Method for making an electrically conductive wire and device therefor

专利摘要:
The present invention relates to a method of manufacturing an electrically conducting wire for windings for a rotating electric machine from a conducting wire (14) having a generally round cross-sectional shape, which method comprises the steps of continuously withdrawing the round conducting wire (14) from a source; And applying longitudinal force to the wire on the radially opposed region to form longitudinal flats M, M 'on that region. Round wire 14 is provided with an insulating coating (E), characterized in that a force is applied through the coating.
公开号:KR20040002421A
申请号:KR1020027017936
申请日:2002-04-30
公开日:2004-01-07
发明作者:에방데니
申请人:발레오 에뀝망 엘렉뜨리끄 모떼르；
IPC主号:

专利说明:

METHOD FOR MAKING AN ELECTRICALLY CONDUCTIVE WIRE AND DEVICE THEREFOR}
[3] One application of such wires is to form windings for stators, starters or transformer inductors, inductances, etc. of automotive alternators or alternator starters.
[4] In this regard, in order to form this type of winding, and in view of optimizing the compactness of the machine it forms part of or improving cooling, it is necessary to use conducting wire with flat parts formed. That is, it is necessary to produce a conducting wire having a cross section flattened, for example in the form of a rectangle, in particular a rectangle.
[5] While the use of such wires is beneficial for forming windings, it nevertheless has some significant drawbacks.
[6] First, during the manufacture of the wire, it is inevitable that the speed at which the wire of rectangular cross section is drawn through the machine and especially the machine applying the insulating enamel coating is slower than the drawing speed of the wire with round cross section, which is acceptable in mass production lines. Hard to do
[7] Also, in the coating machine, enamel is difficult to apply to the edge of the conducting wire. This results in a difference in enamel thickness on the wire surface.
[8] To overcome this drawback, rounded corners are formed with a minimum radius of curvature so that the insulating coating is properly attached. Nevertheless, this results in a reduction in the overall effective cross section of the wire.
[9] In this connection, for a wire having a cross section having a thickness of 1.4 mm and a width of 2 mm, having a radius of curvature of 0.5 mm, for example a rectangular cross section, the wire having a rectangular cross section having a total cross section of 2.585 mm 2 and In comparison, the loss is 8%.
[10] In addition, the use of a wire having a flat portion tends to twist if the wire is not guided completely, making it relatively difficult to wind or unwind. Thus, it is essential to perform the adjustment operation on the turret, while round wires can be easily coiled into bins and withdrawn from the bins without the need to rotate the bins when the wires are drawn.
[11] Therefore, winding and unrolling the flat wire on the turret requires the rotation of the barrel, unlike the case of a round wire barrel.
[12] In addition, while finding a flat turret having a weight of 80 kg or more on the market is not easy, a round wire barrel can easily accommodate 200 kg or 300 kg or more of wire, thereby reducing the frequency of production interruptions.
[13] After all, there is only a single diameter for round wires of any cross-section, but there are various configurations that can be considered for flat wires of certain cross-sections, which means that the producers and sellers of such wires have a large inventory. It can prevent.
[14] Summary of the Invention
[15] It is an object of the present invention to overcome these disadvantages.
[16] Thus, the present invention provides a method of manufacturing an electrically conducting wire for windings for a rotating electric machine from a conducting wire having a generally round cross section, which method
[17] Continuously drawing round conducting wire from the source,
[18] Applying a longitudinal force to the wire on the radially opposite region to form a longitudinal flat on the region,
[19] The round wire has an insulating envelope, and is characterized in that a force is applied through the covering.
[20] The method according to the invention thus enables a flat wire to be obtained advantageously at low cost, the wire being insulated by a coating such as enamel, for example, and the layer constitutes an insulating coating. To this end, it is much easier and cheaper to apply an insulating layer on round wires than on wires having a shape other than at least one flat or circular cross section.
[21] The method may include one or more of the following features of individually or technically possible combinations.
[22] After applying the force in the thickness direction of the wire, an additional force is applied in the width direction of the wire on the radially opposed region at right angles to the formed flat part, thereby forming a wire having a generally rectangular cross section.
[23] The generally rectangular cross-sectional insulated wire obtained in accordance with the present invention allows the wound stator to be economically manufactured hairpin-type. Preferably this hairpin form has two branches which define the conducting bar, which are introduced into the slots of the stator. Each slot can receive at least two conductors. Four branches are preferably inserted in radial alignment into each slot of the stator, for example to constitute a six phase alternator. The generally rectangular cross section enables the filling factor of the slot to be optimized.
[24] A force is applied in the longitudinal direction of the wire in the thickness direction and at the same time an additional force is applied on the radially opposite area of the wire in the width direction of the wire to form a wire having a rectangular cross section in which adjacent flat portions define a right angle.
[25] Thus, the wire produced has a perfect rectangular cross section which allows the slots of the stator or rotor of the rotary electric machine to be filled with high filling rates.
[26] Each said step of applying said force consists in passing a wire between at least a pair of forming rolls.
[27] The ratio between the length and the width of the cross section of the wire is 2 or less, each step of applying the force in the thickness and width direction of the wire consists of passing the wire between a single pair of forming rolls.
[28] The invention also relates to an apparatus for producing an electrically conducting wire for windings for a rotating electric machine from a conducting wire having a generally round cross-sectional shape, the wire being provided with an insulating sheath, the apparatus being provided on the radially opposite area of the wire. At least one pair of forming rolls suitable for exerting a force together through the coating to form a flat on the wire with means for passing the wire between the rolls.
[1] The present invention relates to a method of manufacturing an electrically conducting wire for a winding electric machine winding and to an apparatus for carrying out such a method.
[2] In particular, the present invention relates to a method for producing an electrically conducting wire having a longitudinal flat from a conducting wire having a generally round cross section.
[29] 1 is a view of an apparatus for producing an electrically conducting wire according to the present invention,
[30] 2 shows one phase of shaping of the wire by the method according to the invention,
[31] 3 shows another forming phase in the method according to the invention,
[32] 4 shows how a phase for forming a wire is performed in the method according to the invention,
[33] 5 is a schematic view from the direction of movement of the wire, showing an embodiment of another device for producing an electrical wire, in particular a conductor according to the invention,
[34] 6 is a schematic view of an alternator having a stator wound with a wire manufactured according to the present invention;
[35] 7 is a perspective view of the stator of FIG. 1, with the conducting element removed to show the slots in the stator; FIG.
[36] 8 is a schematic diagram showing an example of the connection of a phase winding;
[37] 9 is a cross-sectional view showing a state in which a conductive element manufactured according to the present invention is disposed in a slot in the stator of FIG.
[38] 1 shows an apparatus for manufacturing a wire having a longitudinal flat, which is indicated generally by the reference numeral 10.
[39] The wire is made of a wire of round cross section which is drawn continuously from the feed bin 12 in which it is coiled.
[40] The flat wire to be produced is intended to form a winding for a rotating electric machine, for example.
[41] To produce such a wire, the starting material is a wire of round cross section comprising a central core A of an electrically conductive material such as copper coated with an insulating material layer E constituting the electrically insulating coating. It is preferable that this electrical insulation coating body is enamel.
[42] As can be seen in FIG. 1, the apparatus basically provides a set of forming rolls suitable for forming a shape by forcing the wires together, and feeding the wires in the direction indicated by the arrow F between them. For example, means (not shown) composed of a motor driven roller feeder.
[43] In the embodiment shown, the wire to be produced has a rectangular cross section.
[44] Thus, the wire passes between two sets of forming roller pairs, i.e., the first set of forming roller pairs P1, P2, P3, and P4, each roll being in the area facing in the radial direction of the wire 14. Longitudinal forces are applied to each other to form, with the second set of forming rolls P1 and P2, a generally parallel portion in this area, the axis of the second set of forming rolls P1 and P2 being the first set of forming rolls. It is perpendicular to the axis of (P1, P2, P3, P4), thereby forming the lateral flat portion at right angles to the flat portion formed by the first set of rolls.
[45] 2 and 3, at the proximal end of the wire, this forming operation is carried out in two successive forming phases, during which the proximal end of the wire passes between the two assemblies of the forming roll to correspond. Flat portions M and M 'are formed, respectively.
[46] The force exerted on this forming operation is applied directly on the enamel layer surrounding the conductor of the wire 14.
[47] Thus, for each set of rolls, it is preferable that a plurality of sets of rolls be used, each applying a sufficiently weak compressive force not to deform the enamel layer constituting the insulating coating.
[48] In particular, if the ratio of the length and width of the cross section of the final conducting wire is greater than 2, several pairs of forming rolls are used for each forming phase.
[49] Depending on the form of the finished product, it is possible to use a single set of rolls.
[50] In this regard, if it is appropriate to simply form only two radially opposing flats on the wire, in order to form two radially opposing longitudinal flats, a single assembly consisting of one or more pairs of rolls may be It is used to apply a force on the radially opposite area.
[51] Finally, with reference to FIG. 4, an upstream roll to be used when the configuration of the finished wire does not need to use multiple sets of rolls positioned in the downstream direction in consideration of the direction of movement of the wire in each forming phase. The silver roll is preferably a forming roll whose outer working surface, ie the surface to which the force is applied, is concave, while the downstream roll has a flat working surface.
[52] In this way, the level of stress applied to the insulating enamel layer is significantly reduced.
[53] 5 shows another embodiment of an apparatus for producing a wire of rectangular cross section from a round cross section wire. In the case of FIG. 5, the final rectangular shape places two pairs of rolls (e.g. P1, P1 ') such that their axes of rotation are perpendicular to each other as shown in FIG. Directly attained by being coplanar at right angles, ie allowing them to act simultaneously in the thickness and width directions. The roll P1 flat across the thickness is motor driven to advance as the wire is molded. On the other hand, the roll P1 'which deforms the wire in the width direction may not be motor driven. Thus, the device described in the embodiment of FIG. 5 has the advantage that from a round wire with an insulating sheath, it is possible to form a wire of rectangular cross section in which the flat parts M, M 'of the finished wire define a right angle. . This right angle acts simultaneously on the four sides where the pairs of rolls define the flat portions M, M ', so that the first set of forming rolls P1, P2, P3, P4 forms a larger width. The second set of rolls P'1 and P'2 are obtained by preventing the twist that may occur in the wire when the lateral flat portion is obtained. This embodiment also has the advantage of providing a very compact wire manufacturing apparatus since the axes of the two sets of rolls P1, P2 ... and P'1, P'2 are on the same plane.
[54] The roll P1 extends axially on either side of the wire at least a distance equal to the thickness of the wire. Roll P'1 lies between rolls P1.
[55] Generally, in the diameter of a roll, the roll P1, P2 ... which acts in a thickness direction gives a diameter up to 60 times the thickness of the flattened wire, and the roll P'1 which acts in the width direction , P'2 ...) is advantageously given a diameter of at least 30 times the width of the flattened wire. The use of large diameter rollers is advantageous because it makes it possible to reduce the rotational speed of the rolls, thereby reducing the heating of the rolls and reducing wear. In this regard, the force is distributed over a larger surface. Another advantage is that the deformation is more gradual and therefore not more severe for enamel coating.
[56] The invention advantageously comprises a stator and a claw-type rotor having an exciter winding with an input wire and an output wire formed with N pairs of magnetic poles disposed within the stator, and an alternator or alternator starter for a vehicle. Can be applied to The stator includes a plurality of phases each composed of a cylindrical body, a plurality of electrically conductive elements mounted in a line along the periphery of the stator between the input and output portions, the cylindrical body having radial slots on its radially inner side, Within this slot, at least four radially adjacent conductive phase elements are received to form a layer of at least four conductive elements, each conductive element being in the form of a hairpin-type extending between the two slots, the desired layer A first branch disposed in the slot of the second branch and a second branch disposed in the other slot of the predetermined layer, comprising a head on one axial side of the body of the stator between the two branches, the head having an outer edge. "U" shaped in the direction, while on the other side of the body the free end of the branch of the conducting element is the branch of the other conducting element Half of the conducting elements, electrically connected to the ends, by their first branches in the slots, are joined through their second branches in another common slot, each defining the "U" shape between the two slots. do.
[57] For example, Figure 6 shows a general structure of a vehicular alternator. This alternator comprises a drive pulley 21 fixed to the front end of the shaft 22, from left to right, ie from front to back of FIG. 6, with a collector 23 at the rear end of the shaft 22. Slip ring (not shown). The axis of the shaft 22 is the axis of rotation of the machine.
[58] The shaft 22 carries a rotor 24 and is located in the center of the rotor and fixed to it, the rotor having an excitation winding 25 whose end is connected to the collector 23 via a connection to the collector 23. do. The rotor 4 in this example is a Lundell type claw-type rotor and thus comprises two pole wheels, namely the front pole wheel 26 and the rear pole wheels, each of which is a fan, i.e. It involves a front fan 28 and a rear fan 28. Each wheel 26, 27 comprises a radial plate perpendicular to the axis of the shaft 22. The outer edge of this radial plate is formed with an integral tooth extending in the axial direction. This tooth has a trapezoidal shape and a chamfer is formed. One tooth of the wheel faces the other wheel and is angularly offset with respect to the tooth of the other wheel. When voltage is applied to the winding 25, the rotor 24 magnetizes to define a pair of poles, so that each pole wheel includes N N poles and N S poles, each composed of teeth.
[59] The regulator is connected to a rectifier 31, such as a diode bridge (two of which are shown in FIG. 6), which is itself connected to the output of the phase winding, which is part of the stator 32 of the alternator.
[60] The fans 28, 29 are arranged in proximity to the front bearing 33 and the rear bearing 34, respectively. The bearings 33, 34 are internal to the alternator by the fans 28, 29 when the assembly consisting of the fans 28, 29, the rotor 24, and the shaft 22 is rotationally driven by the pulley 21. It has a device for evacuation, which is coupled to the engine of the vehicle via a transmission device comprising at least one belt associated with the pulley 21. This exhaust cools the windings and windings 25 of the stator 32 as well as the generator and rectifier 31 of the bush carrier 30. In FIG. 6, the arrows indicate the path through which cooling fluid, such as water, for example, flows into the machine through various devices in the bearings 33, 34.
[61] The rectifier 31, bush carrier 30 and perforated protective cap (not given reference) are supported and fixed on the bearing 34 such that the rear fan 29 is stronger than the front fan 28. In this method, the bearings 33 and 34 are connected to each other by screws in this example, or bolts (not shown) in another example, forming a casing or support suitable for mounting on a stationary part of the vehicle. .
[62] Each bearing 33, 34 carries a central ball bearing 35, 36 for rotational support at the front and rear ends of the shaft 22 passing through the bearing, so that the ring of the pulley 21 and collector 23. Entails.
[63] 7 and 8 show two sets of three that act like a six phase winding shown on the side of the rectifier and a stator comprising a cylindrical body 38 having an axis X-X '. Two sets of three phases P1 to P3 and P4 to P6 constituting the phase windings are shown. The expression "6 phases" refers to two sets of three phase windings that are electrically offset by 30 °, each of which is wound in a star shape with an independent neutral point.
[64] Each phase P1 to P6 consists of a plurality of electrically conductive elements 40 connected in series along the periphery of the stator 32 between the inputs E1 to E6 and the outputs S1 to S6, FIG. As shown in Fig. 9, at least one phase winding is constituted per radial slot L. As shown in FIG.
[65] Thus, as shown in FIG. 9, the cylindrical body 38, referred to as a stack of laminations, comprises at its radially inner side a radial slot L which houses at least four conducting phase elements 40. In the case of a slot with four conductive elements as shown in FIG. 8, in order to form a layer of at least four conductive elements C1 to C4 to increase the distance from the inner radial face of the body, the conductive element ( 40 is radially close in slot L. As shown in FIG.
[66] Preferably, conductive elements C1 to C4 are produced by the method described according to the invention. Thus, the basically rectangular conductive elements C1 to C4 draw continuously round conductive wires from the source 12 and apply longitudinal force on the wires in the thickness direction on the radially opposite areas. Obtained by forming the longitudinal flat portion M on the wire, the round wire 14 has an insulating coating, and a force is applied on the wire through the coating. Thus, after or at the same time as the step of applying the force, an additional force is applied in the width direction of the wire on the radially opposed region of the wire at right angles to the formed flat portion, thereby forming a wire having a basically rectangular cross section.

权利要求:
Claims (13)
[1" claim-type="Currently amended] In a method of manufacturing an electrically conducting wire for windings for a rotating electric machine from a conducting wire 14 having a generally round cross-sectional shape,
Continuously withdrawing the rounded conducting wire from the source 12,
Applying longitudinal force on a radially opposite region of the wire to form longitudinal flats (M, M ′) on the region,
The round wire 14 has an insulating coating, and a force is applied through the coating.
Method of manufacturing electrically conductive wires.
[2" claim-type="Currently amended] The method of claim 1,
After the step of applying the force in the thickness direction of the wire, an additional force is applied in the width direction of the wire on the radially opposed region at right angles to the formed flat portion, thereby forming a wire having a generally rectangular cross section.
Method of manufacturing electrically conductive wires.
[3" claim-type="Currently amended] The method of claim 1,
Force is applied in the longitudinal direction of the wire in the thickness direction, while additional force is applied on the radially opposite area of the wire in the width direction of the wire to form a wire having a rectangular cross section, and adjacent flat portions M, M 'are perpendicular to each other. Characterized by
Method of manufacturing electrically conductive wires.
[4" claim-type="Currently amended] The method of claim 1,
Each said step of applying said force is performed by passing a wire between at least a pair of forming rolls (P1, P2, P4; P'1, P'2).
Method of manufacturing electrically conductive wires.
[5" claim-type="Currently amended] The method of claim 4, wherein
The ratio between the length and width of the cross section of the wire is 2 or less, wherein each said step of applying the force in the thickness and width direction of the wire is performed by passing the wire between a single pair of forming rolls.
Method of manufacturing electrically conductive wires.
[6" claim-type="Currently amended] An apparatus for manufacturing winding electric conductive wire for a rotating electric machine from a conductive wire having a generally round cross-sectional shape,
The wire is provided with an insulating sheath (E), the apparatus comprising at least a pair of forming rolls (P1, O2, P3,) suitable for forcing together through the sheath (E) on the radially opposed region of the wire. P4; P'1, P'2, including forming a flat portion on the wire with means for passing the wire between the rolls.
Electrical conduction wire manufacturing device.
[7" claim-type="Currently amended] The method of claim 6,
At least two pairs of forming rolls P1, P2, P3, P4; P'1, P'2 disposed respectively upstream and downstream with respect to the direction in which the wire is drawn, the pair of upstream rolls having a concave outer working surface Characterized in having
Electrical conduction wire manufacturing device.
[8" claim-type="Currently amended] The method of claim 6,
At least two pairs of forming rolls (P1, P'1), the axes of rotation of which are at right angles and the forming rolls are arranged such that the axes are located in a common plane at right angles to the direction in which the wire is drawn.
Electrical conduction wire manufacturing device.
[9" claim-type="Currently amended] The method of claim 6,
The pair of rolls P'1 and P'2 acting in the width direction of the wire lies between the pairs of rolls P1 and P2 acting in the thickness direction of the wire.
Electrical conduction wire manufacturing device.
[10" claim-type="Currently amended] The method of claim 6,
The rolls P1, P2, P3 and P4 acting in the thickness direction of the flattened wire have a diameter greater than 60 times the thickness of the flattened wire.
Electrical conduction wire manufacturing device.
[11" claim-type="Currently amended] The method of claim 6,
The rolls P'1, P'2, P'3 and P'4 acting in the width direction of the flattened wire have a diameter larger than 30 times the width of the flattened wire.
Electrical conduction wire manufacturing device.
[12" claim-type="Currently amended] The method of claim 6,
Rolls P1, P2, P3, P4 acting in the thickness direction of the flattened wire are motor driven to advance the wire during its molding.
Electrical conduction wire manufacturing device.
[13" claim-type="Currently amended] An on-vehicle alternator comprising a stator 32 and a claw-type rotor 24 carrying an excitation winding 25 with N pairs of poles disposed within the stator, the stator 32 being a cylindrical body 38. And a plurality of phases, each phase consisting of a plurality of electrically conductive elements 40 mounted along the periphery of the stator between the input portion E and the output portion S, wherein the cylindrical body 38 is At least two conducting phase elements arranged radially in parallel in said slot L to define at least two layers of conducting elements having essentially rectangular cross-sections, including radial slots L on their radially inner sides; 40, wherein each conducting element 40 is in the form of a hairpin extending between two slots,
Basically the conductive element of rectangular cross section is produced by the method according to any one of the preceding claims.
Automotive Alternator

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同族专利:

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公开号 | 公开日

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MXPA03000052A|2003-09-25|

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KR100884141B1|2009-02-17|

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CN1461244A|2003-12-10|

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FR2824004A1|2002-10-31|

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EP1383617A1|2004-01-28|

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FR2824004B1|2003-05-30|

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CN1253256C|2006-04-26|

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US20030173860A1|2003-09-18|

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JP2004519993A|2004-07-02|

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EP1383617B1|2017-06-28|

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WO2002087797A1|2002-11-07|

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BR0205109A|2003-05-13|

引用文献:

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公开号 | 申请日 | 公开日 | 申请人 | 专利标题

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法律状态:
2001-04-30|Priority to FR0105832A

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2001-04-30|Priority to FR01/05832

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2002-04-30|Application filed by 발레오 에뀝망 엘렉뜨리끄 모떼르

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2002-04-30|Priority to PCT/FR2002/001501

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2004-01-07|Publication of KR20040002421A

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2009-02-17|Application granted

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2009-02-17|Publication of KR100884141B1

优先权:

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申请号 | 申请日 | 专利标题

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FR0105832A|FR2824004B1|2001-04-30|2001-04-30|Method for manufacturing an electrically conductive wire and device for carrying out such a method|

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FR01/05832|2001-04-30|

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PCT/FR2002/001501|WO2002087797A1|2001-04-30|2002-04-30|Method for making an electrically conductive wire and device therefor|