WO2020151459A1 - 一种高效率扁线电机绕组端部焊接装置及焊接工艺 - Google Patents

一种高效率扁线电机绕组端部焊接装置及焊接工艺 Download PDF

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Publication number
WO2020151459A1
WO2020151459A1 PCT/CN2019/129702 CN2019129702W WO2020151459A1 WO 2020151459 A1 WO2020151459 A1 WO 2020151459A1 CN 2019129702 W CN2019129702 W CN 2019129702W WO 2020151459 A1 WO2020151459 A1 WO 2020151459A1
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Prior art keywords
solder
tray
stator
welding
winding end
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PCT/CN2019/129702
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English (en)
French (fr)
Inventor
刘蕾
朱标龙
马文明
孙纯哲
田旭
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合肥巨一动力系统有限公司
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Application filed by 合肥巨一动力系统有限公司 filed Critical 合肥巨一动力系统有限公司
Priority to DE112019000260.0T priority Critical patent/DE112019000260T5/de
Priority to US16/959,167 priority patent/US11235406B2/en
Publication of WO2020151459A1 publication Critical patent/WO2020151459A1/zh

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06Solder feeding devices; Solder melting pans
    • B23K3/0646Solder baths
    • B23K3/0669Solder baths with dipping means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/08Soldering by means of dipping in molten solder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/20Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • B23K1/203Fluxing, i.e. applying flux onto surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/08Auxiliary devices therefor
    • B23K3/082Flux dispensers; Apparatus for applying flux
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/08Auxiliary devices therefor
    • B23K3/087Soldering or brazing jigs, fixtures or clamping means
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0062Manufacturing the terminal arrangement per se; Connecting the terminals to an external circuit
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0056Manufacturing winding connections
    • H02K15/0068Connecting winding sections; Forming leads; Connecting leads to terminals
    • H02K15/0081Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings
    • H02K15/0087Connecting winding sections; Forming leads; Connecting leads to terminals for form-wound windings characterised by the method or apparatus for simultaneously twisting a plurality of hairpins open ends after insertion into the machine
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/46Fastening of windings on the stator or rotor structure
    • H02K3/50Fastening of winding heads, equalising connectors, or connections thereto

Definitions

  • the invention relates to a welding device and a welding process for the stator winding end of an automobile drive motor or generator.
  • Stator windings of flat wire motors are usually formed by first inserting the formed hairpin coil or unilateral coil into the stator core slot, and then bend the open end of the coil through a twisting die, and the adjacent conductors after bending are welded to realize the electrical connection of the winding .
  • the existing welding methods mainly include laser welding or argon arc welding. Both of these methods form solder joints by melting copper at an instant of high temperature, thereby realizing electrical connection of windings.
  • the prior art has two main disadvantages. One is that laser welding and argon arc welding need to generate high temperature instantly to melt the copper, which easily damages the enameled wire paint film around the welding point and reduces the insulation reliability.
  • the second is that the number of hairpin coils or unilateral coils constituting the stator winding of the flat wire motor is large, and a large number of welding points are required.
  • Laser welding or argon arc welding generally welds the welding points one by one, which seriously affects the production efficiency of the flat wire stator.
  • the purpose of the present invention is to provide a welding device and a high-efficiency welding process mainly for the stator winding of a rectangular wire motor.
  • the welding process is to dip the end of the stator winding into the molten solder to complete the welding of all the solder joints at one time, improving the efficiency and quality of production.
  • the technical scheme of the present invention is: a high-efficiency flat wire motor winding end welding device, including a support base, a solder tray, a solder joint isolation limit plate, a shaft and a moving tray; the center of the support base is provided with a solder tray; The solder pallet is provided with a solder joint isolation limit plate; the support base is provided with a shaft; the shaft is provided with a moving tray; the moving tray is on the upper part of the solder pallet; the moving tray is along the shaft The rod moves up and down; the stator is placed in the center of the moving tray, and the winding ends of the stator extend below the moving tray.
  • the solder joint isolation limit plate is provided with a threaded hole; the screw passes through the threaded hole to fix the solder joint isolation limit plate to the solder tray.
  • the solder joint isolation limiting plate is provided with solder joint isolation limiting through holes; the solder joint isolation limiting through holes are uniformly distributed in a ring shape.
  • annular solder groove is provided on the solder tray.
  • the shaft is a smooth shaft.
  • the solder tray is provided with a threaded fixing hole; the solder tray is connected to the support base by a screw passing through the threaded fixing hole.
  • a welding process using a high-efficiency flat wire motor winding end welding device the specific process steps include:
  • the welding device has a compact and reasonable structure and is easy to operate
  • solder joint isolation limit board can make the adjacent conductors easier to solder, and can ensure that the adjacent solder joints will not stick together, improving the production quality
  • the welding process can complete all welding points at one time, and the production efficiency is high.
  • Figure 1 is a schematic diagram of the three-dimensional structure of a high-efficiency flat wire motor winding end welding device of this case;
  • Figure 2 is a schematic diagram of the front structure of a high-efficiency flat wire motor winding end welding device of this case
  • Figure 3 is a schematic diagram of the structure of the welding spot isolation limit plate of a high-efficiency flat wire motor winding end welding device of this case;
  • Figure 5 is a schematic diagram of the iron core slot number and the number of layers of the eight-pole 48-slot rectangular wire motor stator of a high-efficiency rectangular wire motor winding end welding device of this case;
  • Figure 6 is a schematic diagram of the welding point of the winding end of the eight-pole 48-slot rectangular wire motor stator of a high-efficiency rectangular wire motor winding end welding device of the present case;
  • the welding points of the non-outgoing end of the winding end of the stator are evenly distributed along the circumferential direction, and the welding points are named H1, H2, H3 and H4 in the direction away from the center of the circle in the radial direction.
  • the conductors L1 and L2 in the groove form a solder joint H1, L3 and L4 form a solder joint H2, L5 and L6 form a solder joint H3, and L7 and L8 form a solder joint H4;
  • the solder joint isolation limit board 4 is provided with Threaded hole 41; the screw passes through the threaded hole 41 to fix the solder joint isolation limit plate 4 on the solder tray 5;
  • the solder joint isolation limit plate 4 is provided with a solder joint isolation limit through hole 42;
  • the solder joint isolation limit through holes 42 are uniformly distributed in a ring shape; the solder joint isolation limit through holes correspond to the positions of the stator winding solder joints; there are four circles, each of which has 48 solder joint isolation limit through
  • the structure of the solder joint isolation limit plate in this case is not limited to the schematic structure in the text.
  • the arrangement position, number of layers and number of the isolation limit through holes of the solder joint isolation limit plate are based on the design position and layer of the solder joints connected to the end of the flat wire winding. The number and quantity change.
  • a welding process using a high-efficiency flat wire motor winding end welding device the specific process steps include:
  • Coating flux pre-coat or immerse flux to the winding ends of the eight-pole 48-slot rectangular wire motor stator 1 to be dip-welded;

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

Abstract

一种高效率扁线电机绕组端部焊接装置及焊接工艺,包括支撑底座(6),焊料托盘(5),焊点隔离限位板(4),轴杆(3)和移动托盘(2);所述支撑底座(6)中心设置有焊料托盘(5);所述焊料托盘(5)上设置有焊点隔离限位板(4);所述支撑底座(6)上设置有轴杆(3);所述轴杆(3)上设置有移动托盘(2);所述移动托盘(2)在焊料托盘(5)上部;所述移动托盘(2)沿着轴杆(3)上下移动;所述移动托盘(2)中心放置定子(1)且定子(1)的绕组端部伸出于移动托盘(2)之下;工艺步骤包括:(1)融焊料;(2)涂覆助焊剂;(3)放定子;(4)浸焊焊接;(5)归位。该焊接装置结构紧凑合理,操作简便;焊点隔离限位板(4)的设计可以使相邻导体更容易焊接,又能保证相邻焊点不会黏连在一起;焊接工艺可一次完成所有焊点焊接,生产效率高。

Description

一种高效率扁线电机绕组端部焊接装置及焊接工艺 技术领域
本发明涉及一种汽车驱动电机或发电机的定子绕组端部焊接装置及焊接工艺。
背景技术
扁线电机定子绕组成型通常是先将成型发卡线圈或单边线圈插入到定子铁芯槽中,然后通过扭头模具将线圈开口端弯折,弯折过后的相邻导体通过焊接实现绕组的电气连接。现有的焊接方式主要有激光焊或氩弧焊,这两种方法均是通过瞬间高温将铜熔化而形成焊点,从而实现绕组的电气连接。但现有技术主要存在两个缺点,一是激光焊和氩弧焊需瞬间产生高温将铜熔化,易损伤焊接点周围的漆包线漆膜,降低绝缘可靠性。二是构成扁线电机定子绕组的发卡线圈或单边线圈数量较多,需要大量焊点,激光焊或氩弧焊一般对焊点逐个进行焊接,严重影响扁线定子的生产效率。
发明内容
本发明目的是:提供了一种主要针对扁线电机定子绕组的焊接装置及一种高效率焊接工艺。该焊接工艺是将定子绕组端部浸到熔融焊料中,一次性完成所有焊点的焊接,提高生产的效率及质量。
本发明的技术方案是:一种高效率扁线电机绕组端部焊接装置,包括支撑底座,焊料托盘,焊点隔离限位板,轴杆和移动托盘;所述支撑底座中心设置有焊料托盘;所述焊料托盘上设置有焊点隔离限位板;所述支撑底座上设置有轴杆;所述轴杆上设置有移动托盘;所述移动托盘在焊料托盘上部;所述移动托盘沿着轴杆上下移动;所述移动托盘中心放置定子且定子的绕组端部伸出于移动托盘之下。
优选的,所述焊点隔离限位板上设置有螺纹孔;所述螺钉穿过螺纹孔将焊点隔离限位板固定在焊料托盘。
优选的,所述焊点隔离限位板上设置有焊点隔离限位通孔;所述焊点隔离限位通孔呈环形均匀分布。
优选的,所述焊料托盘上设置有环形焊料槽。
优选的,所述轴杆有四根。
优选的,所述轴杆为光滑轴杆。
优选的,所述焊料托盘设置有螺纹固定孔;所述焊料托盘采用螺钉穿过螺纹固定孔与支撑底座连接。
一种使用高效率扁线电机绕组端部焊接装置的焊接工艺,具体工艺步骤包括:
(1)融焊料:将焊料放入焊料托盘中,使焊料达到并保持熔融状态;
(2)涂覆助焊剂:定子放置移动托盘前,定子待浸焊焊接的绕组端部需预先涂覆或浸渍助焊剂;
(3)放定子:将已涂覆或浸渍助焊剂的定子放置移动托盘上,定子绕组端部应伸出于移动托盘之下;
(4)浸焊焊接:将移动托盘沿着轴杆向下移动,使定子的绕组端部部分浸入到盛有熔融焊料的焊料托盘中,并通过焊点隔离限位板,进行浸焊;
(5)归位:所述移动托盘下移到达位置,完成浸焊后,将放置定子的移动托盘沿着轴杆向上移动,回到初始位置,完成焊接过程。
本发明的优点是:
1、焊接装置结构紧凑合理,操作简便;
2、焊点隔离限位板的设计可以使相邻导体更容易焊接,又能保证相邻焊点不会黏连在一起,提高生产质量;
3、焊接工艺可一次完成所有焊点焊接,生产效率高。
附图说明
下面结合附图及实施例对本发明作进一步描述:
图1为本案的一种高效率扁线电机绕组端部焊接装置的立体结构示意图;
图2为本案的一种高效率扁线电机绕组端部焊接装置的主视结构示意图;
图3为本案的一种高效率扁线电机绕组端部焊接装置的焊点隔离限位板的结构 示意图;
图4为本案的一种高效率扁线电机绕组端部焊接装置的焊料托盘的结构示意图;
图5为本案的一种高效率扁线电机绕组端部焊接装置的八极48槽扁线电机定子的铁芯槽号及层数示意图;
图6为本案的一种高效率扁线电机绕组端部焊接装置的八极48槽扁线电机定子的绕组端部焊点示意图;
其中:1、八极48槽扁线电机定子;2、移动托盘;3、轴杆;4、焊点隔离限位板;5、焊料托盘;6、支撑底座;41、螺纹孔;42、焊点隔离限位通孔;51、环形焊料槽;52、螺纹固定孔。
具体实施方式
实施例:
如附图1-4所示,一种高效率扁线电机绕组端部焊接装置,一台八极48槽扁线电机定子1为例进行说明,包括支撑底座6,焊料托盘5,焊点隔离限位板4,轴杆3和移动托盘2;所述支撑底座6中心设置有焊料托盘5;所述焊料托盘5上设置有环形焊料槽51;所述焊料托盘设置有螺纹固定孔52;所述焊料托盘5采用螺钉穿过螺纹固定孔52与支撑底座6连接;所述焊料托盘5上设置有焊点隔离限位板4;所述支撑底座6上设置有轴杆3;所述轴杆3上设置有移动托盘2;所述轴杆3有四根,分布于支撑底座6的四个角上;所述轴杆3为光滑轴杆;所述移动托盘2在焊料托盘5的上方;所述移动托盘2沿着轴杆3上下移动;所述移动托盘2的中心放置八极48槽扁线电机定子1且定子的绕组端部非出线端伸出于移动托盘2之下;如图5-6所示,八极48槽扁线电机定子1的铁芯槽号沿顺时针依次标记为S1、S2、……、S47、S48;每槽导体数为8,槽中导体层数沿径向远离圆心方向依次命名为L1、L2、……、L7、L8;八极48槽扁线电机定子1的绕组由若干个单边线圈组成,单边线圈两端通过焊接实现绕组的电气连接。定子的绕组端部非出线端焊点沿圆周方向均匀分布,焊点沿径向远离圆心方向依次命名为H1、H2、H3和H4。其中,槽中导体L1和L2层形成焊点H1,L3和L4形成焊点H2,L5和L6形成焊点H3, L7和L8形成焊点H4;所述焊点隔离限位板4上设置有螺纹孔41;所述螺钉穿过螺纹孔41将焊点隔离限位板4固定在焊料托盘5上;所述焊点隔离限位板4上设置有焊点隔离限位通孔42;所述焊点隔离限位通孔42呈环形均匀分布;所述焊点隔离限位通孔与定子的绕组焊点位置对应;共有四圈,每圈48个焊点隔离限位通孔。
本案中的焊点隔离限位板结构不局限于文中示意图结构,焊点隔离限位板的隔离限位通孔排布位置、层数和数量根据扁线绕组端部连接焊点设计位置、层数和数量的变化而变化。
一种使用高效率扁线电机绕组端部焊接装置的焊接工艺,具体工艺步骤包括:
(1)融焊料:将焊料放入焊料托盘5中的环形焊料槽51,使焊料达到并保持熔融状态;
(2)涂覆助焊剂:将八极48槽扁线电机定子1待浸焊焊接的绕组端部预先涂覆或浸渍助焊剂;
(3)放定子:将绕组端部已涂覆或浸渍助焊剂的八极48槽扁线电机定子1放在移动托盘,定子的绕组端部伸出于移动托盘2之下;
(4)浸焊焊接:将移动托盘2沿着轴杆3向下移动,使定子的绕组端部部分浸入到盛有熔融焊料的焊料托盘5的环形焊料槽51中,并通过焊点隔离限位板,进行浸焊;焊点隔离限位通孔42用来限制相邻焊接导体位置,并隔离相邻焊点,既可以使相邻导体更容易焊接,又能保证相邻焊点不会黏连在一起;
(5)归位:所述移动托盘2下移到达位置,完成浸焊后,将放置八极48槽扁线电机定子1的移动托盘2沿着轴杆向上移动,回到初始位置,完成焊接过程。
本案中的焊接工艺对焊料的熔点、附着性和导电性有着较高的要求,可以选用合适的铜基钎料或银基钎料;该焊接工艺适用于Hair-pin发卡扁线绕组定子和I-pin双端焊接扁线绕组定子。
上述实施例仅例示性说明本发明的原理及其功效,而非用于限制本发明的。任何熟悉此技术的人士皆可在不违背本发明的精神及范畴下,对上述实 施例进行修饰或改变。因此,举凡所属技术领域中具有通常知识者在未脱离本发明的所揭示的精神与技术思想下所完成的一切等效修饰或改变,仍应由本发明的权利要求所涵盖。

Claims (8)

  1. 一种高效率扁线电机绕组端部焊接装置,其特征在于:包括支撑底座,焊料托盘,焊点隔离限位板,轴杆和移动托盘;所述支撑底座中心设置有焊料托盘;所述焊料托盘上设置有焊点隔离限位板;所述支撑底座上设置有轴杆;所述轴杆上设置有移动托盘;所述移动托盘在焊料托盘上部;所述移动托盘沿着轴杆上下移动;所述移动托盘中心放置定子且定子的绕组端部伸出于移动托盘之下。
  2. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述焊点隔离限位板上设置有螺纹孔;所述螺钉穿过螺纹孔将焊点隔离限位板固定在焊料托盘。
  3. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述焊点隔离限位板上设置有焊点隔离限位通孔;所述焊点隔离限位通孔呈环形均匀分布。
  4. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述焊料托盘上设置有环形焊料槽。
  5. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述轴杆有四根。
  6. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述轴杆为光滑轴杆。
  7. 根据权利要求1所述的一种高效率扁线电机绕组端部焊接装置,其特征在于:所述焊料托盘设置有螺纹固定孔;所述焊料托盘采用螺钉穿过螺纹固定孔与支撑底座连接。
  8. 一种使用根据权利要求1至7任一项所述的高效率扁线电机绕组端部焊接装置的焊接工艺,其特征在于:具体工艺步骤包括:
    (1)融焊料:将焊料放入焊料托盘中,使焊料达到并保持熔融状态;
    (2)涂覆助焊剂:定子放置移动托盘前,定子待浸焊焊接的绕组端部需预先涂覆或浸渍助焊剂;
    (3)放定子:将已涂覆或浸渍助焊剂的定子放置移动托盘上,定子绕组端部应伸出于移动托盘之下;
    (4)浸焊焊接:将移动托盘沿着轴杆向下移动,使定子的绕组端部部分浸入到盛有熔融焊料的焊料托盘中,并通过焊点隔离限位板,进行浸焊;
    (5)归位:所述移动托盘下移到达位置,完成浸焊后,将放置定子的移动托盘沿着轴杆向上移动,回到初始位置,完成焊接过程。
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