Motor structure with connector or terminal block to which a conductive crimped connection is soldered

Abstract

Motor structure with a motor (10) wherein a winding wire (12) is wound around a stator core and one end of the winding wire is connected to a connector (16) or a terminal block (40), where a connecting element (14) attached to the end of the winding wire (12) is directly connected to the connector or terminal block by soldering, and the connecting element (14) has a wire receiving section (18) at one end and a connecting section (20) at the other end, wherein the end of the winding wire (12) is received in the wire receiving section (18) and is fixed by conductive crimping, and the connecting section (20) is directly connected to the connector or the terminal block, wherein a soldering container (30) having a hole section (28) is arranged on the connector or terminal block.

Description

Background of the invention 1. Field of the invention

[0001] The present invention relates to a motor structure with a connector or terminal block to which a conductively crimped connection is connected. 2. Description of the related prior art

[0002] In a motor structure where a wire is wound around a stator core and one end of the wire is connected to a terminal block or connector, removing a wire coating requires many man-hours. Conductive caulking can be used as a technique to reduce the man-hours required for coating removal. Conductive caulking is a manufacturing technique in which a wire is covered by a terminal, and a large current is applied to the terminal, causing the coating on the wire to vaporize due to heat. For example, JP 2004 - 343 831 A (or its related document EP 1 478 078 A2) discloses an electric motor and describes that "ends of guide wires 21U, 21V and 21W from each phase of a stator coil in an electric motor 20 are connected to ends of conductive elements 12U, 12V and 12W corresponding to each phase of a relay element 10 by means of a conductive crimping element 22".

[0003] The JP 2009 - 303 300 A reveals a three-phase electric motor and describes that “as in Fig. As shown in Figure 2(a), a coil guide wire B1 is inserted into an end terminal 31 from one end. Then, using a conductive crimping machine 40, the end terminal 31 is crimped such that the guide wire B1 is fixed to the end terminal 31 (see crimped marking 31b). Next, a corresponding connector guide wire A1 is inserted into the end terminal 31 from its other end. The guide wire A1 is inserted until it abuts a guide wire B2 inside the end terminal 31. By means of this, the guide wire A1 is electrically connected to the guide wire B1.

[0004] JP 2010-110 168 A discloses a connection method and a device in which the connection between a coil end and a terminal is automated, and describes that “a conductive rapping device 138 is a robot with a multi-jointed arm, and a movable electrode 138a and a fixed electrode 138b for conductive rapping are arranged on a front end of the arm. The conductive rapping device 138 performs conductive rapping by clamping a terminal 210 between the movable electrode 138a and the fixed electrode 138b and by applying current to the electrodes.”

[0005] JP 2000 - 69 705 A discloses a stator of an electric lathe and describes that "the other end of a connecting wire 24 for a common-mode coil is inserted into an annular section 28a of a phase terminal 28, as shown in Fig. 2 shown, and is joined and fixed by folding, ultrasonic welding or conductive caulking. In the case according to Fig. 1 Two coils 18a of common operating mode and two coils 18b of common operating mode (i.e., four coils) are provided. A ring section 28a of the phase terminal 28 is fixed to a corresponding terminal of a power cable terminal block 20 (e.g., the U-phase terminal 20a) by means of a fixing device, such as a screw, after the coil 18a (18b) has been inserted into a slot 16a of a stator core 16.

[0006] In contrast, a technique for saving space and the number of components was disclosed. For example, JP H11 - 150 904 A (or its related document DE 698 25 236 T2) discloses a stator connection and describes that “in Fig. 6, Fig. 7 to Fig. 8 A first connection terminal 451 is formed by conductive metal, wherein the outer wire connection terminal section 48, which is inserted and fixed into a first fitting hole 391 such that one end of the section protrudes from the first fitting hole 391, a flat connection plate section 49 having one end vertically connected to the other end of the connection section 48, and a coil connection terminal section 50, which is connected to the other end of the plate section 49, are formed in one piece. Before the first connection terminal 451 is attached to the stator 21, the coil connection terminal section 50 is vertically connected to the connection plate section 49 and extends in the opposite direction to the connection section 48 (i.e., in the direction away from a coil 34 when the connection section 48 is inserted into the first fitting hole 391).

[0007] In this regard, the coil connection terminal section 50 can be bent to overlap the connection plate section 49".

[0008] Furthermore, JP 2008 - 295 213 A discloses a structure and a method for motor coil connection and describes that “ Fig. Figure 1 shows an example of a coil connection structure, which is an embodiment of the invention. Conductors 11 are formed from a conductively crimped material, such as copper. One end of each conductor 11 is formed in the shape of a terminal as a terminal-shaped section 10, and the other end is attached to a current input section (connector) 12. The conductors 11 are formed in such a way as to correspond to and maintain the shape of the coil ends of a stator coil, and therefore the conductors 11 do not protrude outside the electric motor.

[0009] In JP 2004 - 343 831 A, the stator coil guide wire and the conductive element are inserted into the sleeve-shaped conductive crimping element, overlapping each other, and the guide wire is connected to the conductive element via the relay element. In JP 2009 - 303 300 A, one end of the coil guide wire and one end of the connector guide wire are electrically connected by conductive crimping within the end terminal, and the other end of the connector guide wire is connected to the connector. Furthermore, in JP 2010 - 110 168 A, the robot with the multi-jointed arm performs conductive crimping to automate the connection between the coil end and the terminal.

[0010] However, none of JP 2004 - 343 831 A, JP 2009 - 303 300 A, and JP 2010 - 110 168 A describe the method of connecting the conductive crimped terminal on the coil side to the connector or terminal block. Furthermore, in JP 2000 - 69 705 A, the ends of the multiple coils are conductively crimped to the round terminal, and the round terminal is connected to the terminal block. However, the round terminal is connected to the terminal block by means of a screw. As described above, in the conventional method, a considerable amount of space may be required for the screw connection of the crimped terminal, the design of the coil and / or guide wire, and the insulation between the components, etc. Moreover, if the relay element is used, the number of components may increase.

[0011] In contrast, it is understood that the technique described in JP H11-150904A intends to provide a special and flexible structure for the connection terminal, thus saving space by bending the connection terminal after the guide wire is conductively crimped. This is necessary because the connection terminal must be positioned at a distance from the coil core to perform the conductive crimping of the guide wire. Furthermore, it is understood that the technique described in JP 2008-295213A intends to save space by using a special one-piece connector with the insulating element and the conductor. However, such a specially structured terminal or one-piece connector can be expensive. Summary of the invention

[0012] The object of the invention is to provide a motor structure that is able to easily save space, is cost-effective and has few components, while utilizing a joining method using conductive crimping.

[0013] According to the invention, a device is provided as defined in the independent claim. Developments are described in the dependent claims.

[0014] Preferably, a motor structure is provided comprising a motor, wherein a winding wire is wound around a stator core and one end of the winding wire is connected to a connector or terminal block, wherein a connection element attached to the end of the winding wire is directly connected to the connector or terminal block by soldering, and wherein the connection element has a wire receiving section at one end and a connecting section at the other end, wherein the end of the winding wire is received in the wire receiving section and is fixed by conductive crimping, and the connecting section is directly connected to the connector or terminal block.

[0015] Preferably, the connecting section of the connecting element is a rod section, and the connector or the connecting block has a hole section into which the rod section can be inserted, so that the rod section is inserted into the hole section and soldered.

[0016] Preferably, the shape of a radial cross-section of the rod section of the connecting element is non-circular.

[0017] Preferably, the connection element is oriented such that it is separated from a peripheral element by a predetermined distance or more, or the connection element is oriented such that it is separated from a peripheral element by a predetermined distance or more, and soldering of the connection element is facilitated.

[0018] Preferably, the hole section of the connector or the connecting block has a cylindrical shape, and the radial cross-section of the rod section of the connecting element partially corresponds to a radial cross-section of the hole section as a circumscribed circle of the rod section, so that a gap is formed between the hole section and the rod section that is inserted into the hole section.

[0019] Preferably, the hole section of the connector or terminal block has a countersunk bore at its open end, the diameter of which is larger than the diameter of the hole section.

[0020] Preferably, the hole section of the connector or terminal block has a rotation-stopping structure configured not to be rotated, with the terminal element being soldered to the hole section. Brief description of the drawings

[0021] The above-described and other problems, features, and advantages of the invention will become more apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings. These show: Fig. 1 a perspective view showing an engine structure according to a first embodiment of the invention; Fig. 2 an example of a connecting element attached to one end of a coiled wire; Fig. 3 a state in which the connecting element is conductively crimped; Fig. 4 a partial cross-sectional view of the engine structure according to Fig. 1; Fig. 5 another example of a connecting element attached to the end of the winding wire; Fig. 6 Another example of a connecting element attached to the end of the winding wire; Fig. 7 an example of positioning the connection element of the first embodiment; Fig. 8 an example of a rotation-stopping structure to prevent simultaneous rotation of the connection element and the hole section after soldering; Fig. 9 a perspective view showing an engine structure according to the second embodiment of the invention; and Fig. 10 an example of positioning the connection element of the second embodiment. Detailed description

[0022] Fig. Figure 1 shows a perspective view illustrating the basic structure of a motor according to a first embodiment of the invention. In the motor structure 10, a winding wire 12 is wound around a stator core (not shown), a connecting element 14 is attached to one end of the winding wire 12 by conductive crimping, and the connecting element 14 is directly connected to a connector 16 by soldering.

[0023] Fig. Figure 2 shows a view illustrating an embodiment of the terminal element 14 before conductive crimping. The terminal element 14 has a wire receiving section 18 which receives one end of each of at least one (5 in the embodiment according to Fig. 1) The winding wire 12 receives, and a connecting section 20 is attached, which can be directly connected to the connector 16 or a terminal block (as described below) by soldering. In the embodiment according to Fig. In Figure 2, the wire receiving section 18 is essentially a cylindrical element, and the connecting section 20 is a rod element that can be inserted into a connecting hole of the connector 16. Although the wire receiving section 18 can be directly connected to the rod section 20, it is preferred that they be connected to each other via a tapered section 22, as shown. Furthermore, it is preferred that a central axis 24 of the wire receiving section 18 and a central axis 26 of the rod section 20 are parallel to each other but do not coincide (i.e., are offset from each other). In addition, the connecting element 14 can be easily manufactured by a method in which a plate element is stamped in a specific shape and the stamped element is rolled.

[0024] Fig. Figure 3 shows a view depicting a state in which a winding wire 12 is inserted into the wire receiving section 18 of the terminal element 14 according to Fig. 2 is inserted, and the winding wire 12 and the connecting element 14 are connected by conductive crimping. As in Fig. As shown in Figure 3, the wire receiving section 18 is contracted in its radial direction by conductive crimping, so that the received winding wire 12 is securely fixed. Such conductive crimping can be carried out at a location separate from the connector 16 or a terminal block, as will be described below. Furthermore, by means of the tapered section 22 as described above, the size of the crimped structure is smoothly increased from the wire receiving section 18 to the rod section 20, thereby improving the strength of the terminal element 14.

[0025] Fig. Figure 4 shows a partially enlarged view of a connection section between the terminal element 14 and the connector 16. The terminal element 14, which is conductively crimped, as shown in Fig. As shown in Figure 3, the connector 14 is directly connected to the connector 16 by soldering. Specifically, a hole section 28, capable of receiving the rod section 20 of the connecting element 14, is formed on the connector 16, and the rod section 20 is inserted into the hole section 28 and soldered to it. In the illustrated embodiment, an element (or soldering container) 30 with the hole section 28 is arranged on the connector 16, the number of which is the same as the number of connecting elements to be connected to the connector 16 (four soldering containers are arranged in the illustrated embodiment).

[0026] Since the conductive crimping process of the terminal element 14 and the winding wire 12 can be performed at a location separate from the connector 16 or the terminal block, heat generated by the conductive crimping is not transferred to the connector 16 or the terminal block. Therefore, it is prevented that a section (e.g., a resin section) of the connector 16 or the terminal block with a low melting point melts, and it is also prevented that a coating on a current-carrying section of the connector 16 or the terminal block oxidizes, thus improving the reliability of the motor. Furthermore, by directly soldering the terminal element 14 to the connector 16 or the terminal block, the number of connection components can be reduced.

[0027] As described above, a section of the terminal element 14 opposite the wire insertion side is formed as the rod section 20, the hole section 28 is formed on the connector 16 or the terminal block, and the rod section 20 is inserted into the hole section 28 and soldered. By means of this, the terminal element can be easily connected to the connector or terminal block using the structure (referred to as the solder cup) adapted for soldering.

[0028] The shape of a section of the connecting element 14, which is connected to the connector 16, can be designed arbitrarily, as long as the section can be directly connected to the connector by soldering. However, as in Fig. As shown in Figure 2, it is preferred that a radial cross-section of the bar section 20 of the connecting element 14 is non-circular. For example, the bar section 20 of the connecting element 14 has a radial cross-section of 20 as shown in Figure 2. Fig. 2. A general triangular cross-section (more precisely, a triangle with rounded corners). Due to such a design, if the central axes of the wire receiving section 18 and the rod section 20 are offset from each other, the positional relationship between the rod section 20 and the wire receiving section 18, which is flattened by the conductive crimping, can always be constant. In other words, if the conductive crimping is performed automatically using a robot, etc., a ring position with respect to the central axis of the rod section (or the terminal element) to be gripped cannot be determined if the rod section has a simple column shape, which means that the positional relationship between the rod section and the flattened wire receiving section can be different between each terminal element.However, if the rod section has a polygonal shape, the orientation (or angular position) of the connection element can be constant by utilizing a plane of the polygonal shape, thus ensuring a constant positional relationship between the rod section and the wire receiving section after conductive crimping. Furthermore, if the positional relationship between the rod section and the wire receiving section is constant, the multitude of connection elements can have the same shape. Therefore, even if the distance between each hole 28 is comparatively small, as in . Fig. As shown in Figure 1, wire reception sections 18 do not interfere with each other.

[0029] Although Fig. Figure 2 shows a triangular prism as an example, in which the rod segment 20 does not have a column shape; another shape can be used for the rod segment. For example, Figure 2 shows... Fig. 5 a rod section 20a of the connecting element 14a with a generally square prism, i.e., whose cross-section is generally a square (more precisely, a square with rounded corners). In contrast, shows Fig. 6. The rod section 20b of the connecting element 14b has a column shape, wherein a part of it is planarly cut off or removed along its axial direction. In other words, a cross-section of the rod section 20b has a general circular shape, wherein a part of it (in the illustrated embodiment, two sections that are radially opposite each other) is linearly cut off or removed.

[0030] Sections (a) to (c) according to Fig. Figure 7 shows top views of the connector 16 and examples of positioning the connecting element 14 of the invention. Fig. 7. The terminal element 14 is oriented such that it is separated from a peripheral element by a predetermined distance or more, or the terminal element 14 is oriented such that it is separated from a peripheral element by a predetermined distance or more, and the soldering of the terminal element 14 is simplified. Specifically, adjacent terminal elements 14 are separated from each other by a predetermined distance or more, and the orientation of the wire receiving section 18 is varied after the conductive crimping of the terminal element 14. Such configurations allow for the required distance to insulate terminal elements 14 from each other or from a housing to which the connector is attached.Specifically, in sections (a) and (b), a movement path (shown by an arrow 42) of a soldering iron used to solder each terminal element is close together, whereby an amount of movement of the soldering iron can be reduced and the terminal element can be soldered effectively.

[0031] If the cross-section of the connecting element is non-circular, as in Fig. 2, Fig. 5 and Fig. As shown in Figure 6, and since the hole section 28 of the connector 16 is cylindrical, the bar section of the connecting element can be inserted into the hole section, reducing the clearance between them. Specifically, the radial cross-section of the bar section of the connecting element partially corresponds to the radial cross-section of the hole section 28 (i.e., the circle) as a circumscribing circle of the bar section. In other words, bar sections 20, 20a, and 20b, as shown in Figure 6, exhibit a circumscribing circle of the bar section. Fig. 2, Fig. 5 and Fig. Figure 6 shows cross-sections in which 3, 4, or 2 circumferential sections are cut off from the circle, corresponding to the cross-section of the hole section 28. This allows the rod section to be inserted into the hole section without play by contacting the uncut section of the rod section with the inner surface of the hole section. Furthermore, since a certain gap is formed between the inner surface of the hole section and the cut-off section of the rod section after insertion, a soldering compound can easily flow within the hole section, thus enabling suitable soldering without trapping air within the hole section.

[0032] Furthermore, as in Fig. As shown in Figure 4, it is preferred that the diameter of the hole section 28 is enlarged at one of its open ends, or more specifically, that a countersunk bore 32 is formed on a solder container 30 at its open end, the diameter of which is larger than the diameter of the hole section 28. This allows the countersunk bore 32 to retain molten solder, thus preventing it from flowing out of the solder container 30. Since the solder contacts both the terminal element 14 and the solder container 30, heat can be easily transferred between them, and soldering conditions, such as the heating time of the components to be soldered and / or the solder flow rate, can be easily controlled, thereby simplifying the soldering process.

[0033] Fig. Figure 8 shows an example of a rotation-stopping structure for preventing simultaneous rotation of the connector element and the hole section after soldering the connector element. Specifically, to prevent the orientation of the connector element 14 from being changed by simultaneous rotation of the connector element 14 and the hole section 28 after soldering, a convex section 36, which does not have a simple cylindrical shape, is formed on a sleeve element 34 with the hole section 28, and a concave section 38, which has an essentially complementary shape to the convex section 36, is formed on the side of the connector 16 into which the sleeve element 34 is inserted, so that simultaneous rotation is prevented by the convex section 36 fitting with the concave section 38.For example, the convex section 36 has a polygonal column shape, such as a square column shape, and the concave section 38 has a tall section that has a polygonal or square column shape. By means of such a rotation-stopping structure, even if a force is applied to the winding wire 12 to rotate the connecting element 14 relative to the hole section 28, the simultaneous rotation of the connecting element and the hole section can be avoided.

[0034] Fig. Figure 9 shows a motor structure according to a second embodiment of the invention. Specifically, the terminal element 14 is connected to a terminal block 40 and not to a connector 16. The terminal block 40 has a solder cup 30 similar to the connector 16, and the method of connecting the terminal element 14 can be the same as that shown in Figure 9. Fig. 1, and therefore a detailed description will be omitted. Although the connecting element 14 is connected to the connecting block 40 in the lateral direction in Fig. 9 is connected, it is preferred that during the soldering process the orientation of the terminal block is changed such that the terminal element 14 is connected to the solder container 30 from above.

[0035] Sections (a) to (c) according to Fig.Figure 10 shows front views of the terminal block 40, illustrating examples of positioning the terminal element 14 in the second embodiment. In one example, the terminal element 14 is oriented such that it is separated from a peripheral element by a predetermined distance or more. In the other example, the terminal element 14 is oriented such that it is separated from a peripheral element by a predetermined distance or more, facilitating soldering of the terminal element. Specifically, adjacent terminal elements 14 are separated from each other by a predetermined distance or more, and the orientation of the wire receiving sections 18 is varied after conductive crimping of the terminal element 14. Such configurations allow for the necessary separation of the terminal elements 14 to be achieved.In each of sections (a) to (c), a movement path (indicated by an arrow 44) of a soldering iron used to solder each terminal element is aligned in the same direction, enabling the terminal elements to be soldered effectively.

[0036] According to the invention, since the conductive crimping of the terminal element and the winding wire can be performed at a location separate from the connector or terminal block, heat generated by the conductive crimping is not transferred to the connector or terminal block, thus preventing melting or degradation of the components. Furthermore, since the terminal element is directly connected to the connector or terminal block by soldering, no additional connecting element, etc., is required, thereby reducing the number of components and the cost of the motor structure.

[0037] By forming a section of the connecting element that is connected to the connector or terminal block, such as the rod section, and by forming the hole section into which the rod section can be inserted on the connector or terminal block, the soldering process can be easily carried out using a structure that is called a soldering container.

[0038] By forming the connecting element such that the radial cross-section of the rod section is non-circular, the positional relationship between the wire receiving section and the rod section can easily be constant after conductive crimping.

[0039] By aligning the connection elements at a predetermined or more intervals and by appropriately changing the orientation of the connection element when the connection element is inserted into the connector or terminal block, a specific distance between each terminal block can be achieved, and the soldering process is simplified.

[0040] If the radial cross-section of the rod section of the connecting element partially corresponds to a radial cross-section of the hole section as a circumscribing circle of the rod section, so that a gap is formed between the hole section and the rod section that is inserted into the hole section, the solder can easily flow within the hole section, allowing the soldering to be carried out properly without including air within the hole section.

[0041] By forming the countersunk hole at the open end of the hole section of the connector or terminal block, it is prevented that the solder flows out of the hole section, and / or a soldering condition can be appropriately controlled.

[0042] By positioning the anti-rotation structure at the hole section of the connector or terminal block, simultaneous rotation of the terminal element and the hole section after soldering can be prevented, thus achieving an insulation gap between each terminal element. Furthermore, operation during soldering can be simplified.

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