阅读说明：本技术 一种电机绕组多层导体的点焊方法 (Spot welding method for multi-layer conductor of motor winding ) 是由 林中尉 于 2019-09-12 设计创作，主要内容包括：本发明提供一种在有多个导体、且相邻的导体之间间距较小的情况下,对其中任意两个相邻导体进行快速可靠焊接的电机绕组多层导体的点焊方法。它是在至少3个导体的任何两个需要焊接在一起的相邻导体间设置有助于将所述相邻两个导体焊接在一起的助焊构件,电阻焊设备的两个电极夹住所有导体,焊接电流流过所有的导体,将助焊构件两侧的两个导体焊接在一起。(The invention provides a spot welding method for a motor winding multilayer conductor, which can quickly and reliably weld any two adjacent conductors under the condition that a plurality of conductors are arranged and the distance between the adjacent conductors is small. The welding aid is characterized in that a welding aid component which is helpful for welding any two adjacent conductors needing to be welded together in at least 3 conductors is arranged between the two adjacent conductors, all the conductors are clamped by two electrodes of resistance welding equipment, welding current flows through all the conductors, and the two conductors on two sides of the welding aid component are welded together.)

1. A spot welding method for a multilayer conductor of a motor winding is characterized by comprising the following steps: a welding aid member for assisting in welding any two adjacent conductors of the at least 3 conductors together is disposed between the two adjacent conductors, and two electrodes of the resistance welding apparatus sandwich all the conductors, and a welding current flows through all the conductors to weld the two conductors on both sides of the welding aid member together.

2. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the welding-assistant component is made of welding-assistant materials.

3. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the two conductors to be welded are provided with a bulge which reduces the contact area between the two conductors and increases the contact resistance, and the bulge is a welding-assistant component.

4. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 3, characterized by: and a welding assistant material is arranged between the bulge and at least one of the two conductors to be welded, and the bulge and the welding assistant material are welding assistant components.

5. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 3, characterized by: the bump is of an integral structure with one of the two conductors to be welded, and the bump is a bump on the surface of the conductor.

6. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 3, characterized by: the bump is independent of the two conductors to be welded and is of a split structure with the two conductors to be welded.

7. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the fluxing component is an electrical conductor with fluxing material.

8. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the conductors are copper wires and the flux components are made of a material that helps to braze the copper wires together.

9. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the conductors which are not welded to each other are reliably contacted to reduce contact resistance.

10. A method of spot welding a multilayer conductor of a winding for an electric machine according to claim 1, characterized by: the transition conductor is arranged between the conductors which are not welded with each other, so that the reliable connection between the conductors is realized, and the contact resistance is reduced.

Technical Field

The invention relates to a conductor welding method of a motor winding, in particular to a spot welding method of a multilayer conductor of a flat wire motor winding.

Background

With the improvement of the performance requirements of the power motor, the winding tends to be from a round wire to a flat wire, the flat wire winding is mostly a welding winding, the conventional method is to adopt electric welding on the end face of the wire, the welding can cause the heating of welding points and the low strength of the welding points, and the volume consistency of the conductive section is difficult to ensure (because the recrystallization of copper after melting in the air is large crystal, the resistance of the large crystal is increased, and the brittleness is large); or spot welding between each two layers. However, when the gap between the conductors of the respective layers is small, the two electrodes in the spot welding apparatus cannot be placed outside the two conductors to be welded, and the two conductors to be welded are directly clamped, so that the spot welding process cannot be operated in this case.

Disclosure of Invention

The invention aims to provide a spot welding method for a multilayer conductor of a motor winding, which can quickly and reliably weld any two adjacent conductors under the condition that a plurality of conductors exist and the distance between the adjacent conductors is small.

The invention relates to a spot welding method of a motor winding multilayer conductor, which is characterized in that a welding assistant component which is helpful for welding any two adjacent conductors needing to be welded together in at least 3 conductors is arranged between the two adjacent conductors, two electrodes of resistance welding equipment clamp all the conductors, welding current flows through all the conductors, and the two conductors on the two sides of the welding assistant component are welded together.

As a further improvement of the spot welding method for the multilayer conductor of the motor winding, the welding assistant component is welding assistant material.

As a further improvement of the spot welding method for the multilayer conductor of the motor winding, a bulge which reduces the contact area and increases the contact resistance between the two conductors is required to be welded between the two conductors, and the bulge is a welding assisting component.

And a welding assistant material is arranged between the bulge and at least one of the two conductors to be welded, and the bulge and the welding assistant material are welding assistant components.

The bump is of an integral structure with one of the two conductors to be welded, and the bump is a bump on the surface of the conductor. Or the bulge is independent of the two conductors to be welded and has a separated structure with the two conductors to be welded.

the flux material is sheet solder or ribbon solder or cream solder.

As a further improvement to the spot welding method for the multi-layer conductor of the motor winding, the welding assistant component is an electric conductor carrying welding assistant materials.

As a further improvement to the above-described method of spot welding the multilayer conductors of the motor winding, the conductors are copper wires and the flux assist members are made of a material that helps to braze the copper together, such as silver pads, silver copper pads, various copper alloy pads, amorphous pads, etc.

As a further improvement to the above-described method of spot welding of the multi-layer conductors of the motor winding, the conductors that are not welded to each other are reliably contacted to reduce contact resistance.

As a further improvement to the above-described spot welding method for the multilayer conductors of the motor winding, the transition conductors provided between the conductors that are not welded to each other achieve reliable connection between the conductors to reduce contact resistance.

The beneficial effect of this patent: when resistance welding is used, a welding aid material (solder), a projection, a combination of the welding aid material and the projection, or a welding aid material-carrying conductor and other welding aid members are required to be arranged between two target welding joint surfaces so as to increase the resistance of the joint surfaces, generate heat on the joint surfaces when power is supplied, and melt the welding aid members and the conductor at the joint surfaces so as to realize welding. The conductors are not welded together because the conductors are not easy to melt due to small resistance and small heat productivity between the contact surfaces of the conductors without the welding assistant components. The invention utilizes the principle to realize the spot welding of any two layers of conductors with smaller multi-layer spacing. For a plurality of conductors arranged at intervals, welding-assistant members are arranged on the joint surfaces of two adjacent conductors to be welded, all the conductors are clamped by two electrodes during welding, then the electrodes are electrified, and after current flows through the conductors, the resistance of the welding-assistant members is larger than that of other contact surfaces, so that the current generates large heat at the welding-assistant members, melts the welding-assistant members and the conductors, and realizes welding and combination of the conductors.

Flux materials (solders) are a generic term for metal alloy materials used to add to welds, overlay layers and braze seams, as is known in the art. Including welding wire, welding rods, brazing filler metal, etc. The solder has various types, and can be divided into hard solder and soft solder according to different melting points; the solder can be classified into tin-lead solder, silver solder, copper solder and the like according to different components. In the soldering process, tin-lead alloy solder, A, B, E grade tin-lead alloy solder for wire end soldering of motor and F, H grade pure tin solder are generally used. The solder is usually formed into a predetermined size in use, and has various shapes such as a sheet, a block, a rod, a ribbon, and a wire. Soldering flakes (soldering flakes) are commonly used for soldering silicon chips and other flaky soldering parts, the soldering flakes are generally formed by extrusion and are generally used for soldering, such as soldering flakes, silver soldering flakes, nickel soldering flakes and copper soldering flakes, and are mainly used for soldering. Strip solder is commonly used in a production line for automatically assembling chips, and an automatic welding machine is used to punch a section from the strip solder to weld the section, so as to improve the production efficiency.

A bulge is arranged between the welded conductors to serve as a welding assisting component, the bulge can be a bulge of the conductors or an independent component, the function of the bulge is to enable the contact area between the conductors to be increased, the contact resistance between the conductors is increased, during welding, heat generated by electric energy is mainly concentrated at a place with large resistance, the bulge part with small contact area is heated rapidly, and then the bulge part is melted and connected to form a reliable welding point. The protrusions are circular, rectangular, circular or any other geometric shape.

for the purpose of this patent, the conductor is generally a copper wire with a rectangular cross section, and the flux material usually used is a sheet solder or a ribbon solder or a cream solder, including silver soldering flakes, silver copper soldering flakes, various copper alloy soldering flakes, amorphous soldering flakes, and cream solder of corresponding material.

In order to avoid generating larger heat between conductors which do not need to be welded, contact surfaces of the conductors which do not need to be welded are reliably contacted, or transition conductors are arranged between the conductors which are not welded, so that reliable connection between the conductors is realized, and the contact resistance is reduced.

Drawings

FIG. 1 is a schematic illustration of spot welding of a multi-layer conductor to a winding of an electric machine;

FIG. 2 is another schematic illustration of spot welding of a multi-layer conductor to a winding of an electric machine;

FIG. 3 is yet another schematic illustration of spot welding of a multi-layer conductor to a winding of an electric machine;

fig. 4 is yet another illustration of spot welding of multiple layers of conductors to a motor winding.

FIG. 5 is a schematic illustration of spot welding of a multi-layer conductor to a winding of an electric machine;

Fig. 6 is a bottom view of the conductor 11 or 14 in fig. 5.

Detailed Description

Referring to the schematic diagram of spot welding of the multi-layer conductors of the motor winding shown in fig. 1, a plurality of copper conductors 11, 12, 13, 14, 15 extending from slots of the core are arranged with their ends in the radial direction of the core, in order to weld the conductor 11 with the conductor 12 and the conductor 14 with the conductor 15, a welding flux material (solder) 2 is inserted between the conductor 11 and the conductor 12 and between the conductor 14 and the conductor 15, two electrodes 31, 32 sandwich all the conductors in the radial direction of the core, the conductor 12 with the conductor 13 and the conductor 13 with the conductor 14 are reliably contacted, a welding current flows through all the conductors, and the conductor 11 and the conductor 12 and the conductor 14 with the conductor 15 on both sides of the welding flux material 2 as a welding flux member are welded together.

In order to further reduce the contact resistance between the conductors 12 and 13 and between the conductors 13 and 14, referring to fig. 2, transition conductors (e.g., conductive pads) 4 are disposed between the conductors 12 and 13 and between the conductors 13 and 14.

Referring to the schematic diagram of spot welding of the multi-layer conductors of the motor winding shown in fig. 3, a plurality of copper conductors 11, 12, 14, 15 extending from the slots of the iron core are arranged with their ends in the radial direction of the iron core, in order to weld the conductor 11 with the conductor 12 and the conductor 14 with the conductor 15, a welding flux material 2 is inserted between the conductor 11 and the conductor 12 and between the conductor 14 and the conductor 15, two electrodes 31, 32 clamp all the conductors in the radial direction of the iron core, the conductor 12 and the conductor 14 are reliably contacted, a welding current flows through all the conductors, and the conductor 11 and the conductor 12, the conductor 14 and the conductor 15 on both sides of the welding flux material 2 as a welding flux component are welded together. To further reduce the contact resistance between the conductors 12 and 14, a transition conductor (e.g., a conductive pad) 4 is disposed between the conductors 12 and 14, see fig. 4.

Of course, the flux components may be in addition to flux material, may be made of materials that assist in brazing together, or may be multiple layers of electrical conductors that carry flux material.

The conductor may be two or more conductors that have been welded together.

Referring to the schematic diagram of spot welding of the multi-layer conductors of the motor winding shown in fig. 5 and 6, a plurality of copper conductors 11, 12, 13, 14, 15 are extended from the slots of the iron core, the ends of the copper conductors are arranged in the radial direction of the iron core, and the conductors 11 and 12 and the conductors 14 and 15 need to be welded. The conductors 11, 14 each have a projection 6 on an end surface thereof.

The welding flux material (solder) 2 is extended between the projection 6 on the conductor 14 and the conductor 15, the two electrodes 31 and 32 clamp all the conductors along the radial direction of the iron core, the projection 6 on the conductor 11 is contacted with the conductor 12, the conductor 12 is reliably contacted with the conductor 13 and the conductor 13 is reliably contacted with the conductor 14, the projection 6 on the conductor 14 is contacted with the conductor 15 through the welding flux material 2, welding current flows through all the conductors, the conductor 11 and the conductor 12 on both sides of the projection 6 serving as a welding flux component are welded together, and the projection 6 serving as a welding flux component and the conductor 14 and the conductor 15 on both sides of the welding flux material 2 are welded together.

the soldering components can be any materials such as any amount of solder and the like which are helpful for brazing together, and can also be a multi-layer electric conductor structure carrying solder, and the structural form, the material, the state and the like of the soldering components do not affect the protection scope of the invention.