Laser Welding Method

Abstract

To provide a method for welding two flat wires by uniformly heating the flat layers using a laser.SOLUTION: This laser welding method comprises: a preparation step; and a welding step. In the preparation step, side surfaces of ends of conductors 91 of two flat wires 90 in a longitudinal direction are joined together. In the welding step, a region including a boundary between end surfaces of the conductors 91 of the two flat wires 90 is irradiated with a laser beam to weld the flat wires 90 together. The laser beam is passed through a transmission optical system, and then applied to the end surfaces of the flat wires 90. The transmission optical system is rotatable, and the irradiation position of the end surfaces with the laser beam changes in a first direction in accordance with a rotational phase of the transmission optical system. In the welding step, the first direction is set parallel to the long sides of the end surfaces of the flat wires 90, and the region including the boundary between the end surfaces of the conductors 91 of the two flat wires 90 is irradiated with a pulse laser beam to weld the flat wires 90 together.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates primarily to a method for welding rectangular wires using a laser. [Background technology]

[0002] In recent years, rectangular wires have been used in electrical equipment such as motors. A rectangular wire is an electric wire in which an insulating coating is formed around a conductor with a rectangular cross section. Since rectangular wires have a higher space factor than electric wires with a circular cross section, they can be used to miniaturize devices or increase their output. When using rectangular wires as segment coils, the ends of the rectangular wires need to be welded together. Patent Document 1 discloses a method for welding rectangular wires together.

[0003] In Patent Document 1, the end sides of the conductors of two rectangular wires are first butted together, and then a laser is irradiated onto the end face of the first rectangular wire. At this time, the laser is scanned in a loop to form a molten pool. After that, the loop diameter of the laser path is increased until the molten pool reaches the butt face of the first rectangular wire and the second rectangular wire. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6593280 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the welding method of Patent Document 1, the molten pool formed in the first rectangular wire is larger than the molten pool formed in the second rectangular wire, which means that the two rectangular wires are not heated evenly.

[0006] The present invention has been made in consideration of the above circumstances, and its main object is to provide a method for welding two rectangular wires by evenly heating the two rectangular wires using a laser. [Means for solving the problem]

[0007] The problem to be solved by the present invention has been described above. Next, the means for solving this problem and the effects thereof will be described.

[0008] According to an aspect of the present invention, the following laser welding method is provided. That is, the laser welding method includes a preparation step and a welding step. In the preparation step, the side surfaces of the longitudinal ends of two rectangular wire conductors are aligned. In the welding step, a region including a boundary between the end faces of the two rectangular wire conductors is aligned. Irradiation time intervals are on the order of nanoseconds or less The rectangular wires are welded together by irradiating a pulsed laser. The pulsed laser is irradiated onto the end faces of the rectangular wires after passing through a transmission optical system. The transmission optical system is rotatable, and the irradiation position of the pulsed laser onto the end faces changes in a first direction according to the rotation phase of the transmission optical system. In the welding process, the pulsed laser is irradiated onto an area including the boundary between the end faces so that the first direction is parallel to the long sides of the end faces of the rectangular wires, thereby welding the rectangular wires together.

[0009] This allows welding to be performed by scanning a pulsed laser in a direction parallel to the long side of the end faces of the rectangular wires, so that the two rectangular wires can be heated evenly using the laser. Effect of the Invention

[0010] According to the present invention, a method for welding two rectangular wires by uniformly heating the two rectangular wires with a laser can be provided. [Brief description of the drawings]

[0011] [Figure 1] 1 is a perspective view of a laser processing apparatus according to a first embodiment. [Diagram 2] FIG. [Diagram 3] FIG. [Figure 4] 13A and 13B are diagrams showing how the path of a laser changes when the laser passes through a light-transmitting member. [Diagram 5]FIG. 4 is a plan view showing how the optical scanning device scans with a laser in a first direction. [Figure 6] 11 is a side view showing how the optical scanning device scans with a laser in a second direction. FIG. [Figure 7] FIG. 2 is a schematic diagram showing laser marks left on a rectangular wire. [Figure 8] FIG. 13 is a diagram showing the difference in the range of the melted portion of the rectangular wire between the conventional technology and this embodiment. [Figure 9] 13 is a plan view showing how an optical scanning device according to a second embodiment scans with a laser in a first direction. [Figure 10] 13 is a side view showing how the optical scanning device of the second embodiment scans with a laser in a second direction. FIG. [Figure 11] 13 is a plan view showing how the rectangular wire is welded while the processing head is moved in a direction parallel to the long side direction of the rectangular wire. FIG. [Figure 12] 13 is a plan view showing how the rectangular wire is welded while the processing head is moved in a direction parallel to the short side direction of the rectangular wire. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Next, an embodiment of the present invention will be described with reference to the drawings. First, a configuration of a laser processing device 1 will be described with reference to Fig. 1. Fig. 1 is a perspective view of the laser processing device 1. The laser processing device 1 is used to weld rectangular wires 90.

[0013] The rectangular wire 90 is an electric wire in which an insulating coating 92 is formed around a conductor 91 having a rectangular cross section. When the rectangular wire 90 is used for a segment coil for a motor or the like, it is necessary to weld the ends of the rectangular wire 90 together. Specifically, as shown in FIG. 1, the insulating coating 92 at the ends of two rectangular wires 90 is peeled off, and the sides of the ends of the conductors 91 of the two rectangular wires 90 are brought together. In this state, the conductors 91 are welded by irradiating the end faces of the conductors 91 of the two rectangular wires 90 (particularly, the area including the boundary between the two conductors 91) with a laser.

[0014] As shown in FIG. 1, the laser processing apparatus 1 includes a laser generator 11, a support member 12, and a processing head 13.

[0015] The laser generator 11 generates a pulsed laser with a short time interval by pulse oscillation. The time interval of the pulsed laser is not particularly limited, but the laser generator 11 generates a pulsed laser with a short time interval, for example, on the order of nanoseconds, picoseconds, or femtoseconds. In the following description, the "pulsed laser" generated by the laser generator 11 will be simply referred to as a "laser."

[0016] The support member 12 supports the processing head 13. A plurality of optical components (mirrors, prisms, etc.) are arranged inside the support member 12 for guiding the laser generated by the laser generator 11 to the processing head 13. Instead of a configuration using a plurality of optical components, the laser may be guided from the laser generator 11 to the processing head 13 using an optical fiber.

[0017] The processing head 13 irradiates the rectangular wire 90 with a laser generated by the laser generator 11 and transmitted through the support member 12. The processing head 13 is provided with an optical scanning device 14. The processing head 13 of this embodiment is fixed and configured to perform welding without moving relative to the rectangular wire 90. Instead of this configuration, the processing head 13 may be configured to perform welding while moving relative to the rectangular wire 90 (details will be described later). Alternatively, welding may be performed by moving the rectangular wire 90 while the processing head 13 is fixed.

[0018] As shown in FIGS. 2 and 3, the optical scanning device 14 includes a light collecting member 21, a reflecting member 22, an electric motor 23, a rotating table 24, and a transmission optical system 30. The light collecting member 21 is a light condensing member.

[0019] The focusing member 21 is a focusing lens that focuses the laser. The focusing member 21 is not limited to a focusing lens, and may be, for example, a parabolic mirror. The reflecting member 22 is a mirror or a prism that reflects the laser. The reflecting member 22 reflects the laser focused by the focusing member 21, thereby changing the traveling direction of the laser. The laser reflected by the reflecting member 22 travels toward the transmission optical system 30.

[0020] The electric motor 23 generates a rotational driving force. The rotational driving force generated by the electric motor 23 is transmitted to the turntable 24. As a result, the turntable 24 rotates about a rotation axis 81. Note that the light collecting member 21 and the reflecting member 22 are rotatable relative to the turntable 24, and the light collecting member 21 and the reflecting member 22 do not rotate even when the turntable 24 rotates.

[0021] The turntable 24 is provided with a transmission optical system 30. When the turntable 24 rotates, the transmission optical system 30 also rotates integrally with the turntable 24. The transmission optical system 30 is composed of a plurality of light-transmitting members that transmit a laser. Specifically, the transmission optical system 30 includes a first light-transmitting member 31, a second light-transmitting member 32, a third light-transmitting member 33, a fourth light-transmitting member 34, a fifth light-transmitting member 35, and a sixth light-transmitting member 36. The first light-transmitting member 31 to the sixth light-transmitting member 36 of this embodiment are plate-like members with a constant thickness, and are arranged to form a polygon (a regular hexagon in this embodiment).

[0022] When the laser passes through the light-transmitting member, the path of the laser changes (is offset). The laser processing device 1 utilizes this principle to scan the laser. Hereinafter, the principle of the change in the path of the laser will be described with reference to FIG. 4. The light-transmitting member has an incident surface where the laser is incident and an exit surface where the laser is emitted. The incident surface and the exit surface of the light-transmitting member are parallel. Furthermore, if the incident surface and the reflecting surface of the light-transmitting member are perpendicular to the laser, the path of the laser does not change, and if the incident surface and the reflecting surface of the light-transmitting member are not perpendicular to the laser, the path of the laser changes.

[0023] When a laser enters a light-transmitting member, the laser is refracted. Specifically, the refraction angle θ2 is different from the incident angle θ1. The relationship between the incident angle θ1 and the refraction angle θ2 depends on the ratio of the refractive index of the air to the refractive index of the light-transmitting member. The laser is also refracted when it is emitted to the outside from the light-transmitting member. Since the incident surface and the emission surface of the light-transmitting member are parallel, the direction of the laser entering the light-transmitting member and the direction of the laser exiting from the light-transmitting member are parallel. However, the position of the laser entering the light-transmitting member and the position of the laser exiting from the light-transmitting member differ by a distance D.

[0024] The distance D depends on the angle of the light-transmitting member with respect to the laser, the thickness of the light-transmitting member, and the ratio of the refractive index of the light-transmitting member to the refractive index of the air. In this embodiment, the ratio of the thickness of the light-transmitting member to the refractive index is constant, so the distance D changes depending on the angle of the light-transmitting member with respect to the laser.

[0025] The first light-transmitting member 31 to the sixth light-transmitting member 36 of this embodiment are fixed to the rotary table 24. Therefore, the first light-transmitting member 31 to the sixth light-transmitting member 36 can be rotated by rotating the rotary table 24. For example, when a laser is transmitted through the first light-transmitting member 31, the angle of the first light-transmitting member 31 with respect to the laser changes according to the rotation phase of the first light-transmitting member 31 (transmission optical system 30) as shown in FIG. 5. As a result, according to the above-mentioned principle, the above-mentioned distance D changes according to the rotation phase of the first light-transmitting member 31 (transmission optical system 30). That is, the laser is scanned by rotating the transmission optical system 30 while irradiating the laser. The direction of the laser at this time is hereinafter referred to as the "first direction".

[0026] The optical scanning device 14 of this embodiment also scans the laser in a direction (second direction) perpendicular to the first direction using the same principle. As shown in FIG. 6, the first light-transmitting member 31 and the fourth light-transmitting member 34 stand upright with respect to the rotary table 24, while the second light-transmitting member 32 and the fifth light-transmitting member 35 are inclined inward (toward the rotation axis 81), and the third light-transmitting member 33 and the sixth light-transmitting member 36 are inclined outward. In other words, the angle of the light-transmitting member with respect to the laser changes as the light-transmitting member through which the laser passes is switched. As a result, the distance D in the second direction changes as the light-transmitting member through which the laser passes is switched. As described above, the optical scanning device 14 also scans the laser in the second direction.

[0027] In summary, while the laser is passing through one light-transmitting member, the laser irradiation position changes in a first direction (scans in the first direction). Then, when the rotation of the turntable 24 progresses and the laser is about to pass through the next light-transmitting member, the laser irradiation position moves in a second direction (scans in the second direction).

[0028] FIG. 7 shows a schematic diagram of the order in which the conductor 91 of the rectangular wire 90 is irradiated with a laser. In FIG. 7, the laser marks are adjacent to each other to make the order of laser irradiation easier to see, but in reality, the laser marks overlap each other. Also, in FIG. 7, the number of times the laser is irradiated in the first direction is 10, but in reality, it is highly likely that more than that number of times is irradiated. In FIG. 7, three rows of laser are irradiated in the second direction, but in reality, it is highly likely that four or more rows of laser are irradiated.

[0029] Next, the welding method of the present embodiment will be compared with the conventional technology with reference to Figs. 7 and 8. As shown in Fig. 7, the first direction is parallel to the long side of the cross section (rectangular shape) of the conductor 91 of the rectangular wire 90. In other words, the first direction is parallel to the line (boundary line) drawn by the boundary between the conductors 91 of the two rectangular wires 90. The conductors 91 of the two rectangular wires 90 are welded together by irradiating a laser onto an area including the boundary between the end faces of the conductors 91 of the two rectangular wires 90 and scanning in the first direction. Note that, since the beam diameter of the laser of this embodiment is small, the laser is scanned in the second direction in addition to the first direction.

[0030] In the conventional method, a preparation step is first performed in which the side faces of the longitudinal ends of the conductors 91 of two rectangular wires 90 are aligned. Next, as shown in Fig. 8, a laser is irradiated onto the end face of the conductor 91 of one of the rectangular wires 90, and the laser is scanned in a loop to form a molten pool. After that, the diameter of the laser path is increased until the molten pool reaches the area including the boundary between the conductors 91 of the two rectangular wires 90.

[0031] In the conventional method, the conductor 91 of one of the rectangular wires 90 is heated intensively, so the conductors 91 of the two rectangular wires 90 are not heated evenly. Specifically, as shown in the lower diagram of FIG. 8, the melted portion of the conductor 91 of the rectangular wire 90 that is first irradiated with the laser is smaller than the melted portion of the conductor 91 of the other rectangular wire 90.

[0032] In contrast, in the method of the present embodiment, as in the conventional technology, a preparation process is first performed in which the side surfaces of the longitudinal ends of the conductors 91 of two rectangular wires 90 are aligned. Next, a welding process is performed in which a laser is irradiated to an area including the boundary between the end faces of the conductors 91 of the two rectangular wires 90 to weld the rectangular wires 90 together. In the welding process, as shown in Figures 7 and 8, the laser is scanned along the long side of the conductor 91. Therefore, as shown in the lower diagram of Figure 8, the conductors 91 of the two rectangular wires 90 can be evenly melted.

[0033] In addition, in the conventional technology, the laser irradiation position needs to be adjusted so that the diameter increases while repeatedly drawing the loop, so the program for laser irradiation tends to be complicated. In contrast, in the method of the present embodiment, if the shape and direction of the transmission optical system 30 are determined so that the laser is irradiated to the range suitable for welding the rectangular wires 90 together, the two rectangular wires 90 can be accurately welded by simply placing the rectangular wires 90 in the appropriate position relative to the processing head 13.

[0034] Next, an optical scanning device 14 according to a second embodiment will be described with reference to FIGS.

[0035] The optical scanning device 14 of the second embodiment includes a light collecting member 21, a rotating table 24, and a light transmitting member 37. As shown in Fig. 9, the light transmitting member 37 has a hexagonal shape. The light transmitting member 37 is fixed to the rotating table 24. In detail, the light transmitting member 37 is fixed to the rotating table 24 so that the center of the light transmitting member 37 coincides with the center of the rotating table 24 (i.e., the rotation axis 81). The light transmitting member 37 rotates by rotating the rotating table 24. On the other hand, even if the rotating table 24 rotates, the light collecting member 21 does not rotate.

[0036] As shown in Fig. 9, the incident surface of the light-transmitting member 37 on which the laser (bold line) is incident and the exit surface from which the laser is emitted from the light-transmitting member 37 are parallel to each other. Also, the incident angle of the laser changes according to the rotation phase of the light-transmitting member 37. Therefore, according to the principle described with reference to Fig. 4, the path of the laser changes according to the rotation phase of the light-transmitting member 37. In this way, also in the second embodiment, the laser is scanned in the first direction.

[0037] The optical scanning device 14 of the second embodiment can also scan the laser in a second direction. Hereinafter, a configuration for scanning the laser in the second direction will be described with reference to Fig. 10. Fig. 10 shows three sets of perspective views and side views showing how the laser passes through the light-transmitting member 37.

[0038] 10, the light-transmitting member 37 includes a first side surface 37a, a second side surface 37b, a third side surface 37c, a fourth side surface 37d, a fifth side surface 37e, and a sixth side surface 37f. The first side surface 37a and the fourth side surface 37d are positioned opposite each other, the second side surface 37b and the fifth side surface 37e are positioned opposite each other, and the third side surface 37c and the sixth side surface 37f are positioned opposite each other.

[0039] The top perspective view and side view of Fig. 10 show how a laser is incident on the first side surface 37a and emitted from the fourth side surface 37d. As shown in the side view, the first side surface 37a and the fourth side surface 37d are perpendicular to the rotary table 24. Therefore, when a laser is incident on the first side surface 37a and emitted from the fourth side surface 37d, the position of the laser in the second direction does not change. Similarly, when a laser is incident on the fourth side surface 37d and emitted from the first side surface 37a, the position of the laser in the second direction does not change.

[0040] The oblique view and side view in the center of FIG. 10 show how the laser is incident on the second side surface 37b and emitted from the fifth side surface 37e. As shown in the side view, the second side surface 37b and the fifth side surface 37e are inclined toward the downstream side of the laser with respect to the perpendicular line of the rotary table 24. In other words, the second side surface 37b and the fifth side surface 37e are not perpendicular to the laser. Therefore, when the laser is incident on the second side surface 37b and emitted from the fifth side surface 37e, the position of the laser in the second direction changes (more specifically, it changes to the side approaching the rotary table 24). Similarly, when the laser is incident on the fifth side surface 37e and emitted from the second side surface 37b, the position of the laser in the second direction changes.

[0041] The perspective view and side view at the bottom of Fig. 10 show how a laser is incident on the third side surface 37c and emitted from the sixth side surface 37f. The inclination direction of the third side surface 37c and the sixth side surface 37f is opposite to that of the second side surface 37b and the fifth side surface 37e. Therefore, when a laser is incident on the third side surface 37c or the sixth side surface 37f, the position of the laser in the second direction changes (specifically, changes to the side away from the rotary table 24).

[0042] In summary, while the laser is passing through one surface of the light-transmitting member 37, the laser irradiation position changes in a first direction (scanned in the first direction). Then, when the laser passes through the next surface of the light-transmitting member 37, the laser irradiation position moves in a second direction (scanned in the second direction). Therefore, in the second embodiment, the laser can be scanned in the same way as in the first embodiment.

[0043] Next, a method for welding the rectangular wire 90 while moving the processing head 13 will be described with reference to Figs.

[0044] 11 shows a state in which the flat wire 90 is welded while the processing head 13 is moved in a direction parallel to the long side of the flat wire 90. In this case, the length of the laser scanning in the first direction by the optical scanning device 14 can be made smaller than the length of the long side of the flat wire 90.

[0045] FIG. 12 shows a state in which the flat wire 90 is welded while moving the processing head 13 in a direction parallel to the short side of the flat wire 90. The laser processing device 1 moves the processing head 13 in a direction parallel to the short side of the flat wire 90, and then moves the processing head 13 in a first direction relative to the flat wire 90. After that, the laser processing device 1 welds the flat wire 90 while moving the processing head 13 again in a direction parallel to the short side of the flat wire 90. By performing the method shown in FIG. 12, even if there is a gap at the boundary between the flat wires 90 to be welded, the flat wires 90 can be properly welded together.

[0046] As described above, the laser welding method of this embodiment includes a preparation step and a welding step. In the preparation step, the side surfaces of the longitudinal end portions of the conductors 91 of the two rectangular wires 90 are aligned. In the welding step, the flat wires 90 are welded together by irradiating a laser onto an area including the boundary between the end faces of the conductors 91 of the two rectangular wires 90. The laser is irradiated onto the end faces of the rectangular wires 90 after passing through the transmission optical system 30. The transmission optical system 30 is rotatable, and the irradiation position of the laser onto the end faces changes in the first direction according to the rotation phase of the transmission optical system 30. In the welding step, the first direction is parallel to the long side of the end faces of the rectangular wires 90, and the pulse laser is irradiated onto an area including the boundary between the end faces of the conductors 91 of the rectangular wires 90 to weld the flat wires 90 together.

[0047] As a result, welding is performed by scanning the laser in a direction parallel to the long sides of the end faces of the rectangular wires 90, so that the two rectangular wires 90 can be uniformly heated by the laser.

[0048] In this embodiment, depending on the rotation phase of the transmission optical system 30, the irradiation position of the laser on the end face of the conductor 91 of the rectangular wire 90 also changes in a second direction on the end face that is perpendicular to the first direction.

[0049] This allows the laser to be irradiated not only to the boundary between the conductors 91 of the two rectangular wires 90 but also to the surroundings, so that the rectangular wires 90 can be more appropriately welded together.

[0050] In this embodiment, a laser is emitted from the processing head 13 toward the conductor 91 of the rectangular wire 90. In the welding process, welding of the rectangular wires 90 together is completed with the relative positions of the processing head 13 and the rectangular wire 90 fixed.

[0051] This eliminates the need to move the processing head 13 or the rectangular wire 90, allowing welding to be completed in a short time.

[0052] In this embodiment, the laser is emitted from the processing head 13 toward the conductor 91 of the rectangular wire 90. In the welding process, the processing head 13 is moved relative to the rectangular wire 90 in a direction parallel to the long side of the rectangular wire 90 or in a direction parallel to the short side of the rectangular wire 90 while irradiating the pulsed laser, thereby welding the rectangular wires together.

[0053] This makes it possible to weld rectangular wires together even when the laser scanning range is smaller than that of rectangular wires.

[0054] Although the preferred embodiment of the present invention has been described above, the above configuration can be modified, for example, as follows.

[0055] The structure for scanning the laser in the first direction is one example, and an optical scanning device with a structure other than that described above may be used.

[0056] In the above embodiment, the optical scanning device 14 scans with the laser in the first direction and the second direction. Alternatively, the optical scanning device 14 may be configured to scan with the laser only in the first direction. [Explanation of symbols]

[0057] 1 Laser processing equipment 11 Laser generator 12 Support member 13 Processing head 14 Optical scanning device 21 Light collecting member 22 Reflective material 23 Electric Motor 24 Rotating Table 30 Transmission optical system 90 Rectangular wire 91 Conductor 92 Insulation coating

Claims

1. A preparation step of aligning the side surfaces of the longitudinal ends of two rectangular wire conductors; a welding process for welding the rectangular wires together by irradiating a pulsed laser having an irradiation time interval of nanoseconds or less to an area including a boundary between end faces of the conductors of the two rectangular wires; Including, The pulsed laser is irradiated onto the end surface of the rectangular wire after passing through a transmission optical system, the transmission optical system is rotatable, and an irradiation position of the pulse laser onto the end surface is changed in a first direction according to a rotation phase of the transmission optical system; A laser welding method characterized in that, in the welding process, the pulse laser is irradiated to an area including the boundary between the end faces so that the first direction is parallel to the long side of the end faces of the rectangular wire, thereby welding the rectangular wires together.

2. 2. The laser welding method according to claim 1, a rotation phase of the transmission optical system being rotated so that the irradiation position of the pulsed laser on the end face is further changed in a second direction on the end face perpendicular to the first direction.

3. 3. The laser welding method according to claim 1 or 2, The pulsed laser is emitted from the processing head toward the conductor of the rectangular wire, A laser welding method characterized in that in the welding step, welding of the rectangular wires to each other is completed with the relative positions of the processing head and the rectangular wire fixed.

4. 3. The laser welding method according to claim 1 or 2, The pulsed laser is emitted from the processing head toward the conductor of the rectangular wire, The laser welding method is characterized in that in the welding process, the processing head is moved relative to the flat wire in a direction parallel to the long side of the flat wire or in a direction parallel to the short side of the flat wire while irradiating the flat wire with a pulsed laser, thereby welding the flat wires together.

Images