JP2016110806A - Electric wire with terminal fitting, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric wire with a terminal fitting with which reliability of electrical connection can be improved when one end part of a conductive wire formed of solid electric wires is collectively connected.SOLUTION: An electric wire 5 with a terminal fitting includes: a first electric wire 51 having a first conductive wire 511 formed of a solid wire; a second electric wire 52 having a second conductive wire 521 formed of a solid wire; and a terminal fitting 50 having a caulking part 50a for caulking and fixing the first and second conductive wires 511, 521. The caulking part 50a has: a bottom plate part 500; a first caulking piece 501 for holding the first conductive wire 511 between itself a bottom plate part 500 and itself; and a second caulking piece 502 for holding the second conductive wire 521 between the bottom plate part 500 and itself. The first conductive wire 511 is held between the first protrusion 61 of an upper die 6 and a lower die 7, and the second conductive wire 521 is held between the second protrusion 62 of the upper die 6 and the lower die 7.SELECTED DRAWING: Figure 9

Description

  The present invention relates to an electric wire with terminal metal fittings including a plurality of electric wires and terminal metal fittings that collectively crimp and fix one end portions of conductive wires of the plurality of electric wires, and a method of manufacturing the electric wire with terminal metal fittings.

  2. Description of the Related Art Conventionally, for example, a connection member that is used for electrical connection of a stator winding of a three-phase rotary motor and that is obtained by caulking and fixing conductive wires of a plurality of electric wires collectively to a terminal fitting is known (for example, a patent Reference 1).

  In the device described in Patent Document 1, after a plurality of enamel-coated conductors are inserted into a cylindrical crimp connector, the crimp connector is temporarily crimped by mechanical pressurizing means, and then enamel-coated conductor is further subjected to fusing. They are manufactured by electrically joining together in a crimping connector.

  Each of the plurality of enamel-coated conductive wires is formed of a stranded wire obtained by twisting a plurality of strands. In the fusing process, the enamel-coated conductive wire is heated and pressure-bonded by applying pressure and sandwiching the crimped connector after temporary crimping with a pair of electrodes.

JP 2010-3439 A

  However, for example, depending on the configuration of the electric motor, it may be necessary to connect a plurality of electric wires having a single conductive wire to one terminal fitting. In this case, the conductive wire made of a single wire is harder to deform in the caulking process than the stranded wire, so if there is variation in the thickness of the single wire, the conductive wire of one relatively thick electric wire is strongly caulked, but the other There is a possibility that the conductive wire of the wire is not sufficiently crimped and the electrical connection is not reliably performed.

  Therefore, the present invention provides an electric wire with a terminal fitting capable of enhancing the reliability of electrical connection when connecting one end portions of conductive wires made of a single wire of a plurality of electric wires to the terminal fitting together, and the An object is to provide a manufacturing method.

  In order to solve the above problems, the present invention provides a first electric wire having a first conductive wire made of a single wire, a second electric wire having a second conductive wire made of a single wire, and the first and A crimping portion that collectively crimps and fixes one end portion of the second conductive wire, and a terminal fitting having a connection portion that is electrically connected to a connection target. And a bottom plate portion that contacts one end of the second conductive wire, a first crimping piece that sandwiches the first conductive wire between the bottom plate portion, and the second plate between the bottom plate portion. A second caulking piece sandwiching the conductive wire, the caulking by sandwiching the bottom plate portion and the first and second caulking pieces between a pair of caulking molds, and the pair of caulking pieces. One caulking mold of the clamping molds is provided with first and second protrusions that are narrower than the first and second conductive lines, The first conductive wire is sandwiched between the first protrusion and the other caulking mold of the pair of caulking molds, and the second protrusion and the other caulking mold, An electric wire with a terminal fitting is provided in which the second conductive wire is sandwiched between them and the caulking portion is caulked.

  In order to solve the above problems, the present invention provides a first electric wire having a first conductive wire made of a single wire, a second electric wire having a second conductive wire made of a single wire, and the first electric wire. A method of manufacturing an electric wire with a terminal fitting, comprising: a crimping portion that crimps one end of each of the first and second conductive wires collectively; and a terminal fitting having a connection portion that is electrically connected to a connection target. And a caulking step for caulking the caulking portion by sandwiching the caulking part between a pair of caulking molds, and one caulking mold of the pair of caulking molds includes the first and second caulking molds. First and second protrusions having a width smaller than that of the first conductive line are provided, and the first conductive line is provided between the first protrusion and the other crimping mold of the pair of crimping molds. Sandwiching the second conductive wire between the second protrusion and the other crimping mold The crimped, to provide a method of manufacturing a wire with the terminal fitting.

  According to the electric wire with terminal fitting and the manufacturing method thereof according to the present invention, when connecting one end portions of conductive wires made of a single wire of a plurality of electric wires to the terminal fitting together, the reliability of the electrical connection is increased. Is possible.

It is a perspective view which shows the motor apparatus to which the electric wire with a terminal metal fitting which concerns on this Embodiment was applied. It is a side view of a motor apparatus. It is a circuit diagram which shows the structural example of the electric circuit in the motor formed with a motor winding. It is the elements on larger scale of FIG. 1 which shows the peripheral part of the electric wire with a terminal metal fitting in a motor apparatus. (A) is a perspective view of the edge part of the electric wire with a terminal metal fitting which shows the one surface side of a terminal metal fitting, (b) is a perspective view of the edge part of the electric wire with a terminal metal fitting which shows the other surface side of a terminal metal fitting. is there. (C) is the sectional view on the AA line of (a). It is a perspective view which shows the crimping process which crimps a terminal metal fitting with an upper mold | type and a lower mold | type. The upper mold | type is shown, (a) is a bottom view, (b) is a side view, (c) is a perspective view which shows a lower end surface side. The lower mold | type is shown, (a) is an upper end surface view, (b) is a side view, (c) is a perspective view which shows the upper end surface side. (A) is sectional drawing which shows the state before the crimping process by which the crimping part of the terminal metal fitting was arrange | positioned between the upper mold | type and the lower mold | type, (b) is a terminal metal fitting by an upper mold | type and a lower mold | type. It is sectional drawing which shows the state after the crimping process by which the crimping part of this was crimped.

[Embodiment]
FIG. 1 is a perspective view showing a motor device 1 to which an electric wire 5 with terminal fittings according to the present embodiment is applied. FIG. 2 is a side view of the motor device 1. In FIG. 2, a cross section inside the motor 2 is shown inside the fracture area surrounded by the fracture line.

  The motor device 1 includes a motor 2 and a plurality (three in this embodiment) of electric wires 5 with terminal fittings that connect the motor winding 3 of the motor 2 and the terminal block 4. . The motor 2 includes a bottomed cylindrical motor case 20, an annular stator core 21 housed in the motor case 20, a rotor 22 disposed on the inner side of the stator core 21, and a rotor 22 penetrating through the center of the rotor 22. The motor shaft 23 is rotatably supported integrally therewith, and a lid member 24 made of mold resin that covers the opening of the motor case 20.

  The motor device 1 is used, for example, as a driving source for running a vehicle, and is supported by a support portion of a vehicle body (not shown). The terminal block 4 is connected to a wire harness (not shown) having one end connected to the inverter, and the other end of the wire harness and the electric wire 5 with terminal fittings are electrically connected to the terminal block 4. The motor current output from the inverter is supplied to the motor 2 via the wire harness and the electric wire 5 with terminal fittings. The terminal block 4 is fixed to a terminal block fixing part of a vehicle body (not shown).

  Each of the three electric wires 5 with terminal fittings is connected to the end of the motor winding 3. In addition, the three electric wires 5 with terminal fittings are formed in the same shape, but when it is necessary to distinguish them in the following description, the electric wires 5 with terminal fittings are designated as the first terminals. A description will be given of the electric wire with bracket 5A, the second electric wire with terminal fitting 5B, and the third electric wire with terminal fitting 5C.

  The stator core 21 is made of a magnetic material such as a steel material. The stator core 21 is provided with a plurality of teeth 211 protruding inward toward the rotor 22, and the motor winding 3 is wound around each of the plurality of teeth 211. In the present embodiment, the motor winding 3 is a rectangular wire having a rectangular cross section. More specifically, the motor winding 3 is a flat insulated wire in which an insulating coating layer made of enamel is formed on the surface of a conductor made of copper. A portion of the motor winding 3 is exposed to the outside of the motor case 20 from the lid member 24 and is molded on the lid member 24.

  The rotor 22 includes a cylindrical rotor core 221 in which a through-hole through which the motor shaft 23 is inserted is formed, and a magnet 222 disposed on the outer periphery of the rotor core 221. The magnet 222 is provided with a plurality of magnetic poles so that the south pole and the north pole are alternately positioned. The motor shaft 23 is rotatably supported by the motor case 20 by a bearing (not shown).

  FIG. 3 is a circuit diagram showing a configuration example of an electric circuit in the motor 2 formed by the motor winding 3. In the present embodiment, the motor 2 is a three-phase AC motor, and the motor winding 3 includes a U-phase winding 3u, a V-phase winding 3v, and a W-phase winding 3w. The U-phase winding 3u, the V-phase winding 3v, and the W-phase winding 3w are connected to the neutral point 3n at the respective central portions. A U-phase current is supplied to one end 31u and the other end 32u of the U-phase winding 3u. A V-phase current is supplied to one end 31v and the other end 32v of the V-phase winding 3v. A W-phase current is supplied to one end 31w and the other end 32w of the W-phase winding 3w.

  FIG. 4 is a partially enlarged view of FIG. 1 showing a peripheral portion of the electric wire 5 with terminal fittings in the motor device 1. The end portions 31u and 32u of the U-phase winding 3u, the end portions 31v and 32v of the V-phase winding 3v, and the end portions 31w and 32w of the W-phase winding 3w are exposed from the lid member 24, and each is a terminal fitting. It is connected to the attached electric wire 5. More specifically, the end portions 31u and 32u of the U-phase winding 3u are connected to the first electric wire 5A with terminal fitting, and the end portions 31v and 32v of the V-phase winding 3v are connected to the second electric wire 5B with terminal fitting. The ends 31w and 32w of the W-phase winding 3w are connected to the third electric wire 5C with a terminal fitting. The connection in each of these parts can be performed by, for example, TIG (Tungsten Inert Gas) welding, fusing (heat caulking), or soldering.

  The electric wire with terminal fitting 5 is electrically connected to the first electric wire 51 having the first conductive wire 511, the second electric wire 52 having the second conductive wire 521, and the first and second conductive wires 511 and 521. Terminal fittings 50 connected to each other. The first and second conductive wires 511 and 521 are single wires made of a highly conductive metal such as copper. Here, the single wire refers to a single conductor formed in a linear shape, unlike a stranded wire obtained by twisting a plurality of strands. Further, the single wire includes, for example, a plurality of linear conductors that are integrated by forming into a certain shape. Such a single wire is harder than a stranded wire and has a characteristic that its deformation width is small even when compressed in a direction orthogonal to the stretching direction.

  The first electric wire 51 is an insulated electric wire formed by covering the first conductive wire 511 with an insulating material 512, and both end portions of the first conductive wire 511 are exposed from the insulating material 512. Similarly, the second electric wire 52 is an insulated wire formed by covering the second conductive wire 521 with an insulating material 522, and both end portions of the second conductive wire 521 are exposed from the insulating material 522. However, the insulating materials 512 and 522 are not necessarily required, and the first electric wire 51 may be a bare electric wire made of only the first conductive wire 511, or the second electric wire 52 may be the second conductive wire 521. The bare electric wire which consists only of may be sufficient.

  The first conductive wire 511 of the first electric wire with terminal fitting 5A has one end connected to the terminal fitting 50 and the other end connected to the end 31u of the U-phase winding 3u. The second conductive wire 521 of the electric wire 5A with the first terminal fitting has one end connected to the terminal fitting 50 and the other end connected to the end 32u of the U-phase winding 3u.

  Similarly, the first conductive wire 511 of the second electric wire with terminal fitting 5B has one end connected to the terminal fitting 50 and the other end connected to the end 31v of the V-phase winding 3v. The second conductive wire 521 of the second electric wire with terminal fitting 5B has one end connected to the terminal fitting 50 and the other end connected to the end 32v of the V-phase winding 3v. In addition, first conductive wire 511 of third electric wire with terminal fitting 5C has one end connected to terminal fitting 50 and the other end connected to end 31w of W-phase winding 3w. Further, the second conductive wire 521 of the third electric wire with terminal fitting 5C has one end connected to the terminal fitting 50 and the other end connected to the end 32w of the W-phase winding 3w.

(Configuration of electric wire with terminal bracket)
FIG. 5A is a perspective view of the end of the electric wire 5 with a terminal metal fitting showing one side of the terminal metal fitting 50, and FIG. 5B is an electric wire with a terminal metal fitting showing the other surface side of the terminal metal fitting 50. 5 is a perspective view of an end portion of 5. FIG. FIG.5 (c) is the sectional view on the AA line of Fig.5 (a).

  The terminal fitting 50 is formed by, for example, tin-plating a base material made of copper, and a caulking portion 50a for collectively caulking and fixing one end portions of the first and second conductive wires 511 and 521, and a connection target. It has the connection part 50b electrically connected integrally. The connection portion 50b is formed with a bolt insertion hole 50c through which a bolt for fixing to the terminal block 4 is inserted.

  The caulking portion 50 a is a first caulking piece that sandwiches the first conductive wire 511 between the bottom plate portion 500 and the bottom plate portion 500 that are in contact with one end portions of the first and second conductive wires 511 and 512. 501 and a second caulking piece 502 that sandwiches the second conductive wire 521 between the bottom plate portion 500. The bottom plate portion 500 and the first and second caulking pieces 501 and 502 are caulked by being sandwiched between a pair of caulking dies described later, and one end portions of the first and second conductive wires 511 and 521. Are fixed together by caulking. The first and second caulking pieces 501 and 502 are formed with a first concave portion 501a and a second concave portion 502a formed when caulking with the pair of caulking dies.

  The extending direction of the first and second conductive wires 511 and 521 at one end fixed by crimping to the crimping portion 50a, that is, the arrangement direction of the crimping portion 50a and connection portion 50b in the terminal fitting 50 is the longitudinal direction of the terminal fitting 50. The first recess 501a and the second recess 502a are defined as the direction in which the direction perpendicular to the longitudinal direction along the arrangement direction of the first and second conductive lines 511 and 521 at the one end is the short direction of the terminal fitting 50. Extends in a groove shape along the longitudinal direction of the terminal fitting 50, and is parallel to the short side direction of the terminal fitting 50. In FIG. 5A, the longitudinal direction of the terminal fitting 50 is indicated by an arrow X, and the short direction of the terminal fitting 50 is indicated by an arrow Y.

  As shown in FIG. 5C, the first and second conductive lines 511 and 521 have a rectangular cross section perpendicular to the extending direction. That is, the first and second conductive lines 511 and 521 are rectangular wires having a rectangular cross section. In the following description, the longitudinal direction in this cross section is defined as the long side direction L, and the short direction in this cross section is defined as the short side direction S. In FIG. 5C, the long side direction L and the short side direction S are indicated by arrows. The long side direction L coincides with the short direction of the terminal fitting 50. The first and second caulking pieces 501 and 502 sandwich the first and second conductive wires 511 and 521 along the short piece direction S between the bottom plate portion 500 and the first and second caulking pieces 501 and 502.

(Configuration of caulking mold)
Next, the structure of the crimping die used for manufacture of the electric wire 5 with a terminal metal fitting is demonstrated with reference to FIG. 6 thru | or FIG.

  FIG. 6 is a perspective view showing a caulking process in which the terminal fitting 50 is caulked by a pair of caulking molds (upper mold 6 and lower mold 7). FIG. 7 shows the upper die 6 as one caulking die, wherein (a) is a bottom view, (b) is a side view, and (c) is a perspective view showing the bottom end side. FIG. 8 shows the lower die 7 as the other caulking die, where (a) is a top view, (b) is a side view, and (c) is a perspective view showing the top surface side. 7 and 8 indicate the curved state of the surfaces of the upper mold 6 and the lower mold 7.

  The terminal fitting 50 is clamped between the upper mold 6 and the lower mold 7 so that the crimped portion 50 a is crimped, and the first conductive wire 511 is interposed between the first crimped piece 501 and the bottom plate portion 500. The second conductive wires 521 are respectively crimped and fixed between the second crimping piece 502 and the bottom plate part 500. The first caulking piece 501 and the second caulking piece 502 are opposed to the upper mold 6, and the bottom plate portion 500 is opposed to the lower mold 7.

  As shown in FIG. 7, the upper mold 6 includes a columnar base 60 and first and second protrusions 61 and 62 provided so as to protrude from the lower end surface 60 a of the base 60. A lower end surface 60 a of the base portion 60 is a flat surface perpendicular to the central axis of the base portion 60. The first protrusion 61 and the second protrusion 62 are formed as protrusions extending in parallel to each other. In addition, notch portions 601 and 602 formed by notching both ends in the extending direction of the first and second protrusions 61 and 62 are provided at the end portion of the base portion 60 on the lower end surface 60a side.

  The first protrusion 61 and the second protrusion 62 have a trapezoidal shape in which the cross-sectional shape orthogonal to the extending direction has a lower base on the lower end surface 60a side, and the front end surfaces 61a and 62a in the protruding direction are lower end surfaces. It is a plane parallel to 60a. Both side surfaces 61b and 61c of the first projection 61 corresponding to the trapezoidal leg and both side surfaces 62b and 62c of the second projection 62 are inclined with respect to the lower end surface 60a. In the upper mold 6, the extending directions of the first protrusion 61 and the second protrusion 62 are the extending directions of the first conductive line 511 and the second conductive line 521 arranged in the crimped portion 50 a of the terminal fitting 50. It faces the first caulking piece 501 and the second caulking piece 502 so as to be parallel.

  The protrusion heights of the first protrusion 61 and the second protrusion 62 from the lower end surface 60a take into consideration the dimensional difference due to the width variation in the short direction S of the first conductive line 511 and the second conductive line 521. Thus, it is set to be larger than the maximum value of the dimensional difference. More specifically, for example, the width of the first conductive line 511 in the short direction S is the smallest within the tolerance range, and the width of the second conductive line 521 in the short direction S is the largest within the tolerance range. The protrusion height dimension from the lower end surface 60a of the first protrusion 61 and the second protrusion 62 is larger than the dimensional difference of the conductor width. The protrusion height from the lower end surface 60a of the first protrusion 61 and the second protrusion 62 is desirably 0.1 mm or more, and more desirably 0.2 mm or more.

The width of the first protrusion 61 is narrower than the width of the first conductive line 511, and the width of the second protrusion 62 is narrower than the width of the second conductive line 521. More specifically, as shown in FIG. 5C and FIG. 7A, the width of the first conductive line 511 in the long side direction is W ₁₁ and the second conductive line 521 in the long side direction. The width is W ₂₁ , the width of the first protrusion 61 in the long side direction of the first conductive line 511 is W _12, and the width of the second protrusion 62 in the long side direction of the second conductive line 521 is W _22. when the the _ratio of _{W 12} for _{W 11 (W 12 / W 11} ), and the ratio of _{W 22} for _{W 21 (W 22 / W 21} ) is both less than 1/5 and 2/3 or less. That is, the following inequalities (1) and (2) are both satisfied.

Here, when W ₁₂ / W ₁₁ and W ₂₂ / W ₂₁ are less than 1/5, the contact between the first and second conductive wires 511 and 521 and the first and second crimping pieces 501 and 502 This is not preferable because the area may be small. Further, if W ₁₂ / W ₁₁ and W ₂₂ / W ₂₁ exceed 2/3, the effect of concentrating the pressing load from the upper mold 6 by the first protrusion 61 and the second protrusion 62 becomes dilute. It is not preferable.

The width W ₁₂ of the first protrusion 61 is the width dimension of the tip surface 61 a in the width direction orthogonal to the extending direction of the first protrusion 61. The width W ₂₂ of the second protrusion 62 is the width dimension of the distal end surface 62 a in the width direction orthogonal to the extending direction of the second protrusion 62. In this _embodiment, a W 11 _{= W 21} and _W 12 _{= W 22,} the ratio _(W 12 _/ W ₁₁₎ of the _{W 12} for _{W 11,} and the ratio of _{W 22} for _{W 21 (W 22 / W 21} ) Are both ½.

  As shown in FIG. 8, the lower mold 7 includes a columnar base portion 70, and first and second protrusions 71 and 72 provided so as to protrude from the upper end surface 70 a of the base portion 70. The upper end surface 70 a of the base portion 70 is a flat surface perpendicular to the central axis of the base portion 70. The first protrusion 71 and the second protrusion 72 are provided at both ends in the radial direction of the base portion 70 with the upper end surface 70a interposed therebetween. Further, notches 701 and 702 are provided at the end of the base 70 on the upper end surface 70 a side at positions shifted by 90 ° with respect to the first and second protrusions 71 and 72.

  The first protrusion 71 of the lower mold 7 is provided between the tip surface 71a parallel to the upper end surface 70a of the base 70, and between the upper end surface 70a and the tip surface 71a of the base 70, and with respect to the upper end surface 70a. And an inclined side surface 71b. The second protrusion 72 is provided between the tip surface 72a parallel to the upper end surface 70a of the base 70, and the upper end surface 70a and the tip surface 72a of the base 70, and is inclined with respect to the upper end surface 70a. Side surface 72b.

  The side surface 71b of the first protrusion 71 and the side surface 72b of the second protrusion 72 extend in parallel to each other, and between the both side surfaces 71b and 72b, the center of the base 70 from the front end surfaces 71a and 72a. A concave portion 7a recessed in the axial direction is formed. The upper end surface 70a of the base portion 70 constitutes the bottom surface of the recess 7a.

(Manufacturing method of electric wire with terminal fitting)
The electric wire 5 with a terminal fitting is obtained by cutting an insulated wire obtained by coating a conductive wire made of a single wire with an insulating material into a predetermined length to obtain a first electric wire 51 and a second electric wire 52, and insulating materials at both ends thereof A preparation step for removing 512 and 522 to expose both end portions of the first and second conductive wires 511 and 521, and one end portion of the first and second conductive wires 511 and 521 are crimped portions of the terminal fitting 50. A first disposing step disposed between the bottom plate portion 500 and the first and second caulking pieces 501 and 502 in 50a, and a caulking portion accommodating one end portions of the first and second conductive wires 511 and 521 A second disposing step of disposing the terminal fitting 50 so that 50a is sandwiched between the upper die 6 and the lower die 7, and a caulking step of caulking the caulking portion 50a by being sandwiched between the upper die 6 and the lower die 7 And the U-phase winding of the first electric wire 51 and the second electric wire 52 It is manufactured by a shaping step of bending and shaping so as to be easily connected to the end portions 31u and 32u of u, the end portions 31v and 32v of the V-phase winding 3v, or the end portions 31w and 32w of the W-phase winding 3w. .

  The order of the first arrangement step and the second arrangement step can be interchanged, and after the caulking portion 50a of the terminal fitting 50 is arranged between the upper mold 6 and the lower mold 7, the first and second conductive processes are performed. One end portions of the wires 511 and 521 may be disposed between the bottom plate portion 500 and the first and second crimping pieces 501 and 502 in the crimping portion 50 a of the terminal fitting 50. That is, before the caulking step, one end portions of the first and second conductive wires 511 and 521 are accommodated in the caulking portion 50a of the terminal fitting 50, and the caulking portion 50a is connected to the upper die 6 and the lower die 7. What is necessary is just to be arrange | positioned between.

  FIG. 9A is a cross-sectional view showing a state before the caulking process in which the caulking portion 50a of the terminal fitting 50 is disposed between the upper mold 6 and the lower mold 7, and FIG. It is sectional drawing which shows the state after the crimping process in which the crimping part 50a of the terminal metal fitting 50 was crimped by the upper mold | type 6 and the lower mold | type 7. FIG.

  In the caulking step, the first conductive wire 511 is sandwiched between the first protrusion 61 of the upper mold 6 and the lower mold 7, and the second protrusion 62 of the upper mold 6 and the lower mold 7 are sandwiched. The second conductive wire 521 is sandwiched, the first protrusion 61 is pressed against the first crimping piece 501, and the second protrusion 62 is pressed against the second crimping piece 502, thereby crimping the terminal fitting 5. The part 50a is crimped.

  The bottom plate portion 500 of the crimping portion 50 a is disposed between the first protrusion 71 and the second protrusion 72 of the lower mold 7. That is, the bottom plate portion 500 is accommodated in the concave portion 7a of the lower mold 7 in the caulking process. Thereby, when the crimp part 50a is crimped, it is suppressed that the crimp part 50a extends in the transversal direction of the terminal metal fitting 50.

  In the present embodiment, the lower mold 7 is fixed, and the upper mold 6 is lowered toward the lower mold 7 to crimp the caulking portion 50a. On the contrary, the lower mold 7 is the upper mold 6. The caulking portion 50a may be caulked by moving upward. That is, the crimping portion 50a is crimped by relative movement in the direction in which the upper mold 6 and the lower mold 7 approach each other.

At this time, the first protrusion 61 contacts the first caulking piece 501 and presses one end of the first conductive wire 511 against the bottom plate part 500 via the first caulking piece 501. Further, the second protrusion 62 abuts on the second crimping piece 502 and presses one end of the second conductive wire 521 against the bottom plate part 500 via the second crimping piece 502. As a result, the shape of the first protrusion 61 is transferred to the first crimping piece 501 and the shape of the second protrusion 62 is transferred to the second crimping piece 502 as shown in FIG. The Thus, the first clamping pieces 501, as shown in FIG. 5 (c), first recess 501a having a bottom surface of a width equal to the width _{W 12} of the first protrusion 61 is formed, the second pressure A second recess 502 a having a bottom surface with a width equal to the width W ₂₂ of the second protrusion 62 is formed in the fastening piece 502.

  In the present embodiment, as shown in FIG. 5A, the first recess 501a is formed over the entire first caulking piece 501 in the longitudinal direction of the terminal fitting 50, and the second recess 502a is formed. Although it is formed over the entire second caulking piece 502 in the longitudinal direction of the terminal fitting 50, the present invention is not limited to this, and the first concave portion 501 a is formed of the first caulking piece 501 in the longitudinal direction of the terminal fitting 50. The second concave portion 502 a may be formed in a part of the second caulking piece 502 in the longitudinal direction of the terminal fitting 50.

  Moreover, in this Embodiment, the crimping part 50a of the terminal metal fitting 50 is heat crimped (fusing). That is, in the caulking step, an electric current is passed between the upper die 6 and the lower die 7, the caulking portion 50a is heated by Joule heat due to the electric current, and the terminal fitting 50 and the first and second conductive wires 511, 521 is welded. The upper mold 6 and the lower mold 7 are made of a conductive metal such as tungsten or molybdenum, for example, one of which functions as a + electrode and the other functions as a − electrode.

  In the electric wire 5 with terminal fittings manufactured by the above manufacturing method, electrical continuity between the terminal fitting 50 and the first and second conductive wires 511 and 521 can be reliably obtained, and the output current from the inverter is the terminal fitting. It is supplied to the U-phase winding 3u, the V-phase winding 3v, and the W-phase winding 3w of the motor winding 3 through a connection target (wire harness) connected to the 50 connection portions 50b.

(Operation and effect of the embodiment)
According to the embodiment described above, the following operations and effects can be obtained.

(1) Since the upper mold 6 is provided with the first protrusion 61 narrower than the first conductive line 511 and the second protrusion 62 narrower than the second conductive line 521, When the crimping portion 50a of the terminal fitting 50 is sandwiched between the upper mold 6 and the lower mold 7, compared to the case where the first and second protrusions 61 and 62 are not provided on the upper mold 6. The pressing force from the upper mold 6 acts in a narrow range. As a result, the first crimping piece 501 in the range of contact with the first protrusion 61 is reliably pressed against one end of the first conductive wire 511 and the second of the range of contact with the second protrusion 62. The caulking piece 502 is reliably pressed against one end of the second conductive wire 521, and the reliability of the electrical connection between the first and second conductive wires 511 and 521 and the terminal fitting 50 is increased.

(2) The first protrusion 61 and the second protrusion 62 have protrusion heights from the lower end surface 60a due to variations in the width in the short direction S of the first conductive line 511 and the second conductive line 521. Since it is set to be larger than the maximum value of the dimensional difference, the variation in the thickness of the first conductive line 511 and the second conductive line 521 depends on the height of the first and second protrusions 61 and 62. It can absorb, and the caulking part 50a can be caulked more reliably.

(3) In the terminal fitting 50, the first crimping piece 501 comes into contact with the first protrusion 61 of the upper mold 6, and the second crimping piece 502 comes into contact with the second protrusion 62 of the upper mold 6. That is, the first and second protrusions 61 and 62 are in contact with separate crimping pieces (the first crimping piece 501 and the second crimping piece 502), respectively, so that the first conductive wire 511 is The first protrusion 61 and the second conductive line 521 are independently pressed by the second protrusion 62. Accordingly, even when the first and second conductive lines 511 and 521 have different thicknesses, the first caulking piece 501 is connected to the first conductive line 511 and the second conductive line 521 is connected to the second conductive line 521. The crimping pieces 502 can be pressed more reliably.

(4) The first and second conductive lines 511 and 521 are rectangular wires having a rectangular cross section, and the first and second crimping pieces 501 and 502 and the bottom plate portion along the short direction S in the cross section. The longitudinal direction L in the cross section of the first and second conductive lines 511 and 521 coincides with the width direction of the first and second protrusions 61 and 62. As a result, the postures of the first and second conductive lines 511 and 521 in the caulking step are stabilized, and the first and second conductive lines 511 and 521 and the first and second caulking pieces 501 and 502 are It is possible to appropriately secure the contact area.

(5) The width W _{11 of} the first conductive line 511 in the long-side direction L, the width W _{21 of} the second conductive line 521 in the long-side direction L, and the first width of the first conductive line 511 in the long-side direction L. Since the width W ₁₂ of the protrusion 61 and the width W ₂₂ of the second protrusion 62 in the long side direction L of the second conductive line 521 satisfy the relations of the inequalities (1) and (2), An effect | action and an effect can be show | played more reliably.

(6) When the caulking portion 50a of the terminal fitting 50 is heat caulked, the front end surfaces 61a and 62a of the first and second protrusions 61 and 62 are connected to the first and second caulking pieces 501 and 502, respectively. A current flows through the contact portion. Thereby, compared with the case where the upper mold 6 is not provided with the first and second protrusions 61 and 62, the current flows concentratedly in a narrow region, so that the terminal fitting 50 and the first and second The conductive wires 511 and 521 can be easily welded. Thereby, for example, the current flowing between the upper mold 6 and the lower mold 7 can be reduced, and power saving in the manufacturing process and downsizing of the manufacturing apparatus can be realized.

(Summary of embodiment)
Next, the technical idea grasped from the embodiment described above will be described with reference to the reference numerals in the embodiment. However, each reference numeral in the following description does not limit the constituent elements in the claims to members or the like specifically shown in the embodiment.

[1] A first electric wire (51) having a first conductive wire (511) made of a single wire, a second electric wire (52) having a second conductive wire (521) made of a single wire, and the first And the terminal metal fitting (50a) which has the crimping part (50a) which crimps and fixes the one end part of the 2nd conductive wire (511,521) collectively, and the connection part (50b) electrically connected to a connection object (50) ), And the caulking portion (50a) includes a bottom plate portion (500) contacting one end portion of the first and second conductive wires (511, 521), and the bottom plate portion (500). Second caulking with the second conductive wire (521) sandwiched between the first caulking piece (501) sandwiching the first conductive wire (511) and the bottom plate portion (500) A bottom plate portion (500) and the first and second crimping pieces (501, 502). Is clamped by being sandwiched between a pair of caulking dies (6, 7), and one caulking die (6) of the pair of caulking dies (6, 7) And first and second protrusions (61, 62) narrower than the second conductive lines (511, 521), and the first protrusion (61) and the pair of caulking molds (6 , 7), the first conductive wire (511) is sandwiched between the other caulking die (7) and the second protrusion (62) and the other caulking die (7). ) Between the second conductive wire (521) and the crimped portion (50a).

[2] The first caulking piece (501) is formed with a first recess (501a) that is caulked in contact with the first protrusion (61), and the second caulking piece (501) 502), the electric wire with terminal fitting (5) according to the above [1], wherein a second recess (502a) is formed which is crimped in contact with the second protrusion (62).

[3] The first and second conductive wires (511, 521) are rectangular wires having a rectangular cross section, and the first and second crimping pieces (501, 502) are the bottom plate portion (500). The electric wire (5) with a terminal fitting according to the above [1] or [2], wherein the first and second conductive wires (511, 521) are sandwiched between the first and second conductive wires (511, 521) in the short direction (S).

[4] The width in the long side direction (L) of said first conductive line (511) and _{W 11,} the width in the long side direction (L) of said second conductive line (521) and _{W 21,} wherein The width of the first protrusion (61) in the long side direction (L) of the first conductive line (511) is W _12, and the first length in the long side direction (L) of the second conductive line (521). when the width of the second protrusion (62) has a W _22, meet together two inequalities below, wire with the terminal fitting according to [3] (5).

[5] The caulking part (50a) according to any one of [1] to [4], wherein the caulking part (50a) is heat caulked by a current flowing between the pair of caulking molds (6, 7). Wire with terminal fitting (5).

[6] A first electric wire (51) having a first conductive wire (511) made of a single wire, a second electric wire (52) having a second conductive wire (521) made of a single wire, and the first And a terminal fitting (50) having a crimping part (50a) for collectively crimping one end part of the second conductive wires (511, 521), and a connection part (50b) electrically connected to the connection object A method of manufacturing an electric wire (5) with terminal fittings, comprising a caulking step of caulking the caulking part (50a) by sandwiching between a pair of caulking dies (6, 7), Of the pair of caulking dies (6, 7), one caulking die (6) has first and second narrower widths than the first and second conductive wires (511, 521). Projections (61, 62), provided between the first projection (61) and the pair of caulking dies (6, 7). The first conductive wire (511) is sandwiched between the other caulking die (7), and the first conductive wire (511) is interposed between the second protrusion (62) and the other caulking die (7). The manufacturing method of the electric wire (5) with a terminal metal fitting which clamps the said crimping part (50a) on both sides of 2 conductive wires (521).

[7] The caulking portion (50a) is disposed between the bottom plate portion (500) contacting one end of the first and second conductive wires (511, 521) and the bottom plate portion (500). A second crimping piece (502) sandwiching the second conductive wire (521) between the first crimping piece (501) sandwiching the first conductive wire (511) and the bottom plate part (500). In the caulking step, the first protrusion (61) is pressed against the first caulking piece (501), and the second protrusion (62) is pushed into the second caulking piece. (502) The manufacturing method of the electric wire (5) with a terminal metal fitting as described in said [6] pressed.

[8] In the caulking step for caulking the caulking part (50a), the caulking part (50a) is heat caulked by passing an electric current between the pair of caulking molds (6, 7). The manufacturing method of the electric wire (5) with a terminal metal fitting as described in said [6] or [7].

(Appendix)
While the embodiments of the present invention have been described above, the embodiments described above do not limit the invention according to the claims. In addition, it should be noted that not all the combinations of features described in the embodiments are essential to the means for solving the problems of the invention.

  Further, the present invention can be appropriately modified and implemented without departing from the spirit of the present invention. For example, in the above-described embodiment, the case where the electric wire 5 with terminal metal fittings is applied to the motor device 1 has been described. However, the use of the electric wire 5 with terminal metal fittings is not limited to this and can be applied to various application objects. It is.

  In the above embodiment, the case where two conductive wires (first conductive wire 511 and second conductive wire 521) are caulked on one terminal fitting 50 has been described. The above conductive wires may be crimped. Furthermore, although the case where the first and second conductive lines 511 and 521 are rectangular wires has been described in the above embodiment, the present invention is not limited thereto, and may be a round wire having a circular cross section.

  In the above embodiment, the case where the upper mold 6 faces the first and second crimping pieces 501 and 502 and the lower mold 7 faces the bottom plate portion 500 has been described. The caulking portion 50a may be caulked so that the mold 6 faces the bottom plate portion 500 and the lower die 7 opposes the first and second caulking pieces 501 and 502. Even in this case, the effect of concentrating the caulking load by the first and second protrusions 61 and 62 and the effect of concentrating the current flowing between the upper mold 6 and the lower mold 7 can be obtained.

DESCRIPTION OF SYMBOLS 5 ... Electric wire 50 with a terminal metal fitting ... Terminal metal fitting 50a ... Caulking part 50b ... Connection part 500 ... Bottom plate part 501 ... 1st caulking piece 501a ... 1st recessed part 502 ... 2nd caulking piece 502a ... 2nd recessed part 51 ... first electric wire 52 ... second electric wire 511 ... first conductive wire 521 ... second conductive wire 6 ... upper die (one caulking die)
61 ... 1st protrusion 62 ... 2nd protrusion 7 ... Lower mold | type (the other caulking metal mold | die)

Claims (8)

A first electric wire having a first conductive wire made of a single wire;
A second electric wire having a second conductive wire made of a single wire;
A crimping portion that collectively crimps and fixes one end portions of the first and second conductive wires, and a terminal fitting having a connection portion that is electrically connected to a connection target,
The caulking portion includes a bottom plate portion that contacts one end of the first and second conductive wires, a first caulking piece that sandwiches the first conductive wire between the bottom plate portion, and the bottom plate. A second caulking piece sandwiching the second conductive wire between the base plate portion and the bottom plate portion and the first and second caulking pieces are sandwiched between a pair of caulking dies. Therefore,
One caulking mold of the pair of caulking molds is provided with first and second protrusions narrower than the first and second conductive lines, and the first protrusion and the The first conductive wire is sandwiched between the other caulking molds of the pair of caulking molds, and the second protrusion is interposed between the second caulking molds and the second caulking mold. The caulking portion was caulked with a conductive wire sandwiched between them,
Electric wire with terminal fittings. The first caulking piece is formed with a first recess that is caulked in contact with the first protrusion,
The second caulking piece is formed with a second recess that is caulked in contact with the second protrusion.
The electric wire with a terminal metal fitting according to claim 1. The first and second conductive wires are rectangular wires having a rectangular cross section,
The first and second crimping pieces sandwich the first and second conductive wires in the short piece direction between the bottom plate portion,
The electric wire with a terminal metal fitting according to claim 1 or 2. The width of the first conductive line in the long side direction is W ₁₁ , the width of the second conductive line in the long side direction is W _21, and the first protrusion in the long side direction of the first conductive line the width and W _12, when the width of the second protrusion in the longitudinal direction of the second conductive line and a W _22, meet together two inequalities below,
The electric wire with a terminal metal fitting according to claim 3.

The caulking portion is heat caulked by a current flowing between the pair of caulking molds,
The electric wire with a terminal metal fitting according to any one of claims 1 to 4. A first electric wire having a first conductive wire made of a single wire, a second electric wire having a second conductive wire made of a single wire, and one end portions of the first and second conductive wires are crimped together. A method of manufacturing an electric wire with a terminal fitting, comprising: a crimped portion; and a terminal fitting having a connection portion electrically connected to a connection target,
A caulking step of caulking the caulking portion by sandwiching between a pair of caulking molds;
One caulking mold of the pair of caulking molds is provided with first and second protrusions narrower than the first and second conductive lines, and the first protrusion and the The first conductive wire is sandwiched between the other caulking die of the pair of caulking dies, and the second conductive wire is interposed between the second protrusion and the other caulking die. Clamp the caulking part across
Manufacturing method of electric wire with terminal fittings. The caulking portion includes a bottom plate portion that contacts one end of the first and second conductive wires, a first caulking piece that sandwiches the first conductive wire between the bottom plate portion, and the bottom plate. A second caulking piece sandwiching the second conductive wire between the second conductive line,
In the caulking step, the first protrusion is pressed against the first caulking piece, and the second protrusion is pressed against the second caulking piece.
The manufacturing method of the electric wire with a terminal metal fitting of Claim 6. In the caulking step for caulking the caulking part, the caulking part is heat caulked by passing an electric current between the pair of caulking dies,
The manufacturing method of the electric wire with a terminal metal fitting of Claim 6 or 7.

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