Special induction heating coil for motor winding aluminum row end-to-end welding

Abstract

The utility model discloses a special induction heating coil for motor winding aluminum row end-to-end welding, and relates to the technical field of aluminum row welding, the induction heating coil is a loop structure which is formed by winding the same section of metal piece, one end of the loop structure is a coil main body, and the other end of the loop structure is a coil base; wherein the coil main body is provided with two induction heating parts which are arranged in parallel, and the two induction heating parts can completely cover the two sides of an aluminum bar lap joint area respectively; and the coil base is connected with an induction heating power supply through a flexible cable. The induction heating coil can quickly heat the aluminum bar, the heating temperature of the aluminum bar is uniform, and the induction heating coil has the effect of improving the welding quality and the yield.

Description

TECHNICAL FIELD

[0001] The utility model relates to aluminium bar welding technical field more specifically, it relates to a kind of motor winding aluminium bar joint welding special inductive heating coil. BACKGROUND

[0002] In the field of motor manufacturing, especially in the structure of stator winding of large motor, copper bar is traditionally used as conductive material, and the connection between copper bars is realized by lap welding, as shown in Figure 1 The left side of the figure is a schematic diagram of copper bar 100 before welding, and the right side is a schematic diagram of copper bar 100 after welding. In the figure, A is the copper bar lap welding area. However, the high cost of copper material has always been a key factor restricting manufacturers to reduce production costs. In response to this challenge, some wind power equipment manufacturers have tried to replace copper bars with aluminum bars, aiming to take advantage of the lower cost of aluminum. However, the application of aluminum bars is not without flaws, and the welding process presents more technical challenges compared to copper bars.

[0003] The melting point of aluminum is significantly lower than that of copper, and the thermal conductivity is poorer, which directly increases the difficulty of aluminum bar welding. Initially, manufacturers used resistance welding technology for aluminum bar welding. This method uses the heat generated by the contact resistance to melt the pre-placed welding sheet, thereby achieving aluminum bar welding, as shown in Figure 2 , Figure 2 The figure shows a schematic diagram of the upper electrode 300 and the lower electrode 400 lap welding area resistance welding of aluminum bar 200, where B is the aluminum bar lap welding area. However, the easy oxidation of aluminum results in a layer of non-conductive aluminum oxide film on the surface of the aluminum bar, which needs to be removed before welding, seriously affecting production efficiency.

[0004] In addition, in actual operation, although the upper and lower electrodes try to compress the multiple layers of aluminum bar, the lap surface between the aluminum bars is difficult to achieve complete parallelism. This uneven contact state leads to significant differences in heat transfer efficiency. The well-contacted areas quickly heat up to the welding temperature, while the poorly contacted areas heat up slowly. This uneven temperature distribution phenomenon easily causes unstable welding quality. Some areas may have overheated and melted, while other areas have not yet reached the required temperature for welding, directly leading to low welding yield. According to statistics, the yield of a single welding using resistance welding technology is even lower than 50%.

[0005] In summary, in view of the low efficiency and unstable welding quality of existing aluminum bar welding technology, there is an urgent need to develop a more stable and reliable aluminum bar welding method to meet the urgent needs of the motor industry for low-cost, high-efficiency and high-quality welding technology. After analysis and comparison, it is found that inductive heating welding, as a non-contact welding method, can solve the above problems of aluminum bar welding. However, there is no special inductive heating coil for aluminum bar welding in existing technology. Utility model content

[0006] In view of this problem in actual application, the utility model aims at providing a motor winding aluminum bar butt joint welding special induction heating coil, adopts induction heating welding to realize aluminum bar butt joint welding, not only improves heating efficiency, but also can uniformly heat aluminum bar, guarantees welding quality, makes that welding yield greatly improves, specific scheme is as follows:

[0007] A motor winding aluminum bar butt joint welding special induction heating coil, the induction heating coil is a loop structure that is coiled from the same metal piece, one end of which is a coil body and the other end is a coil base;

[0008] Among them, the coil body has two induction heating parts arranged side by side, and the two induction heating parts can completely cover the two sides of the aluminum bar lap joint area respectively.

[0009] The coil base is connected to the induction heating power supply through a flexible cable.

[0010] Further, the induction heating part is in a mouth-shaped structure.

[0011] Further, a handheld transformer is further connected between the coil base and the flexible cable.

[0012] Further, it further includes a pressure rod device, which is located between the coil body and arranged axially along the induction heating coil, including an elbow clamp, a pressure rod, two insulating supports, the base of the elbow clamp is fixed on the coil base, the pressure rod is connected to the end of the elbow clamp, the pressure rod is located above the induction heating part, and the two insulating supports are respectively fixed to the bottom end of the two induction heating parts, and the top end of the two insulating supports forms a support part that supports the aluminum bar located between the two induction heating parts.

[0013] Further, the pressure rod device further includes a spring, which is installed between the elbow clamp and the pressure rod.

[0014] Further, the pressure rod device further includes an elbow clamp mounting plate and an elbow clamp support, and the base of the elbow clamp is fixed on the coil base through the elbow clamp support, the elbow clamp mounting plate and cooperating bolts.

[0015] Further, it further includes a coil opening and closing device, which includes a rotating screw, two rotating nuts, a knob and two rotating nut mounting plates, the two rotating nut mounting plates are respectively fixed to the opposite sides of the two induction heating parts, the rotating screw penetrates through the two rotating nut mounting plates, and the rotating screw is fixed with the knob at both ends, and the two rotating nuts are screw-connected on the rotating screw and respectively fixed on the two rotating nut mounting plates.

[0016] Further, the pressure rod device further comprises a pull plate connected between the base of the elbow clamp and the screw cap mounting plate.

[0017] Compared with the prior art, the special induction heating coil for aluminum bar butt welding has achieved remarkable beneficial effects in the aluminum bar butt welding of the wind power generator stator winding:

[0018] (1) Uniform heating temperature: The special induction heating coil can ensure uniform heating of the aluminum bar during welding, effectively avoiding welding defects caused by uneven temperature distribution in the existing resistance welding, thereby significantly improving the welding quality;

[0019] (2) Continuous pressure application: During welding, the setting of the pressure rod device can continuously apply pressure to the aluminum bar, which not only helps to maintain the close contact of the welded joint, but also further enhances the stability and reliability of the welding, ensuring the strength and integrity of the welded joint;

[0020] (3) Improve welding quality: Through the above technical features, the yield of aluminum bar butt welding reaches 100%, and the success rate of one-time welding also reaches 100%, significantly improving the welding quality;

[0021] (4) Reduce production cost: The application of this technology enables wind power equipment manufacturers to use aluminum bars instead of copper bars in wind power engine production, as the cost of aluminum material is much lower than that of copper material, which greatly reduces the production cost;

[0022] (5) Convenient and reliable operation: The special induction heating coil for aluminum bar butt welding realizes convenient and reliable operation, which is easy for workers to master, reduces the operation difficulty, and improves the production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 It is a schematic diagram of the state before and after the lap welding of the copper bar in the prior art;

[0024] Figure 2 It is a schematic diagram of the state when the copper bar is welded by resistance welding in the prior art;

[0025] Figure 3 It is a front view of the induction heating coil in Embodiment 1 of the utility model;

[0026] Figure 4 It is a side view of the induction heating coil in Embodiment 1 of the utility model;

[0027] Figure 5 It is a perspective view of the induction heating coil in Embodiment 1 of the utility model;

[0028] Figure 6This is a side view of the aluminum busbar being welded by the induction heating coil in Embodiment 1 of this utility model;

[0029] Figure 7 This is a three-dimensional structural diagram of the aluminum busbar being welded by the induction heating coil in Embodiment 1 of this utility model;

[0030] Figure 8 This is a front view of the coil pressure rod device in Embodiment 2 of this utility model;

[0031] Figure 9 This is a side view of the coil pressure rod device in Embodiment 2 of this utility model;

[0032] Figure 10 This is a three-dimensional structural diagram of the coil pressure rod device in Embodiment 2 of this utility model.

[0033] Figure label:

[0034] 1. Coil body; 11. Main body section; 12. Induction heating section; 2. Coil base; 3. Handheld transformer; 4. Flexible cable;

[0035] 51. Elbow clamp; 52. Elbow clamp mounting plate; 53. Elbow clamp bracket; 54. Spring; 55. Pressure rod; 56. Insulating base; 57. Pull plate;

[0036] 61. Screw; 62. Nut; 63. Knob; 64. Nut mounting plate;

[0037] 100, copper busbar; 200, aluminum busbar. Detailed Implementation

[0038] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0039] Example 1

[0040] like Figures 3-5 As shown, this embodiment provides a dedicated induction heating coil for parallel welding of aluminum busbars in motor windings. The induction heating coil is a loop structure formed by winding a single metal component, with one end being the coil body 1 and the other end being the coil base 2. This metal component can be made of copper. The coil body 1 and the coil base 2 are an integral structure. The coil body 1 is used to clamp and inductively heat the aluminum busbar 200. When the coil base 2 is energized, since the coil body 1 and coil base 2 form a single loop structure, when the coil base 2 is energized, the coil body 1 inductively heats the aluminum busbar 200 to achieve induction welding.

[0041] Specifically, the coil body 1 is a pair of parallel copper pieces, each of which has a main body part 11 and an induction heating part 12, that is, two main body parts 11 are arranged in parallel, and two induction heating parts 12 are also arranged in parallel. Among them, a single main body part 11 is in an L-shaped structure, and the induction heating part 12 is located at the end of the L-shaped structure of the main body part 11, mainly by two induction heating parts 12 clamping and induction heating the aluminum row 200. When the aluminum row 200 is clamped by the two induction heating parts 12, the two induction heating parts 12 can completely cover the two sides of the lap area of the aluminum row 200, respectively. Preferably, the induction heating part 12 is in a mouth-shaped structure, which can completely cover the two sides of the lap area of the aluminum row 200.

[0042] The coil base 2 is connected to the induction heating power supply through the handheld transformer 3 and the flexible cable 4. Among them, the structure of the coil base 2 can be adaptively changed according to the use demand to meet the fixed connection between the coil base 2 and the welding workbench, and the structure thereof is not limited in the application.

[0043] When the induction heating coil works, as Figures 6-7 , Figure 6 , 7 The state diagram when the induction heating coil induction heats and welds the aluminum row 200 is shown.

[0044] Embodiment 2

[0045] The difference between the technical features of this embodiment and embodiment 1 is that, as shown in Figures 8-10 , this embodiment also includes a pressure rod device and a coil opening and closing device. Among them, the pressure rod device is used to compress the multi-layer aluminum row 200, and continuously applies a certain pressure to the aluminum row 200 during welding, so that the multi-layer aluminum row 200 is tightly attached together after welding, to ensure the welding quality of the aluminum row 200. The coil opening and closing device is used to open the coil and hold the aluminum row 200 well after the aluminum row 200 enters between the coils.

[0046] Specifically, the pressing rod device is arranged between a pair of parallel copper pieces on the coil body 1 and along the axial direction of the copper pieces, and comprises an elbow clamp 51, an elbow clamp mounting plate 52, an elbow clamp support 53, a spring 54, a pressing rod 55, and two insulating supports 56. The base (not shown in the figure) of the elbow clamp 51 is fixed on the coil base 2 through the elbow clamp support 53, the elbow clamp mounting plate 52, and cooperating bolts. The working end of the elbow clamp 51 extends towards the induction heating part 12 on the coil body 1, and the pressing rod 55 is connected to the end of the working end through the spring 54. The pressing rod 55 is arranged above the induction heating part 12 and between the two parallel induction heating parts 12. The two insulating supports 56 are respectively fixed to the bottom ends of the two induction heating parts 12, and the top ends of the two insulating supports 56 extend upwards to the side walls opposite to the two induction heating parts 12 to form a support part (not shown in the figure) for supporting the aluminum row 200 between the two induction heating parts 12. It should be noted that the elbow clamp 51 is a vertical elbow clamp 51, which is a prior art and will not be described here.

[0047] The coil opening and closing device comprises a threaded rod 61, two threaded nuts 62, a knob 63, and two threaded nut mounting plates 64. The two threaded nut mounting plates 64 are respectively fixed to the opposite sides of the two induction heating parts 12. The threaded rod 61 penetrates through the two threaded nut mounting plates 64 in a direction perpendicular to the threaded nut mounting plates 64. The knob 63 is fixed to both ends of the threaded rod 61. The two threaded nuts 62 are screw-connected to the threaded rod 61 and are respectively fixed to the two threaded nut mounting plates 64. The threaded rod 61 is a positive and negative threaded rod. The two threaded nuts 62 are screw-connected to the positive and negative threads, respectively. After the threaded rod 61 is rotated, the two threaded nuts 62 can move in opposite or same directions, thereby driving the threaded nut mounting plates 64 to move in opposite or same directions, i.e., driving the two induction heating parts 12 to move in opposite or same directions.

[0048] In addition, the pressing rod device further comprises a pull plate 57 connected between the base of the elbow clamp 51 and the threaded nut mounting plate 64. After the elbow clamp 51 drives the pressing rod 55 to press the aluminum row 200, the pull plate 57 can keep the coil shape unchanged, thereby ensuring the pressing effect.

[0049] In addition, in order to increase the stability of the pressing rod device when pressing the aluminum row 200, grooves are uniformly arranged on the bottom end face of the pressing rod 55 and the end face of the support part (not shown in the figure). The grooves can increase the clamping friction, thereby improving the clamping stability.

[0050] The working principle of the utility model is as follows: during welding, firstly rotate the knob 63 to make the coil open to a width greater than that of the aluminum row 200, then put the induction heating coil down, make the aluminum row 200 inserted into the middle of the two sides of the induction heating coil, rotate the knob 63 in the opposite direction to make the induction heating part 12 on the induction heating coil clamping the aluminum row 200; then pull the handle on the elbow clamp 51 to make the pressing rod 55 press the aluminum row 200 until the aluminum row 200 is supported by the two insulating supports 56, at this time the aluminum row 200 is compressed, and the spring 54 between the elbow clamp 51 and the pressing rod 55 is also compressed, the compressed spring 54 can apply continuous pressure to the aluminum row 200 during welding to ensure the welding quality of the aluminum row 200; then start the induction heating power to make the coil heating part heat the aluminum row 200, complete the welding for about ten seconds, pull the handle of the elbow clamp 51 to make the pressing rod 55 rise, then rotate the knob 63 to open the induction heating coil, take the induction heating coil up to separate from the aluminum row 200, thus the welding process of one aluminum row 200 is completed.

[0051] The above only is the preferred implementation manner of the utility model, the protection scope of the utility model is not only limited to the above-mentioned embodiments, and all technical schemes under the idea of the utility model belong to the protection scope of the utility model. It should be noted that for ordinary skilled in the art, some improvements and decorations without departing from the principle of the utility model, these improvements and decorations should also be considered as the protection scope of the utility model.

Claims

1. A special induction heating coil for parallel welding of aluminum busbars in motor windings, characterized in that: The induction heating coil is a loop structure made of the same piece of metal, with one end being the coil body and the other end being the coil base; The coil body has two induction heating parts arranged in parallel, and the two induction heating parts can completely cover both sides of the aluminum busbar overlapping area. The coil base is connected to the induction heating power supply via a flexible cable.

2. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 1, characterized in that, The induction heating section has a square-shaped structure.

3. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 1, characterized in that, A handheld transformer is also connected between the coil base and the flexible cable.

4. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 1, characterized in that, It also includes a pressure rod device, which is located between the coil bodies and arranged along the axial direction of the induction heating coil. The device includes an elbow clamp, a pressure rod, and two insulating base supports. The base of the elbow clamp is fixed to the coil base, and the end of the elbow clamp is connected to the pressure rod. The pressure rod is located above the induction heating part. The two insulating base supports are respectively fixed to the bottom ends of the two induction heating parts. The top ends of the two insulating base supports form a base support that supports the aluminum strip located between the two induction heating parts.

5. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 4, characterized in that, The pressure bar device also includes a spring, which is installed between the elbow clamp and the pressure bar.

6. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 4, characterized in that, The pressure rod device also includes an elbow clamp mounting plate and an elbow clamp bracket. The base of the elbow clamp is fixed to the coil base via the elbow clamp bracket, the elbow clamp mounting plate, and bolts.

7. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 4, characterized in that, It also includes a coil opening and closing device, which includes a screw rod, two nuts, a knob, and two nut mounting plates. The two nut mounting plates are respectively fixed to the opposite sides of the two induction heating parts. The screw rod passes through the two nut mounting plates, and a knob is fixed at both ends of the screw rod. The two nuts are spirally connected to the screw rod and respectively fixed to the two nut mounting plates.

8. The induction heating coil for parallel welding of aluminum busbars in motor windings according to claim 7, characterized in that, The pressure bar device also includes a pull plate, which is connected between the base of the elbow clamp and the screw nut mounting plate.

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