JP2000295821A - Arrangement of pairs of conductors, method of joining ends of pairs of conductors, and method of manufacturing windings of rotating electrical machine using the same - Google Patents

Abstract

(57) Abstract: A pair of lead wires, a method of joining the ends thereof, and a winding of a rotating electric machine using the same, which can realize a high-density joining by a fusion-type joining material without lowering the joining reliability. To provide a wire manufacturing method. A plurality of conductor wires constituting a pair of conductor wires are arranged in parallel in the extending direction with their end portions aligned in a line, and a pair of adjacent end portions of each end portion are soldered. Are joined. The front end portions 2 of the two conductor wires 1 constituting the same paired conductor 4 are arranged with their side surfaces 22 close to each other, and a predetermined distance between two adjacent conductor wires 1, 1 belonging to different paired conductors 4. A gap (a gap between pairs) is secured. A shape in which the foremost portions 23 of the two distal ends 2 of the pair of conductor wires 1 that are adjacent to each other and form the same paired conductor wire 4 are farther from the paired conductor wire 4 than the base end portion 21 (hereinafter also referred to as a tapered shape). ) Has the advantage that it is hard to be erroneously connected by solder.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an arrangement of pairs of conductors used for, for example, a coil conductor of a rotating electric machine, a method of joining ends thereof, and a method of manufacturing a winding of a rotating electric machine using the same.

[0002]

2. Description of the Related Art Conventionally, in various electric appliances such as a rotating electric machine such as an alternator and an electromagnet, a large number of electric wires are arranged in a line in a direction perpendicular to their extending direction, and each electric insulating resin film is peeled off. A pair of conductors is formed by bringing the ends of the conductor wires into close proximity or close contact with each other to form a pair of conductors, and the ends of both conductor wires of each pair of conductors are collectively joined using a molten joining material such as solder or brazing material. There are cases.

A conventional example will be described with reference to FIG. 20
0 is a solder bath and 201 is a conductor wire. Three pairs of conducting wires 203 each comprising a pair of conductor wires 201 having a tip end portion 202 from which the electrically insulating resin film is peeled off and closely arranged in parallel with each other are perpendicular to the extending direction with a predetermined gap therebetween. A pair of conductors is arranged in one direction. 2
Reference numeral 04 denotes a solder bridge formed when the pair of lead wires is pulled out of the solder bath.

[0004]

However, when the gap between the adjacent conductor wire pairs 203, 203 (inter-pair gap) is reduced for higher density, as shown in FIG.
There is a problem that a so-called bridge connection is formed in which adjacent paired conductors 203 are electrically connected to each other by a fusion bonding material.

[0005] Of course, if the gap between pairs is increased, this bridge connection can be eliminated.
The space required for a paired conductor arrangement in which a number of paired conductors are arranged in a line increases. In addition, it is conceivable that the bridge-connected portion of the fusion-type joining material 204 (referred to as a bridge portion) is melted and blown off by hot air, but a problem arises in that the fusion-type joining material necessary for the pair of conductors is also blown away. Resulting in.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described problems, and has a paired conductor arrangement capable of realizing a high-density joining by a fusion-type joining material without lowering the joining reliability, and a method of joining an end portion thereof. It is an object of the present invention to provide a method for manufacturing a winding of a rotating electric machine using the same.

[0007]

According to the first aspect of the present invention, the conductor wires constituting the paired conductor array are arranged in parallel in the extending direction with their leading ends aligned. And a plurality of tip portions adjacent to each other among the tip portions (usually a pair of adjacent tip portions,
In some cases, three or more tips may be adjacent to each other in a row). Naturally, the tip portions of the two conductor wires constituting the same pair of conductors are arranged with their side surfaces close to each other or at a small interval, and a predetermined distance between two adjacent conductor wires belonging to different pair of conductors. A gap (a gap between pairs) is secured.

In this configuration, particularly, the pair of conductor wires that are adjacent to each other and form the same pair of conductors have a shape in which the tip ends of the two distal ends are farther from the adjacent pair of conductors than their base ends (hereinafter, tapered shape). ). In this way, the pair of conductors has a substantially smaller pair of conductors than the conventional conductor wire having the same shape at both the leading end and the base end of the conductor. Without increasing the gap between the pair, it is possible to substantially increase the pair-to-pair gap at the leading end of the conductor wire,
As a result, the occurrence of the bridge can be reduced.

The bridge will be further described. When melting the fusion bonding material applied to the tip of each conductor wire of the pair of conductor wires, or when applying the melt of the fusion bonding material to the tip, the melt is mainly the conductor wire. In order to prevent the end of the conductor wire from adhering to the electrically insulating resin film side of the portion, it is normal to adopt a posture in which the tip of the conductor wire is disposed at the lowest position. The melt moves to the leading edge due to its own weight. Therefore, the generation of a bridge is suppressed by increasing the inter-pair gap between two adjacent conductor wires belonging to different paired conductor wires by the above method.

According to a second aspect of the present invention, in joining the ends of the pair of conductor wires according to the first aspect with a fusion-type joining material,
The tips of the paired conductors are joined together by a fusion joining material. In this way, while suppressing the occurrence of bridges,
The end connection of the high-density paired conductor array can be performed with high efficiency. According to a third aspect of the present invention, there is provided the method of joining end portions of the pair of conductor wires according to the second aspect, further comprising: melting the tip of the group of conductor wires arranged to form the pair of conductor wires with a melt-type joining material. Lower it into the tank, pull it up and join. In this way, the excess melt adhering to the tip of each conductor wire can drop back into the tank without forming a bridge because the gap between the pair at the foremost end is sufficiently large, and the high melt without the bridge can be obtained. The density versus conductor arrangement can be made with high efficiency.

According to a fourth aspect of the present invention, in the end joining method of the pair of conductor wires according to the second or third aspect, further, the tip of the conductor wire extends in the extension direction, or
Since the cutting is performed by plastically deforming the tip end of the conductor wire so as to extend in the direction perpendicular to the extending direction and the conductor wire group arrangement direction, cutting chips are not generated and the process can be simplified. . Furthermore, when the tip of the conductor wire is expanded in the direction perpendicular to the extending direction and the conductor wire group arrangement direction, the joint area of the two conductor wires forming the same counter conductor can be increased, and the joining reliability can be improved. In addition, the line-to-line electrical resistance can be reduced.

According to a fifth aspect of the present invention, in the method of joining an end portion of a pair of conductor wires according to the second or third aspect, the tip of the conductor wire is further formed into the tapered shape by cutting.
With this configuration, the tapered shape can be realized by a simple process. According to the method of claim 6, claim 5
In the method for manufacturing a winding of a rotating electrical machine using the end joining method of the pair of conductor wires described above, further, when cutting out the conductor wire having a predetermined length from a long wire, the tip portion of the conductor wire is tapered. Since there is no need to add a step of making the tip portion tapered, the manufacturing process can be shortened.

As another aspect, before cutting a conductor wire into a fixed length from a wire (covered electric wire) covered with an electrically insulating resin film, a portion of the electrically insulating resin at an end portion of the conductor wire is cut. The film is cut off with a rotating grindstone. At this time, the tip of the conductor wire may be formed into a tapered shape at the same time as the electric insulating resin film is cut by the rotating grindstone. According to the method of the seventh aspect, the coil of the rotating electric machine is manufactured by using the end joining method of the pair of conductor wires according to any one of the second to seventh aspects.

In this way, since a coil can be manufactured by connecting a large number of thin conductor wires, instead of successively winding a long conductor wire sequentially into a core slot as in the prior art, these many short conductor wires are connected to each other. When a coil manufacturing method of a type in which a stator coil is manufactured by being inserted into a slot is employed, the reliability of connection of each conductor wire can be improved.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described with reference to the following examples.

[0016]

Embodiment 1 A related part of a method for manufacturing a stator coil of an automotive alternator (so-called alternator) using the paired conductor arrangement and the end joining method of the present invention will be described with reference to the process diagram shown in FIG. This will be described below. (Step 1) First, a copper-based conductor wire (coated wire) 1 is prepared,
The electrically insulating resin film 3 at the tip 2 is removed. (Step 2) Next, the tip 2 is cut diagonally to form a tapered shape. A flat wire having an excellent slot space factor is used as the conductor wire 1, and a substantially flat surface on the narrow side thereof is referred to as a side surface. Therefore, the distal end portion 2 of the conductor wire 1 gradually protrudes from the base end portion 21 of the one side surface 20 toward the foremost portion 23 of the other side surface 22 in the extending direction as viewed from the wide side main surface 24 side. It is formed in the shape of a right triangle. (Step 3) Next, one pair of the conductor wires 1 is arranged so that the side surfaces on the side of the leading end portion 23 are in close contact with each other, and the required number of paired conductors 4 are produced. Part 2
Are arranged in the direction parallel to the main surface 24 at right angles to the extending direction with a predetermined pair gap 5 interposed therebetween, while aligning the foremost end 23 with the same position in the extending direction. Hold by. (Steps 4, 5, 6) Next, while maintaining the above arrangement state, the leading end portion 2 of the pair of conductor wires 5 held by the jig is lowered and immersed in a melt bath of a soft brazing material, for example, molten Sn100 solder. Then, the leading ends 2 of the paired conductors 4 are collectively joined.

Thus, the tip 2 of each pair of conductors can be joined together without forming a bridge between the adjacent pair of conductors 4. In the above embodiment, the joining was performed by immersion in a solder melt bath. However, a jet solder bath was used, or a non-oxidizing atmosphere such as nitrogen or an inert gas or a reducing atmosphere in which an appropriate amount of hydrogen was added to this non-oxidizing atmosphere. By doing so, the amount of solder at the joint is stabilized, and the variation in the joint resistance can be reduced.

The soft solder used is not only Sn100 solder but also Pb-Sn solder, Sn-Zn solder, Sn
Of course, a system solder, a Pb system solder, a Zn system solder, or the like may be used. When the conductor wire 1 is made of aluminum, Sn-Zn solder or Zn-based solder is advantageous. In addition, it is naturally preferable to use a predetermined flux suitable for each soft brazing material. In addition, it is also possible to irradiate the melt in the melt bath or the conducting wire 4 with ultrasonic waves to omit the flux.

In addition, if a fusion-type joining material is used for joining, after the fusion-type joining material is applied, it may be melted by thermal convection, ultrasonic waves, laser light, or the like. (Modification) The tapered shape of the tip 2 of the conductor wire 1 is as follows.
In addition to the triangular shape (see FIG. 2) used in the above embodiment, various shapes such as a narrow rectangular shape (see FIG. 3) and a combination thereof (see FIG. 3) can be adopted.

Further, the electrically insulating resin film 3 does not need to peel off the entire tapered tip 2 of the conductor wire 1, and the side surface which comes into contact with the other conductor wire 1 constituting the same pair of conductors 4. Only the portion 22 and its vicinity may be partially peeled off (see FIG. 5), or only the narrowest portion of the tip 2 may be peeled off (see FIG. 6).

[0021]

Embodiment 2 Another embodiment will be described below with reference to FIG. In this embodiment, a partial area 1b of the long conductor wire 1a is used.
The electrically insulating resin film 3 is peeled off in advance and is exposed. By cutting this region 1b obliquely at the cutting position w shown in the figure, the tip 2 of the conductor wire 1 having a required length can be formed into the above-mentioned tapered tip 2. Therefore, in this embodiment, it is possible to automatically manufacture the conductor wire 1 having the tapered end portions 2 from the long conductor wire 1a from which a predetermined portion of the electrically insulating resin film 3 has been peeled in advance. it can.

An example of the above cutting step will be described in more detail with reference to FIG. A rectangular wire coil drum 100 is wound with a rectangular wire 1a. The rectangular wire 1a pulled out of the drum 100 is given a predetermined tension by a pair of tension rollers 102 at a tension portion 101, and is sent to a leading end of the wire at a predetermined speed by a pair of feed rollers (not shown) of a feed portion 103. I have.

Reference numeral 104 denotes a distortion removing section provided with a number of distortion removing rollers 105. The flat wire 1a from which the distortion has been removed is sent to the first stripping section 106, and the electrical insulation property of the area where the resin is to be peeled off. The resin film is partly removed (four main surfaces and two corners) by the rotary grindstone provided in the first stripping part 106, and the remaining two corners of the resin film are left in the second stripping part 107. Is removed by a rotating grindstone. Subsequently, the flat wire 1a is sent to the cutting unit 108 and cut into a predetermined length to form the flat wire 1 having a predetermined length. In this cutting portion 108, the cutting blade is set obliquely to the extending direction, and the tip 2 of the flat wire 1 cut and formed has a tapered shape.

[0024]

Embodiment 3 Another embodiment will be described below with reference to FIG. In this embodiment, in order to change the substantially rectangular parallelepiped distal end 2 of the rectangular wire 1 from which the electrically insulating resin film 3 of the distal end 2 has been peeled off into a triangular shape shown in FIG. 2 is plastically deformed into a tapered shape. At this time, the distal end portion 2 is thickened at an extra portion (see FIG. 8C). In this case, since no chips are produced, the processing can be omitted, and the effect that the joining area of the distal end portion 2 of the conductor wire 1 can be increased while suppressing the generation of the bridge. Can play.

[Brief description of the drawings]

FIG. 1 is a process diagram showing a step of joining end portions of a pair of conductor wires according to a first embodiment.

FIG. 2 is a perspective view showing a modified example of a tip portion of the conductor wire of FIG.

FIG. 3 is a perspective view showing a modified example of a distal end portion of the conductor wire of FIG. 1;

FIG. 4 is a perspective view showing a modified example of the distal end of the conductor wire of FIG. 1;

FIG. 5 is a perspective view showing a modification of the distal end of the conductor wire of FIG. 1;

FIG. 6 is a cross-sectional view of a flat wire ground by the pair of rotary grindstones of FIG. 1;

FIG. 7 is an explanatory view showing a cutting step of forming a tip portion of a conductor wire into a tapered shape.

FIG. 8 is a schematic view of an apparatus for automating a cutting process shown in FIG. 7;

FIGS. 9A and 9B are schematic perspective views showing a state in which the tip of the conductor wire is expanded in a direction perpendicular to the conductor wire adjacent direction by plastic deformation. FIG. 9A is a perspective view before plastic deformation, and FIG. 9B is after plastic deformation. (C) is a side view after plastic deformation.

FIG. 10 is a process diagram showing a conventional end joining process of a pair of conductor wires.

[Explanation of symbols]

1 is a conductor wire, 2 is its tip, 3 is an electrically insulating resin film,
4 is a pair of conductors, and 5 is a pair of conductor arrangement.

Claims (7)

[Claims] A plurality of paired conductors each comprising a pair of conductors arranged in parallel with each other at predetermined minute intervals or in close contact with each other and having a tip portion from which an electrically insulating resin film is peeled off. A conductor line group, which is sequentially arranged in a direction substantially perpendicular to the extending direction with a predetermined gap therebetween, and a tip of each of the conductor wires is arranged at the same position in the extending direction; And a bonding material portion formed of a fusion-type bonding material that is attached to the distal end portion and that bonds the distal end portions of the two conductor wires adjacent to each other of the same pair of conductive wires, The tip of one of the conductor wires of the pair of conductors has a portion closer to the other conductor of the pair of conductors in the extension direction than a portion of the pair of conductors away from the other of the conductors. It has a long tapered shape, and the other of the pair The end portion has a tapered shape in which a portion of the counter conductor near the one of the conductor wires is formed longer in the extending direction than a portion of the counter conductor that is away from the one of the conductor wires. A pair of conductors, characterized in that: 2. A pair of conductors comprising a pair of conductor wires arranged in parallel with each other at predetermined intervals or in close contact with each other in the extending direction, and in a direction substantially perpendicular to the extending direction with a predetermined gap therebetween. Arrange and prepare a conductor wire group in which the distal end of each of the conductor wires is arranged at the same position in the extending direction, and the distal ends of the two conductor wires adjacent to each other of the same counter conductor are joined by a fusion bonding material. In the end joining method of the paired conductor array to be joined, the tip of one of the paired conductors on the side close to the other conductor of the paired conductor is the other conductor of the paired conductor. It is formed in a tapered shape formed longer in the extending direction than the part on the side away from, and the tip of the conductor wire on the other side of the pair of conductors is on the side closer to the one conductor wire of the pair of conductors. The part is closer to the side of one of the pair of conductors away from the conductor wire. The extension line to form a long-formed tapered in the direction, the end connection of the pairs conductors sequence, characterized in that bonding the distal ends of the pair wires collectively by the melt bonding material. 3. The method according to claim 2, wherein the tip of the conductor wire group is lowered into a tank in which a melt of the fusion bonding material is stored. An end joining method for a pair of conductor wires, wherein the joining is performed by immersing a tip end in the melt, raising the tip, applying the melting type joining material to a tip end of the conductor wire group, and performing the joining. 4. The method according to claim 2, wherein the step of forming the tip of the conductor wire group into the tapered shape is performed so as to extend in the extension direction. End joining of a pair of conductor wires, which is carried out by plastically deforming the front end of the conductor wire so as to extend in a direction perpendicular to the extending direction and the conductor wire group arrangement direction. Method. 5. The method according to claim 2, wherein the step of forming the tip of the conductor wire group into the tapered shape is performed by cutting the tip of the conductor wire. A method of joining end portions of a pair of conductor wires, characterized in that: 6. A method for manufacturing a winding of a rotating electrical machine using the method of joining end portions of a pair of conductor wires according to claim 5, wherein when the conductor wire having a predetermined length is cut out from a long wire,
A method for manufacturing a winding of a rotating electrical machine, wherein the tip of the conductor wire has the tapered shape. 7. The method according to claim 2, wherein a coil of a rotating electric machine is formed by joining the tip portions of the conductor wires to each other. Method for manufacturing windings of rotating electric machines.