Welding method for rotary transformer and multi-strand cable

Abstract

The invention relates to a welding method for a rotary transformer and a multi-strand cable in the technical field of wire harnesses, which comprises the following steps of: carrying out half stripping and wire twisting treatment on the multi-strand cable, then stranding the multi-strand cable in a pairwise combination mode, horizontally arranging the multi-strand cable side by side in sequence by adopting a wire clamp structure, and finally, welding the multi-strand cable in the wire clamp structure. And welding the multi-strand cable with the connecting terminal. According to the welding method provided by the invention, rapid and accurate connection of the rotary transformer and the multi-strand cable is realized, and the anti-interference capability of the wire harness is remarkably improved. According to the utility model, the rotary transformer and the multi-strand cable can be accurately butted with the connecting terminal rapidly at one time in the welding process by adopting the layout of the twisted wires and the wire clamp structure in pairs, so that the production efficiency is greatly improved. In addition, by means of the convenient and efficient butt joint mode, automation can be conveniently achieved in the welding process, manual operation is reduced, wiring errors are avoided, and then the production speed and the product quality are improved.

Description

Technical Field

[0001] The invention relates to the technical field of wire harnesses, and in particular to a method for welding a rotary transformer and multiple cables. Background Art

[0002] As a type of position sensor, the resolver (referred to as "resolver") can work under harsh environmental conditions, such as mechanical vibration, high speed, high angular acceleration, noise-free, flammable, explosive, high and low temperature (-40~155℃), and has the advantages of high precision, high reliability, simple and compact structure, and low cost. It is widely used in power motors to detect the angle and speed of the motor rotor. Motors with resolvers have been well received in the field of automotive motors for their excellent characteristics. The resolver can accurately control the speed, position, and torque of the motor by adjusting the angle relationship between the resolver stator and the resolver rotor.

[0003] At present, the rotary transformers on the market are mainly composed of a rotor pressed by silicon steel sheets, a stator pressed by silicon steel sheets, an insulating frame installed or injection molded thereon, three coil winding groups wound on the insulating frame, and a signal harness for transmitting signals. In order to improve the efficiency of connecting the three coil winding groups with the signal harness, the insulating frame is usually provided with connecting terminals for connecting the three coil winding groups with the signal harness. At present, the signal harness is mainly welded on the connecting terminal manually, and the production capacity is difficult to further increase. Since the three coil winding groups of excitation, sine and cosine must be connected, the six cables of this harness are respectively connected to the ports corresponding to the connecting terminals. Since the existing harnesses are usually distributed in irregular bundles, it is easy to make wiring errors during the welding process, and the welding work cannot be completed at one time, which is not suitable for large-scale automated production. Therefore, the welding of the harness and the rotary transformer still relies on manual operation, which not only reduces the production efficiency, but also limits the further improvement of the yield rate due to the problem of wrong wiring. Summary of the invention

[0004] The present invention provides a method for welding a rotary transformer and a plurality of cables to solve the problems mentioned in the above background technology.

[0005] The object of the present invention is achieved in the following ways:

[0006] A method for welding a rotary transformer and a plurality of cables comprises the following steps:

[0007] Step 1: Cut the multiple cables to be connected to the rotary transformer to the same length;

[0008] Step 2: peel off a portion of the insulation skin at one end of the multi-strand cable to form an exposed core portion of the cable, and retain a certain length of insulation skin at the end of the cable to ensure that both ends of the exposed core portion are wrapped with insulation skin;

[0009] Step 3: Using a wire twisting machine to twist the exposed part of the battery core;

[0010] Step 4: Twisting the multiple cables in pairs;

[0011] Step 5: using a plurality of limiting grooves of the line card structure to sequentially arrange the plurality of cables side by side and horizontally;

[0012] Step six: directly connecting the multiple cables arranged side by side and horizontally to the connection terminals of the rotary transformer, and welding the multiple cables to the connection terminals.

[0013] Furthermore, in step one, the multiple cables use insulation sheaths of different colors.

[0014] Furthermore, the step two is specifically as follows: performing a ring cut on one end of the multi-strand cable to form a detachable first insulating skin in a tubular shape at one end of the multi-strand cable, and pulling the first insulating skin a certain distance toward the end of the cable to form the exposed portion of the battery core.

[0015] Furthermore, the length of the first insulating skin is greater than the length of the exposed portion of the battery core.

[0016] Furthermore, the step three is specifically as follows: the wire twisting machine clamps the two ends of the exposed part of the battery core respectively, and the wire twisting machine drives one end of the exposed part of the battery core to rotate a specified number of circles along the axis of the cable.

[0017] Furthermore, in step six, after the multi-strand cable and the connecting terminal are welded, the first insulating sheath is cut or removed, and the line card structure is removed from the multi-strand cable.

[0018] Furthermore, the step four is specifically as follows: the twisted wire starts from the cable away from the exposed part of the battery cell until the exposed part of the battery cell ends, and a first distance is set between the end of the twisted wire and the exposed part of the battery cell.

[0019] Furthermore, the length of the first spacing is less than 3-8 times the length of the exposed portion of the battery cell.

[0020] Furthermore, in step six, the connection terminal is provided with a plurality of ports respectively connected to the plurality of cable strands, the plurality of ports are horizontally spaced apart, and the spacing between the plurality of ports is the same as the spacing between the plurality of limiting grooves.

[0021] The welding method provided by the present invention not only realizes the rapid and accurate connection between the rotary transformer and the multi-strand cable, but also significantly improves the anti-interference ability of the wiring harness. By adopting the layout of two-by-two twisted wires and the wire card structure, the rotary transformer and the multi-strand cable can be quickly and accurately connected to the connection terminal at one time during the welding process, thereby greatly improving production efficiency. In addition, this convenient and efficient docking method makes it easy to automate the welding process, reduces manual operation, avoids wiring errors, and thus improves production speed and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a schematic diagram of the rotary transformer and the multi-strand cables after welding in the first embodiment;

[0023] Figure 2 This is a first schematic diagram of completing step five in the first embodiment;

[0024] Figure 3 This is a second schematic diagram of completing step five in the first embodiment;

[0025] Figure 4 This is a schematic diagram of completing step five in the second embodiment;

[0026] Figure 5 This is a first schematic diagram of completing step five in the third embodiment;

[0027] Figure 6 This is a second schematic diagram of completing step five in the third embodiment;

[0028] Figure 7 It is a partial cross-sectional view of the cable after completing step 2 in the first embodiment;

[0029] Figure 8 It is a partial cross-sectional view of the cable after completing step 2 in the fourth embodiment;

[0030] The reference numerals in the figure are: 1-rotating transformer, 1A-connecting terminal, 2-cable, 2A-exposed part of the battery cell, 2B-first insulating skin, 3-wire clamp structure, 3A-handle, 3B-first elastic arm, 3C-second elastic arm, 3D-limiting groove, 3E-elastic clamp plate, 3F-fixing cover. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0032] Embodiment 1:

[0033] In this embodiment, a method for welding a rotary transformer and a plurality of cables is specifically implemented, comprising the following steps:

[0034] Step 1: Cut the multiple cables 2 to be connected to the rotary transformer 1 to the same length;

[0035] Step 2: peel off a portion of the insulation at one end of the multi-strand cable 2 to form a core exposed portion 2A of the cable 2, and retain a certain length of insulation at the end of the cable 2 to ensure that both ends of the core exposed portion 2A are wrapped with insulation;

[0036] Step 3: Use a wire twisting machine to twist the exposed part 2A of the battery core;

[0037] Step 4: Twisting the multiple cables 2 in pairs;

[0038] Step 5: Use the multiple limiting grooves 3D of the line card structure 3 to arrange the multiple cables 2 in parallel and horizontally in sequence;

[0039] Step 6: directly connect the multiple cables 2 arranged side by side and horizontally to the connection terminal 1A of the rotary transformer 1, and weld the multiple cables 2 and the connection terminal 1A.

[0040] In this embodiment, the multiple cables 2 are respectively insulated with different colors for easy identification. Each color can represent the cables 2 of three coil winding groups (excitation, sine and cosine). At the same time, through color coding, installation and maintenance personnel can quickly identify and handle specific cables 2, thereby improving work efficiency and reducing wiring errors. In particular, in step three, cables 2 of different colors can facilitate accurate pairing of multiple cables 2. In addition, this approach also helps to comply with relevant safety regulations and standards to ensure the safe operation of the electrical system.

[0041] The insulation retained at the end of the cable 2 in step 2 of this embodiment can prevent the battery core at the end of the cable 2 from splitting, improve the stability of the cable 2 during the transfer process, and when the cable 2 is inserted into the connecting terminal 1A, the insulation retained at the end of the cable 2 will protrude outside the connecting terminal 1A. Due to the different colors of different cables 2, it can play a striking identification effect and avoid the cable 2 from being connected to the wrong position. After the multi-strand cable 2 is welded to the connecting terminal 1A, the insulation retained at the end of the cable 2 during the stripping process needs to be cut to ensure that it does not affect the subsequent glue injection process. At the same time, remove the wire card structure 3 on the multi-strand cable 2 for recycling and reuse. After completing the last welding step, the welding points need to be carefully checked to ensure that there is no cold welding or short circuit. This step is crucial because any welding defects may cause circuit instability or even complete failure. Inspection work is usually performed by experienced technicians using a multimeter to ensure that each welding point meets quality standards.

[0042] The wire twisting process in step 3 is as follows: use a wire twisting machine to clamp the two ends of the exposed part 2A of the battery core respectively, and use the wire twisting machine to drive the outer end of the exposed part 2A of the battery core to rotate 0.8-5 circles along the axis of the cable 2. After the rotation is completed, ensure that the tightness of the twisted wire meets the technical specifications to prevent looseness or bifurcation during the subsequent welding process. Then, perform a visual inspection of the twisted battery core to ensure that there is no damage or abnormal twisting of the cable 2. Through these steps, the stability and safety of welding can be effectively improved.

[0043] The purpose of the wire twisting process is to further increase the compactness of the battery core and improve the strength of the exposed portion 2A of the battery core. In the subsequent welding process, the high-strength battery core can avoid the copper core from becoming loose and bifurcated.

[0044] The twisting process in step 4 is specifically as follows: spirally wrap the two corresponding cables 2 around each other to twist the two cables 2 into a wire harness, and the twisting process starts from the cable 2 away from the exposed part 2A of the battery cell and ends at the exposed part 2A of the battery cell, and a first spacing is set between the end of the twisted wire and the exposed part 2A of the battery cell.

[0045] The purpose of the twisted wire process is to twist the two cables 2 connected to the same coil winding group to avoid twisting the cable 2 with the cables 2 of other coil winding groups, thereby reducing the probability of mutual interference, significantly improving the stability of each group of coil cables 2, and completely solving the problem of subsequent wiring sequencing errors. In actual operation, the application of twisted wire processing not only effectively reduces electromagnetic interference, but also improves the flexibility and reliability of the bending of the wire harness. In addition, twisted wire processing also simplifies maintenance and repair work, because the clear twisting pattern makes fault location more convenient, thereby shortening maintenance time and reducing maintenance costs.

[0046] In this embodiment, the length of the exposed portion 2A of the cell depends on the port width of the connection terminal 1A. In actual operation, the length of the exposed portion 2A of the cell is usually slightly larger than the port width. Preferably, the length of the first spacing is less than 3-8 times the length of the exposed portion 2A of the cell. The purpose of setting the first spacing is to reserve length for the subsequent installation of the line card structure 3.

[0047] Furthermore, in order to improve the safety performance of the multi-strand cable 2, at least one circle of protective tape can be spirally wrapped around the position of the multi-strand cable 2 corresponding to the twisted wire processing, so as to concentrate the multi-strand cable 2 and prevent it from being scattered. In addition, in order to ensure the stability and durability of the cable 2 in long-term use, it can also be covered with a layer of heat shrink tube after winding the protective tape. After heating, the heat shrink tube will fit tightly to the surface of the cable 2 to form an additional protective layer, which effectively resists external physical damage and chemical corrosion. When selecting a heat shrink tube, it should be ensured that its material is compatible with the insulating material of the cable 2 to avoid possible chemical reactions. At the same time, the diameter of the heat shrink tube should be slightly larger than the diameter of the cable 2 after winding, so that it can be completely shrunk and tightly wrapped around the cable 2 after heating. Through such double protection measures, the overall performance and service life of the multi-strand cable 2 can be significantly improved.

[0048] like Figure 1-3 As shown, the line card structure 3 used in step five includes a plurality of limiting grooves 3D for fixing the cable 2, and the plurality of limiting grooves 3D and the plurality of ports for docking with the cable 2 provided on the connection terminal 1A are arranged in the same side-by-side horizontal manner, which is used to ensure that multiple strands of cable 2 can be accurately inserted into the port at one time, so that the wire harness can complete the welding function at one time, eliminating the problem of wiring errors, and at the same time, significantly improving the welding efficiency of the wire harness. This welding method simplifies the complex steps of wiring one by one in the traditional welding process, reduces the dependence on highly skilled operators, and reduces labor costs. At the same time, due to the extremely high wiring accuracy, rework and scrap rates are greatly reduced, further reducing production costs.

[0049] Furthermore, a handle portion 3A is integrally formed on one side of the cable card structure to improve grip stability, and a limiting groove 3D is arranged in a C shape to facilitate fixing and clamping the cable.

[0050] Furthermore, since the two cables 2 of the same coil winding group have been twisted in step 4, it is not easy to separate the two cables 2 of the same coil winding group when the wire card structure 3 is used to connect and sort the multiple cables 2 in step 5, thereby greatly reducing the error probability of sorting the multiple cables 2.

[0051] The welding method provided by the present invention not only realizes the fast and accurate connection between the rotary transformer 1 and the multi-strand cable 2, but also significantly improves the anti-interference ability of the wiring harness. By adopting the layout of two-by-two twisted wires and the wire card structure 3, the rotary transformer 1 and the multi-strand cable 2 can be quickly and accurately connected to the connection terminal 1A at one time during the welding process, thereby greatly improving production efficiency. In addition, this convenient and efficient docking method makes it easy to automate the welding process, reduces manual operation, avoids wiring errors, and thus improves production speed and product quality.

[0052] Embodiment 2:

[0053] like Figure 4 As shown, the difference between this embodiment and the first embodiment is that the line card structure is composed of a first elastic arm 3B and a second elastic arm 3C arranged in parallel and spaced relation, a plurality of limiting grooves 3D are formed between the first elastic arm 3B and the second elastic arm 3C, and an opening expanding outward is provided on one side of the line card structure to facilitate access to the cable. The one-way limiting channel formed by the first elastic arm 3B and the second elastic arm 3C is adopted, so that the cables can be conveniently loaded into the limiting grooves 3D in sequence. Compared with the one-by-one alignment installation of the first embodiment, the installation difficulty of this solution is lower and it is more suitable for use with the automatic pairing equipment.

[0054] Embodiment three:

[0055] like Figure 5-6 As shown, the difference between this embodiment and the above embodiment is that the line card structure 3 is composed of an elastic card plate 3E and a fixed cover 3F, the two ends of the elastic card plate 3E are snap-fitted with the fixed cover 3F through buckles, and multiple limiting grooves 3D are located between the elastic card plate 3E and the fixed cover 3F.

[0056] Furthermore, in order to facilitate the disassembly and recovery of the line card structure 3 of this embodiment, a gap is left between the buckle and the fixing cover 3F.

[0057] Embodiment 4:

[0058] like Figure 7 As shown, in step 2 of embodiment 1, part of the insulation skin is directly stripped off at one end of the cable 2. Although this can form an exposed portion 2A of the battery core, it is impossible to retain a longer length of insulation skin at the end of the cable 2, and the marking effect is limited.

[0059] like Figure 8 As shown, this embodiment is a preferred solution of the first embodiment. In step 2, one end of the multi-strand cable 2 is cut in a ring so that one end of the multi-strand cable 2 forms a detachable first insulating skin 2B in a tubular shape, and the first insulating skin 2B is pulled out a certain distance toward the end of the cable 2 to form a battery cell exposed portion 2A. This retains the insulating skin that should be stripped, significantly increases the length of the first insulating skin 2B, and improves the identification effect of the cable. At the same time, the longer first insulating skin 2B is also conducive to subsequent cutting and removal, and reduces the cutting length of the battery cell, reducing resource waste.

[0060] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention is disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with the profession can make some changes or modifications to equivalent embodiments of equivalent changes by using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent changes and modifications made to the above embodiments according to the technology of the present invention are within the scope of the technical solution of the present invention without departing from the content of the technical solution of the present invention.

Claims

1. A method for welding a rotary transformer and a plurality of cables, characterized in that: The steps include: Step 1: Cut the multiple cables to be connected to the rotary transformer to the same length; Step 2: peel off a portion of the insulation skin at one end of the multi-strand cable to form an exposed core portion of the cable, and retain a certain length of insulation skin at the end of the cable to ensure that both ends of the exposed core portion are wrapped with insulation skin; Step 3: Using a wire twisting machine to twist the exposed part of the battery core; Step 4: Twisting the multiple cables in pairs; Step 5: using a plurality of limiting grooves of the line card structure to sequentially arrange the plurality of cables side by side and horizontally; Step six: directly connecting the multiple cables arranged side by side and horizontally to the connection terminals of the rotary transformer, and welding the multiple cables to the connection terminals.

2. The method for welding a rotary transformer and a plurality of cables according to claim 1, characterized in that: In the step 1, the multiple cables are respectively insulated with different colors.

3. The method for welding a rotary transformer and a plurality of cables according to claim 1, characterized in that: The step 2 specifically comprises: performing a ring cut on one end of the multi-strand cable to form a detachable first insulating skin in a tubular shape at one end of the multi-strand cable, and pulling the first insulating skin a certain distance toward the end of the cable to form the exposed portion of the battery core.

4. The method for welding a rotary transformer and a plurality of cables according to claim 3, characterized in that: The length of the first insulating skin is greater than the length of the exposed portion of the battery core.

5. A method for welding a rotary transformer and a plurality of cables according to any one of claims 1 to 4, characterized in that: The step three is specifically as follows: the wire twisting machine clamps the two ends of the exposed part of the battery core respectively, and the wire twisting machine drives one end of the exposed part of the battery core to rotate a specified number of times along the axis of the cable.

6. The method for welding a rotary transformer and a plurality of cables according to claim 5, characterized in that: In the step six, after the multi-strand cable and the connecting terminal are welded, the first insulating sheath is cut or removed, and the line card structure is removed from the multi-strand cable.

7. The method for welding a rotary transformer and a plurality of cables according to claim 1, characterized in that: The step four is specifically as follows: the twisted wire starts from the cable away from the exposed part of the battery core until the exposed part of the battery core ends, and a first distance is set between the end of the twisted wire and the exposed part of the battery core.

8. The method for welding a rotary transformer and a plurality of cables according to claim 7, characterized in that: The length of the first interval is less than 3-8 times the length of the exposed portion of the battery cell.

9. The method for welding a rotary transformer and a plurality of cables according to claim 1, characterized in that: In the step six, the connection terminal is provided with a plurality of ports respectively connected to the plurality of cable strands, the plurality of ports are horizontally spaced apart, and the spacing between the plurality of ports is the same as the spacing between the plurality of limiting grooves.

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