-joined bodies can fully be ensured.
- FIG. 1 is a perspective view of the rotating electrical machine 1 as viewed from one side in the axial direction.
- FIG. 2 is a perspective view of the rotating electrical machine 1 as viewed from the other side in the axial direction.
- the axial direction refers to the rotational axis direction of the rotating electrical machine 1.
- the rotating electrical machine 1 is used, for example, to start a vehicle engine or to generate electric power by using rotation of a crankshaft (not shown) of the vehicle engine.
- a crankshaft not shown
- the rotating electrical machine 1 includes a stator 2 fixed to an engine block (not shown) and a rotor 3 fixed to a crankshaft (not shown) and formed to cover the periphery of the stator 2.
- the rotation axis direction of the rotor 3 is the rotation axis direction of the rotating electrical machine 1.
- the rotational direction of the rotor 3 is described as the circumferential direction, the axial direction, and the radial direction of the rotor 3 orthogonal to the circumferential direction is simply referred to as the radial direction.
- illustration of the rotor 3 is omitted.
- the stator 2 electrically connects a stator core 4, an insulator 5 attached to the stator core 4, a plurality of coils 6 wound around the stator core 4 via the insulator 5, and a harness 7 extending from these coils 6 and the outside. And a plurality of (two in the first embodiment) terminals 8 connected to each other.
- the stator core 4 is formed by laminating electromagnetic steel plates or press-molding soft magnetic powder.
- the stator core 4 has a main body portion 4a formed in a substantially annular shape, and a plurality of tooth portions 4b that project radially outward from the outer peripheral surface of the main body portion 4a.
- the insulator 5 is formed so as to cover the periphery of the tooth portion 4b and to expose both end surfaces in the axial direction of the main body portion 4a. And the some coil 6 is wound by the concentrated winding system on each teeth part 4b from the top of the insulator 5.
- the terminal 8 is obtained by tinning the surface of a metal plate such as iron that is long in the axial direction.
- the terminal 8 is provided so as to penetrate the main body portion 4a of the stator core 4 in the axial direction while being insulated from the stator core 4. Both ends of the terminal 8 in the axial direction protrude from both ends of the main body 4a in the axial direction.
- the first end portion 11 (see FIG. 1) of the terminal 8 protruding to one side in the axial direction of the main body portion 4a is formed in a bifurcated shape.
- One end of the harness 7 is connected so as to be sandwiched between the first end portions 11.
- the harness 7 is a copper wire, for example, and is joined to the terminal 8 by solder or the like.
- the terminal portion 6a of the coil 6 drawn from the tooth portion 4b is joined to the second end portion 12 (see FIG. 2) of the terminal 8 protruding to the other axial side of the main body portion 4a.
- a joined body 10 is constituted by the terminal portion 6 a of the coil 6 and the terminal 8.
- the coil 6 is formed of an aluminum alloy, and is joined to the second end portion 12 of the terminal 8 by resistance welding (for example, spot welding).
- resistance welding for example, spot welding
- FIG. 3 is a simplified diagram illustrating the configuration of the joined body 10.
- the joined body 10 includes a joint portion 13 in which the terminal portion 6 a of the coil 6 and the terminal 8 are joined.
- One coil recess 15 is formed on the coil-side bonding surface 14, which is a surface bonded to the terminal 8 of the coil 6, in the bonding portion 13.
- the coil recess 15 is formed to have a rectangular cross section so as to extend in the short direction of the terminal 8.
- One terminal convex portion 17 that can be fitted into the coil concave portion 15 is formed at a position corresponding to the coil concave portion 15 on the terminal side joint surface 16 that is a surface to be joined to the coil 6 of the terminal 8 in the joint portion 13. ing.
- the terminal convex portion 17 is formed in a rectangular cross section so as to correspond to the cross sectional shape of the coil concave portion 15.
- a terminal recess 17 a is formed on a surface 8 a (hereinafter referred to as a back surface 8 a) opposite to the terminal side joining surface 16 of the terminal 8 so as to correspond to the terminal protrusion 17.
- FIG. 4 is an explanatory view showing a processing method of the terminal 8.
- the terminal 8 is formed on the terminal-side joining surface 16 of the terminal 8 by pressing using the molds 18 and 19 (the first mold 18 and the second mold 19).
- a convex portion 17 is formed.
- the first mold 18 is set at a position facing the terminal side joining surface 16 of the terminal 8.
- the second mold 19 is set at a position facing the first mold 18 across the terminal 8.
- a mold recess 18 a having a rectangular cross section is formed on the first pressing surface 18 b on the terminal 8 side.
- a mold convex portion 19 a that can be fitted into the mold concave portion 18 a of the first mold 18 is formed on the second pressing surface 19 b on the terminal 8 side.
- the terminal 8 is pinched
- the terminal convex portion 17 is formed on the terminal side joining surface 16 of the terminal 8, and the terminal concave portion 17 a is formed on the back surface 8 a of the terminal 8.
- the electrodes 21 and 22 are respectively applied to the coil 6 and the terminal 8 from the side opposite to the coil side joining surface 14 of the coil 6 and the back surface 8 a side of the terminal 8.
- the second electrode 22 is pressed.
- a voltage is applied to the coil 6 and the terminal 8 through each electrode 21 and 22 while the coil 6 and the terminal 8 are pressurized with a predetermined pressure by each electrode 21 and 22.
- the coil recess 15 is formed on the coil-side joint surface 14 on which the joint 13 is formed by resistance welding.
- a terminal convex portion 17 is formed on the terminal side joint surface 16 on which the joint portion 13 is formed. Then, the coil 6 and the terminal 8 are melt-bonded so that the terminal convex portion 17 fits into the coil concave portion 15. For this reason, an anchor effect can be produced between the coil 6 and the terminal 8 by the coil concave portion 15 and the terminal convex portion 17. Therefore, it is possible to sufficiently ensure the peel strength between the coil 6 and the terminal 8 in the resistance welded joined body 10.
- the coil concave portion 15 and the terminal convex portion 17 are each formed in a rectangular cross section. For this reason, when the terminal convex part 17 tries to come out from the coil concave part 15, the corner part of the terminal convex part 17 is caught on the inner surface of the coil concave part 15, and the terminal convex part 17 is hard to come off from the coil concave part 15. Therefore, the anchor effect between the coil 6 and the terminal 8 is further enhanced, and the peel strength between the coil 6 and the terminal 8 can be further increased.
- two coil concave portions 15 may be formed in the coil 6 and two terminal convex portions 17 may be formed in the terminal 8 so as to correspond thereto.
- the two terminal protrusions 17 are each formed to extend long in one direction (for example, the short direction of the terminal 8), and are arranged in the other direction (for example, the longitudinal direction of the terminal 8) orthogonal to the one direction. Has been placed. By comprising in this way, the anchor effect between the coil 6 and the terminal 8 can further be heightened.
- the coil concave portion 15 and the terminal convex portion 17 may be formed in an annular shape when viewed from the normal direction of the coil side joint surface 14 and the terminal side joint surface 16.
- die 19 become cyclic
- the present invention is not limited to this, and the coil concave portion 15 into which the terminal convex portion 17 can be fitted may be formed in the coil 6 in advance.
- the terminal convex portion 17 of the terminal 8 can be fitted in the coil concave portion 15 of the coil 6 in advance during resistance welding. For this reason, the positional relationship between the coil side joining surface 14 and the terminal side joining surface 16 can be determined with high accuracy.
- the mold concave portion 18 a is formed on the first pressing surface 18 b of the first mold 18, while the mold convex portion 19 a is formed on the second pressing surface 19 b of the second mold 19.
- the present invention is not limited thereto, and the mold convex portion 19a is formed on the first pressing surface 18b of the first mold 18, while the mold concave portion 18a is formed on the second pressing surface 19b of the second mold 19. May be formed.
- the arrangement of the first mold 18 and the second mold 19 may be reversed across the terminal 8.
- FIG. 6 is a simplified diagram showing the configuration of the joined body 210 in the second embodiment, and corresponds to FIG. 3 described above.
- the same aspects as those in the first embodiment described above are denoted by the same reference numerals and description thereof is omitted.
- the coil 206 constituting the joined body 210 is formed of an aluminum alloy, and the terminal 208 is obtained by tin plating the surface of a metal plate such as iron that is long in the axial direction.
- Basic configurations such as points are the same as those in the first embodiment.
- the difference between the first embodiment and the second embodiment is that the coil concave portion 15 and the terminal convex portion 17 of the first embodiment are reversely formed by the terminal concave portion 215 and the coil convex portion 217 of the second embodiment. It is a point that has been. That is, as shown in FIG. 6, in the joint portion 213 between the coil 206 and the terminal 208, one terminal recess 215 is formed on the terminal-side joint surface 216. One coil convex portion 217 that fits into the terminal concave portion 215 is formed on the coil side joining surface 214. Further, the terminal recess 215 and the coil protrusion 217 are formed so as to extend in the short direction of the terminal 208. A surface 208a of the terminal 208 opposite to the terminal side joining surface 216 (hereinafter referred to as a back surface 208a) is formed flat.
- FIG. 7 is an explanatory view showing a processing method of the terminal 208.
- the terminal 208 is subjected to press working using the molds 218 and 219 (the first mold 218 and the second mold 219), so that the terminal recess 215 ( 6) is formed.
- the first mold 218 is set at a position facing the terminal side joining surface 216 of the terminal 208.
- the second mold 219 is set at a position facing the first mold 218 across the terminal 8.
- a mold protrusion 218a having a rectangular cross section is formed on the first pressing surface 218b on the terminal 208 side.
- the second pressing surface 219b on the terminal 208 side is formed flat.
- the terminal 208 is pinched
- a terminal recess 215 is formed in the terminal side joint surface 216 of the terminal 208.
- the contact area between the back surface 208a of the terminal 208 and the second electrode 22 is recessed in the back surface 208a of the terminal 208 (for example, the terminal recess 17a in FIG. 3). It increases compared with the case where is formed. For this reason, the contact resistance between the terminal 208 and the second electrode 22 is reduced, and a voltage can be efficiently applied to the terminal 208.
- the second embodiment described above can achieve the same effects as those of the first embodiment described above.
- the second pressing surface 219b of the second mold 219 is formed flat.
- the back surface 208a of the terminal 208 can be made flat.
- two coil convex portions 217 may be formed on the coil 206, and two terminal concave portions 215 may be formed on the terminal 208 so as to correspond thereto.
- the anchor effect between the coil 206 and the terminal 208 can be further enhanced.
- the terminal concave portion 215 and the coil convex portion 217 may be formed in an annular shape when viewed from the normal direction of the coil side joint surface 214 and the terminal side joint surface 216.
- die 218 becomes cyclic
- the terminal 208 is formed with an annular and rectangular terminal recess 215
- the terminal 208 needs to be evacuated as much as the terminal 208 is depressed.
- the terminal recess 215 is to be formed in an annular quadrangular shape, it is necessary to escape more meat. Therefore, by forming relief portions 208b on both sides in the short direction of the terminal 208, the terminal recess 215 can be formed while keeping the back surface 208a of the terminal 208 flat.
- the location where the relief portion 208b is formed is not limited to both sides in the short direction of the terminal 208, and can be arbitrarily set.
- the escape portion 208 b may be formed at the longitudinal end portion of the terminal 208.
- the present invention is not limited to this, and a coil convex portion 217 that can be fitted into the terminal concave portion 215 may be formed in the coil 206 in advance.
- the coil convex portion 217 of the coil 206 can be fitted in the terminal concave portion 215 of the terminal 208 in advance during resistance welding. For this reason, the positional relationship between the coil side joining surface 214 of the coil 206 and the terminal side joining surface 216 of the terminal 208 can be determined with high accuracy.
- the mold convex portion 218a is formed on the first pressing surface 218b of the first mold 218 while the second pressing surface 219b of the second mold 219 is formed flat has been described.
- the present invention is not limited thereto, and the first pressing surface 18b of the first mold 18 may be formed flat, while the mold convex portion 218a may be formed on the second pressing surface 19b of the second mold 19. Good.
- the terminal 208 is pressed, the arrangement of the first mold 218 and the second mold 219 may be reversed with the terminal 208 interposed therebetween.
- the present invention is not limited to the above-described embodiment, and includes various modifications made to the above-described embodiment without departing from the spirit of the present invention.
- the rotating electrical machine 1 has been described as being used, for example, to start a vehicle engine or to generate power using rotation of a crankshaft of a vehicle engine.
- the present invention is not limited to this, and it can be used for driving various devices and generating electricity.
- the case where the coils 6 and 206 are formed of an aluminum alloy has been described. Furthermore, the terminal 8 and 208 demonstrated the case where the tin plating was given to the surface of metal plates, such as iron long in an axial direction.
- the present invention is not limited to these, and various conductive members can be used for the coils 6, 206 and the terminals 8, 208.
- the convex portion fits into the concave portion, whereby an anchor effect can be generated between the first joined body and the second joined body at the joined portion. For this reason, when the 1st to-be-joined body and the 2nd to-be-joined body are resistance-welded, the peeling strength of these two to-be-joined bodies can fully be ensured.
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Abstract
Description
本願は、2018年3月27日に、日本に出願された特願2018-059863号に基づき優先権を主張し、その内容をここに援用する。
ところで、例えばターミナル等の接続端子に、アルミ線をはんだにより接合するのは困難である。このため、ターミナル等の接続端子に、抵抗溶接によってアルミ線を接合するさまざまな技術が提案されている。
抵抗溶接は、被溶接材の金属を重ね合わせ、溶接する箇所を電極で挟み、この電極によって被溶接材に適当な加圧力を加えて被溶接材に電流を供給する。すると、溶接部位の接触抵抗により発生するジュール熱で、お互いが溶融接着される。
(回転電機)
図1は、回転電機1を軸方向一方側からみた斜視図である。図2は、回転電機1を軸方向他方側からみた斜視図である。軸方向とは、回転電機1の回転軸線方向をいう。
図1、図2に示すように、回転電機1は、例えば、車両用エンジンを始動するために用いられたり車両用エンジンのクランクシャフト(不図示)の回転を利用して発電するために用いられたりする。
ステータコア4は、電磁鋼板を積層したり、軟磁性粉を加圧成形したりして形成される。ステータコア4は、略円環状に形成された本体部4aと、本体部4aの外周面から径方向外側に向かって放射状に突出する複数のティース部4bとを有している。
ターミナル8は、ステータコア4と絶縁された状態で、このステータコア4の本体部4aを軸方向に貫通するように設けられている。ターミナル8の軸方向両端は、本体部4aの軸方向両端から突出している。本体部4aの軸方向一方側に突出しているターミナル8の第1端部11(図1参照)は、二股状に形成されている。この第1端部11に挟持されるように、ハーネス7の一端が接続されている。ハーネス7は、例えば銅線であり、ターミナル8とはんだ等により接合されている。
ここで、コイル6は、アルミ合金により形成されており、ターミナル8の第2端部12と抵抗溶接(例えば、スポット溶接)により接合されている。以下、接合体10について詳述する。
図3は、接合体10の構成を示す簡略図である。
図3に示すように、接合体10は、コイル6の端末部6aとターミナル8とが接合された接合部13を有する。接合部13には、コイル6のターミナル8と接合される面であるコイル側接合面14に、コイル凹部15が1つ形成されている。コイル凹部15は、ターミナル8の短手方向に延在するように、かつ断面矩形状に形成されている。
接合部13におけるターミナル8のコイル6と接合される面であるターミナル側接合面16には、コイル凹部15に対応する位置に、このコイル凹部15に嵌入可能なターミナル凸部17が1つ形成されている。ターミナル凸部17は、コイル凹部15の断面形状に対応するように、断面矩形状に形成されている。ターミナル8のターミナル側接合面16とは反対側の面8a(以下、裏面8aという)には、ターミナル凸部17に対応するように、ターミナル凹部17aが形成されている。
次に、図4に基づいて、ターミナル8の加工方法について説明する。
図4は、ターミナル8の加工方法を示す説明図である。
図4に示すように、ターミナル8は、金型18,19(第1金型18、第2金型19)を用いてプレス加工を施すことにより、ターミナル8のターミナル側接合面16に、ターミナル凸部17(図3参照)が形成される。
第1金型18には、ターミナル8側の第1押圧面18bに、断面矩形状の金型凹部18aが形成されている。第2金型19には、ターミナル8側の第2押圧面19bに、第1金型18の金型凹部18aに嵌入可能な金型凸部19aが形成されている。そして、これら2つの金型18,19の各押圧面18b,19bによってターミナル8を挟み、所定の圧力で加圧する(図4における矢印参照)。すると、図3に示すように、ターミナル8のターミナル側接合面16にターミナル凸部17が形成されるとともに、ターミナル8の裏面8aにターミナル凹部17aが形成される。
次に、コイル6とターミナル8との接合手順について説明する。
まず、コイル6のコイル側接合面14とターミナル8のターミナル側接合面16とを重ね合わせる。このとき、ターミナル8のターミナル側接合面16には、ターミナル凸部17が形成されている。このため、実際は、ターミナル凸部17にコイル6のコイル側接合面14が当接した状態で、その他の箇所は、コイル6とターミナル8との間に微小隙間が形成される。
上述の第1実施形態では、コイル6にコイル凹部15が1つ形成されているとともに、ターミナル8にターミナル凸部17が1つ形成されている場合について説明した。
しかしながら、これに限られるものではなく、コイル6にコイル凹部15を複数形成するとともに、ターミナル8にターミナル凸部17を複数形成してもよい。
コイル凹部15、及びターミナル凸部17を、コイル側接合面14及びターミナル側接合面16の法線方向からみて環状に加え、四角形状とすることが望ましい。このように構成することで、抵抗溶接した後のコイル6とターミナル8との相対位置のずれを確実に防止できる。また、コイル6とターミナル8との間のアンカー効果をさらに高めることができる。
(接合体)
次に、図6~図9に基づいて、第2実施形態について説明する。
図6は、第2実施形態における接合体210の構成を示す簡略図であって、前述の図3に対応している。前述の第1実施形態と同一態様には、同一符号を付して説明を省略する。
第2実施形態において、接合体210を構成するコイル206は、アルミ合金により形成されている点、ターミナル208は、軸方向に長い鉄等の金属板の表面に錫メッキが施されたものである点、等の基本的構成は、前述の第1実施形態と同様である。
すなわち、図6に示すように、コイル206とターミナル208との接合部213において、ターミナル側接合面216には、ターミナル凹部215が1つ形成されている。コイル側接合面214には、ターミナル凹部215に嵌るコイル凸部217が1つ形成されている。さらに、ターミナル凹部215及びコイル凸部217は、ターミナル208の短手方向に延在するように形成されている。ターミナル208のターミナル側接合面216とは反対側の面208a(以下、裏面208aという)は、平坦に形成されている。
次に、図7に基づいて、ターミナル208の加工方法について説明する。
図7は、ターミナル208の加工方法を示す説明図である。
図7に示すように、ターミナル208は、金型218,219(第1金型218、第2金型219)を用いてプレス加工を施すことにより、ターミナル側接合面216に、ターミナル凹部215(図6参照)が形成される。
第1金型218には、ターミナル208側の第1押圧面218bに、断面矩形状の金型凸部218aが形成されている。第2金型219は、ターミナル208側の第2押圧面219bが平坦に形成されている。そして、これら2つの金型218,219の各押圧面218b,219bによってターミナル208を挟み、所定の圧力で加圧する(図7における矢印参照)。すると、図6に示すように、ターミナル208のターミナル側接合面216にターミナル凹部215が形成される。
次に、コイル206とターミナル208との接合手順について説明する。
まず、コイル206のコイル側接合面214とターミナル208のターミナル側接合面216とを重ね合わせる。
この状態で、図6に示すように、コイル206のコイル側接合面214とは反対側、及びターミナル208のターミナル側接合面216とは反対側から、これらコイル206とターミナル208にそれぞれ電極21,22(第1電極21、第2電極22)を押し当てる。そして、これらコイル6とターミナル8にそれぞれ電極21,22(第1電極21、第2電極22)を押し当てる。この後、各電極21,22によってコイル206とターミナル208とを所定の圧力で加圧しながら、各電極21,22を介してコイル206及びターミナル208に電圧を印加する。
このとき、ターミナル208に形成されているターミナル凹部215に、溶融されたコイル206の一部が流れ込み、コイル206にコイル凸部217が形成される。さらに、コイル側接合面214とターミナル側接合面216とが溶融接着されて、接合部213が形成される。このとき、ターミナル208のターミナル凹部215とコイル6に形成されたコイル凸部217とが嵌り合った状態(図6参照)でコイル206とターミナル208とが溶融接着される。
ターミナル208にプレス加工を施す2つの金型218,219のうち、第2金型219の第2押圧面219bが平坦に形成されている。このため、ターミナル208のターミナル側接合面216にターミナル凹部215を形成する際、ターミナル208の裏面208aを平坦にすることができる。この結果、抵抗溶接の際、ターミナル208と第2電極22との接触抵抗が減少し、効率よくターミナル208に電圧を印加することができる。
上述の第2実施形態では、コイル206にコイル凸部217が1つ形成されているとともに、ターミナル208にターミナル凹部215が1つ形成されている場合について説明した。しかしながら、これに限られるものではなく、コイル206にコイル凸部217を複数形成するとともに、ターミナル208にターミナル凹部215を複数形成してもよい。
ターミナル凹部215、及びコイル凸部217を、コイル側接合面214及びターミナル側接合面216の法線方向からみて環状に加え、四角形状とすることが望ましい。このように構成することで、抵抗溶接した後のコイル206とターミナル208との相対位置のずれを確実に防止できる。また、コイル206とターミナル208との間のアンカー効果をさらに高めることができる。
図9に示すように、ターミナル208にターミナル凹部215を形成する一方、裏面208aを平坦にする場合、ターミナル208を押し凹ます分、ターミナル208の肉の逃げが必要になる。とりわけ、ターミナル凹部215を環状の四角形状に形成しようとすると、その分多くの肉の逃げが必要になる。そこで、ターミナル208の短手方向両側辺に、逃げ部208bを形成することにより、ターミナル208の裏面208aを平坦に維持しながら、ターミナル凹部215を形成することを可能とした。
逃げ部208bの形成箇所はターミナル208の短手方向両側辺に限られるものではなく、任意に設定することができる。例えば、ターミナル208の長手方向端部に、逃げ部208bを形成してもよい。
例えば、上述の実施形態では、回転電機1は、例えば、車両用エンジンを始動するために用いられたり車両用エンジンのクランクシャフトの回転を利用して発電するために用いられたりする場合について説明した。しかしながら、これに限られるものではなく、さまざまな機器の駆動用、発電用として用いることが可能である。
Claims (8)
- 第1被接合体の第1接合面と、第2被接合体の第2接合面とを重ね合わせ、抵抗溶接によって前記第1接合面と前記第2接合面とが接合される接合部を有し、
前記第1接合面及び前記第2接合面のいずれか一方に、少なくとも1つの凹部が形成され、
前記第1接合面及び前記第2接合面のいずれか他方に、前記凹部に嵌る少なくとも1つの凸部が形成されている
接合体。 - 前記凹部及び前記凸部は、断面矩形状に形成されている請求項1に記載の接合体。
- 前記凹部及び前記凸部は、前記第1被接合体及び前記第2被接合体の一方向に長く形成されており、前記一方向と直交する他方向に並んで複数形成されていることを特徴とする請求項1又は請求項2に記載の接合体。
- 前記凹部及び前記凸部は、前記第1接合面及び前記第2接合面の法線方向からみて環状に形成されている
請求項1又は請求項2に記載の接合体。 - 前記凹部及び前記凸部は、前記第1接合面及び前記第2接合面の法線方向からみて四角形状に形成されている
請求項4に記載の接合体。 - 請求項1~請求項5のいずれか1項に記載の接合体を有する回転電機であって、
前記第1被接合体は、ステータに巻回されているアルミ合金からなるコイルであり、
前記第2被接合体は、ターミナルである
回転電機。 - 請求項6に記載の回転電機における前記ターミナルの厚さ方向両面から第1金型と第2金型とを押圧してプレス加工を施すことにより、前記第2接合面に前記凸部及び前記凹部のいずれか一方を形成する回転電機の製造法であって、
前記第1金型の第1押圧面及び前記第2金型の第2押圧面のいずれか一方には、前記凹部を形成するための金型凸部が設けられ、
前記第1金型の第1押圧面及び前記第2金型の第2押圧面のいずれか他方には、前記金型凸部と対向する面に、前記金型凸部を受け入れる金型凹部が設けられており、
前記金型凸部と前記金型凹部は、断面矩形状に形成されている回転電機の製造方法。 - 請求項6に記載の回転電機における前記ターミナルの厚さ方向両面から第1金型と第2金型とを押圧してプレス加工を施すことにより、前記第2接合面に前記凸部及び前記凹部のいずれか一方を形成する回転電機の製造法であって、
前記第1金型の第1押圧面及び前記第2金型の第2押圧面のいずれか一方には、前記凹部を形成するための金型凸部が設けられ、
前記第1金型の第1押圧面及び前記第2金型の第2押圧面のいずれか他方は、平坦面である
回転電機の製造方法。
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JPH02303689A (ja) * | 1989-05-19 | 1990-12-17 | Matsushita Electric Works Ltd | 接点材料の接合方法 |
JP2015053853A (ja) * | 2014-10-17 | 2015-03-19 | 三菱電機株式会社 | モーターの固定子 |
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JPH02303689A (ja) * | 1989-05-19 | 1990-12-17 | Matsushita Electric Works Ltd | 接点材料の接合方法 |
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