JP3740433B2 - Coupling structure of focusing terminal and lead-out coil and small rotating electric machine and vehicular AC generator using the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a connecting structure of a focusing terminal and a lead coil suitable for bundling and taking out a plurality of lead wires of an electric device, and a small rotating electric machine and a vehicle AC generator using the same.
[0002]
[Prior art]
Conventionally, a technique for bundling a plurality of enamel-coated lead wires of an electrical device and taking them out through a joining terminal in which a brazing material containing phosphorus is provided on the conductor joining surface side is known from, for example, Japanese Patent Laid-Open No. 2-137306. In this type of technique, the lead-out coil set is sandwiched between joining terminals via a brazing material, and the joining terminals are pressed and fixed while being electrically heated from the outside.
[0003]
Japanese Patent Publication No. 7-32555 discloses a structure in which the center-side lead-out terminals of a plurality of phases are collectively connected using a connection fitting in a vehicle alternator stator. Discloses that welding or soldering is used.
[0004]
[Problems to be solved by the invention]
In the former prior art, the lead-out coil group is sandwiched between the joining terminals via the brazing material, and the joining terminals are pressed and fixed while being electrically heated from the outside, so that they have high joining strength and heat resistance and have an insulating film. However, only two sets of enamel-coated conductors as lead-out coils are considered, but when there are three or more lead-out coil sets, each lead-out coil is not necessarily a junction terminal. When the vibration is applied, not only the coil that is not joined is pulled out but also the surrounding coupling force is weakened, so that it is not always a reliable connection terminal.
[0005]
In the latter prior art, a structure is shown in which the lead-out ends on the center side of a plurality of phases are bundled together using connecting fittings and joined by welding or soldering, but the lead-out ends are simply put together. Therefore, the lead-out coils are not necessarily firmly fixed to the connection fittings, and the lead-out coils are not necessarily fixed to each other. Therefore, when it is used at the neutral point of a vehicle alternator installed in the engine room, if there is a place that is not fixed even at one place, bond separation is promoted by vibration, etc. It becomes a low product.
[0006]
One of the objects of the present invention is to provide a connecting structure of a focusing terminal and a lead coil, which has a stable coupling force and high reliability.
[0007]
One of the objects of the present invention is to provide a small rotating electrical machine or an AC generator for a vehicle having a connecting structure of a focusing terminal and a lead-out coil, which has a stable coupling force and high reliability.
[0008]
[Means for Solving the Problems]
One aspect of the present invention is a coupling structure of a coil set obtained by bundling a plurality of lead-out coils composed of at least three and a focusing terminal, and each lead-out coil of the lead-out coil set has at least a part around the coil. The focusing terminal is in contact with and joined to the focusing terminal, and the focusing terminal is electrically and mechanically coupled to each of the lead-out coils through a brazing material by conducting energization resistance heating. The portion of the enamel coating of the lead-out coil that is in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal, and the lead-out coil, the focusing terminal, This is achieved by a coupling structure of the focusing terminal and the lead-out coil, characterized in that the gap between the lead- out coils is a metallurgical joint and the lead-out coils are pressure-welded .
[0009]
One aspect of the present invention is a coil in which a stator core in which a stator coil is wound around a plurality of slots formed on a circumference and a plurality of lead coils made of at least three of the stator coils are bundled. and a focusing terminal that relays a set, a rotary electric machine comprising taking out the lead coil to the outside via the said population bundle terminals, all of the above derivation coil set each derivation coil part around the coil at least the The focusing terminal is joined in contact with the focusing terminal, and the focusing terminal is electrically and mechanically coupled to each of the lead-out coils through a brazing material by conducting energization resistance heating. The coating of the enamel coating of the lead-out coil that is in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal, and between the lead-out coil and the focusing terminal Between Gold junction, to each other between the conductor exits coils is achieved by a small rotary electrical machine, characterized by being bonded pressed.
[0010]
One of the present invention is an armature core in which a three-phase armature coil is wound around a plurality of slots formed on a circumference, a rectifier that rectifies an output from the armature coil into a direct current, A plurality of lead-out coil groups that electrically connect the armature coil and the rectifier, and a plurality of at least three or more coils that are drawn from the midline point of the armature coil and connected to one end of the rectifier In the vehicle AC generator comprising a coil set in which neutral point derivation coils are bundled, the neutral point side derivation coil group is connected to the rectifier through a focusing terminal, and each derivation coil All of the coil are joined at least part of the periphery of the coil in contact with the converging terminal, and the converging terminal is connected to each lead-out coil via the brazing material by conducting energization resistance heating. Electrically and mechanically connected The portion of the enamel coating of the lead-out coil that is in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal. This is achieved by a vehicular AC generator characterized by metallurgical bonding between the focusing terminals and pressure welding between the lead-out coils .
[0011]
In the present invention, preferably, the focused neutral point deriving coil sets are arranged in a staggered manner and are bound and fixed by a focusing terminal.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention will be described in the case of application to the vehicle alternator shown in FIGS.
[0013]
In FIG. 2, the three-phase AC generator 1 includes a Y-connected armature coil (stator coil) 2, and the output ends 2 a, 2 b, 2 c and the neutral point end N of each lead-out coil of the armature coil are: It is connected to a full-wave rectifier 4 having one end grounded and the other end connected to the battery 3.
[0014]
The field coil 6 wound around the rotor 5 of the generator shown in FIG. 3 is controlled in energizing current by a voltage adjusting device 7 that operates according to the state of the charging voltage of the battery 3 to adjust the power generation output. Yes. The charge lamp 8 is configured so that the generator is turned on when no power is generated and is turned off when the power is generated.
[0015]
The armature coil 2 is wound around a plurality of slots 10 formed on the circumference of a cylindrical armature core (stator core) 9 as shown in FIG. , W phase output terminals 2a, 2b, 2c and neutral point output terminal N are connected to anode side terminals 4a, 4b, 4c and 4N of full wave rectifier 4, respectively. Here, the lead-out coil of the armature coil 2 is usually composed of two pairs for each phase and directly connected to the anode side terminals 4a, 4b, 4c. Together with the U-phase, V-phase, and W-phase, a single neutral point output end N is bundled together by the focusing terminal 11.
[0016]
Next, returning to FIG. 1, if the relationship between the six lead-out coils 2N at the neutral point, the neutral point output terminal N, and the focusing terminal 11 is described, the lead-out coils 2N are arranged in a two-stage stack and three rows are arranged in the lower stage. The upper stage includes four rows including the neutral point output terminal N, and the upper and lower coils are alternately arranged in a staggered manner so as not to overlap each other. And these arranged lead-out coils are bundled at a focusing terminal 12 made of a copper-based material, and each of them is electrically and mechanically coupled to the focusing terminal 12 via a brazing material 13, and between the wires They are in pressure contact with each other.
[0017]
Next, a method of coupling the focusing terminal and the lead coil having the above configuration will be described later.
[0018]
The neutral point derivation coil 2N that is an extension of the armature coil 2 is generally an AIW wire that is an enamel-coated conductive wire, and the focusing terminal 12 is a copper alloy terminal that provides a good result for the energization heating of the AIW wire. It is done.
[0019]
5 to 10 show the coupling method of the focusing terminal and the lead-out coil. Since the lead-out coil of the armature coil 2 wound around the slot 10 of the armature core 9 normally extends in the axial direction for both the U, V, W-phase output ends 2a, 2b, 2c and the neutral point lead-out coil 2N. In this embodiment, in order to avoid mixing both of them and improve workability, the neutral point-side derived coil is bent in a direction substantially perpendicular to the axial direction of the armature core 9 as shown in FIG. .
[0020]
The neutral point side lead-out coil 2N wound in this way is coil guide space 23 of a pair of left and right bundling blocks 22 and 22a arranged so as to be rotatable via respective support pins 20 and 20a. 23a. Each of the coils is deformed along the circumferential direction of the armature core by pushing the shaping blades 21 and 21a in the outer circumferential direction of the armature core, and an S-shaped piece disposed between the bundling blocks 22 and 22a. 24. Here, the pressing surfaces of the shaping blades 21, 21 a are formed in circular arcs, and the coil guide spaces 23, 23 a are arranged stepwise in the axial direction and face the groove of the S-shaped piece 24.
[0021]
Accordingly, the neutral point derivation coil 2N pushed in the circumferential direction by the shaping blades 21 and 21a is shaped along the arcuate surface 21b of the shaping blade, as can be seen from FIGS. 6A and 6B. The tip direction is bent at a right angle by the parallel surface 21c and pushed into the groove of the S-shaped piece, and is aligned in a stepwise manner.
[0022]
Next, in the process of FIG. 7, the S-shaped piece 24 is raised at a right angle and the same orientation as the U, V, W phase output ends 2a, 2a, 2c of the other armature coils 2 is prepared to prepare for automation of assembly. . If the S-shaped piece 24 is removed in this state, the neutral point derivation coil 2N will be separated, so in the next step, in FIG. 7B, the pair having the orthopedic teeth 25b from both sides with the S-shaped piece 24 fitted. The neutral point derivation coils 2N are aligned and brought into close contact with the chucks 25 and 25a.
[0023]
The lead-out coils arranged in this way are fixed by caulking at the focusing terminal 12 with the neutral point output end N in the next step, FIG. In this step, the neutral point derivation coil 2N is disposed on the bottom of the receiving die 26 having the trapezoidal groove 27 together with the neutral point output end N, and then the binding band 27 serving as a focusing terminal is supplied, as shown in FIG. A), and the process of cutting the supplied focusing terminal 12 to a specified size with a cutter 28, and forming the focusing terminal 12 into a U-shape with the cutter 28, a pressing die 29 and a receiving die 30, FIG. ), And a process of lowering the pressing die 29 and pushing it into the trapezoidal groove of the receiving die 26 while constraining the periphery of the focusing terminal 12 with a cutter 28 and a pressing die 29, and FIG. 8D, the process of lowering the neutral point derivation coil 2N and the neutral point output terminal N by wrapping them with the focusing terminal 12 and fixing them.
[0024]
Of course, in the final step of the process, seven coils are stacked in two stages, the staggered arrangement is processed so as not to change, and the structure is as shown in FIG. At this time, since the enamel coating 30 and the brazing material 31 are interposed, the dimension is set so that the gap g is taken into consideration.
[0025]
After that, the final process, moving to FIG. 10, is performed by pressing the focusing terminal with the electrode 32 having the pressing surface as the flat surface 32a and the electrode 33 having the pressing surface as the concave surface 33a which is the final shape of the focusing terminal. The pressurization and energization conditions at this time are set so that the inner peripheral surface of the terminal is higher than the softening temperature of the coil coating. Incidentally, the carbonization temperature of the heat-resistant electric wire coating (AIW) wire of the stator coil used for the vehicle alternator stator is about 650 ° C. As a result, the lead-out coils N and 2N that are in contact with the terminal during the energization and pressurization process carbonize the coating on the side surface of the outer periphery, and the enamel coating 30 carbonized by the applied pressure of the electrode is discharged outside the focusing terminal 12. The coil will be exposed in the true line. Thereafter, the inner peripheral surface of the terminal in contact with the side surface of the lead-out coil is metallurgically joined. Further, the coils in the terminals are pressure-welded to each other by the binding force of the molded terminals. In this way, the neutral point derivation coil 2N and the neutral point end N are reliably connected by both metallurgical joining between the outer peripheral side surface of each coil and the inner peripheral surface of the focusing terminal 12 and pressure welding between the coils.
[0026]
According to this method, since the peeling of the coil enamel part before joining is omitted, it is possible to reliably reduce work man-hours and work personnel. In addition, the temperature of the neutral point of the AC generator stator for a vehicle rises to about 200 ° C. when the vehicle is running, so that when the connection is soldered, the solder itself has low heat resistance and reliability is difficult. In the case of this method, since the bonding can be performed metallurgically, the heat resistance is remarkably improved, and the reliability is improved together with the vibration resistance.
[0027]
Further, in order to further improve the reliability of the joint portion, the joint portion can be further improved in reliability by attaching phosphorous copper brazing to the inner peripheral surface of the focusing terminal so that this surface is on the coil contact side.
[0029]
In addition, the present invention is not limited to these embodiments, and an effective and high bonding force can be obtained for bundling and fixing three or more lead wires.
[0030]
【The invention's effect】
Since each lead coil of the lead coil group is joined with at least a part of the periphery of the coil in contact with the focus terminal, the coupling force is stable and the connection structure of the focus terminal and the lead coil is highly reliable. A small rotating electric machine and a vehicle alternator using the above can be obtained.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view showing a coupling structure of a focusing terminal and a lead coil according to the present invention.
FIG. 2 is a circuit configuration diagram of a vehicle AC generator using the present invention.
FIG. 3 is a longitudinal sectional view of the vehicle alternator.
FIG. 4 is a perspective view of an armature core and a rectifier of the vehicle alternator.
FIGS. 5A and 5B are a plan view and a side view of a lead coil shaping device according to the embodiment of the present invention. FIGS.
FIG. 6 is a plan view and a side view of a shaping state of the shaping device.
FIG. 7 is a perspective view of the derived coil shaping / aligning device in the next step of the shaping device.
FIG. 8 is a perspective view showing a process of supplying, cutting, shaping, and caulking the focusing terminal of the shaping device.
FIG. 9 is a cross-sectional view of the converging terminal completed by caulking obtained in the same process.
FIG. 10 is a perspective view of the focusing terminal energization heating process.
[Explanation of symbols]
2 ... armature coil, 2a, 2b, 2c ... output end of lead coil, 4 ... full wave rectifier, 4a, 4b, 4c ... anode side terminal, 2N ... neutral point lead coil, N ... neutral point output end, 11: Focusing terminal.

Claims (5)

A coupling structure of a coil set and a focusing terminal obtained by bundling a plurality of lead coils composed of at least three,
All of the above derivation coil set for each conductive output coil is joined portion of the circumference coil in contact with at least the focusing terminals,
The focusing terminal is electrically and mechanically coupled to each of the lead-out coils via a brazing material by conducting energization resistance heating,
Of the enamel coating of the lead-out coil, the coating of the portion in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal,
A coupling structure of a focusing terminal and a lead coil, wherein the lead coil and the focus terminal are metallurgically joined and the lead coils are press-welded to each other. A stator core in which a stator coil is wound around a plurality of slots formed on a circumference, and a focusing terminal that relays a coil set in which a plurality of lead-out coils including at least three of the stator coils are bundled. A rotating electric machine that takes out the lead-out coil through the focusing terminal,
All of the above derivation coil set for each conductive output coil is joined portion of the circumference coil in contact with at least the focusing terminals,
The focusing terminal is electrically and mechanically coupled to each of the lead-out coils via a brazing material by conducting energization resistance heating,
Of the enamel coating of the lead-out coil, the coating of the portion in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal,
A small rotating electric machine characterized in that the lead-out coil and the focusing terminal are metallurgically joined and the lead-out coils are press-welded to each other. An armature core in which a three-phase armature coil is wound around a plurality of slots formed on a circumference, a rectifier that rectifies an output from the armature coil into a direct current, the armature coil, and the rectifier A plurality of lead-out coil sets that are electrically connected to each other, and a plurality of neutral-point lead-out coils that are drawn from the middle line point of the armature coil and connected to one end of the rectifier. In a vehicle AC generator comprising a bundled coil set,
The neutral side derivation coil sets will be the rectifier and connected through a focusing terminal, and all are part of the periphery coils are joined in contact with at least the focusing terminals of each conductive output coils ,
The focusing terminal is electrically and mechanically coupled to each of the lead-out coils via a brazing material by conducting energization resistance heating,
Of the enamel coating of the lead-out coil, the coating of the portion in contact with the focusing terminal via the brazing material is carbonized and discharged to the outside of the focusing terminal,
An AC generator for vehicles, wherein the lead-out coil and the focusing terminal are metallurgically joined, and the lead-out coils are pressure-welded to each other.   4. The vehicle alternator according to claim 3, wherein the neutral point derivation coil sets are arranged in a zigzag pattern and are fixed by focusing terminals.   The vehicular AC generator according to claim 4, wherein the neutral point derivation coil set includes a jumper.

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