JP2003134754A - Positioning jig for welding and coil formation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the quality of welding in forming a segment coil. SOLUTION: Objects subject to welding (welding objects) to the tip of a coil segment 20 that is a material of the segment coil are aligned at a prescribed position using an aligning jig 46. The aligning jig 46 includes an aligning ring 48 arranged corresponding to the respective welding objects disposed on the same circumference. The aligning ring 48 includes aligning protrusions positioned in the circumferential directions of the welding objects, and also includes a spacer for keeping intervals between the adjacent welding objects in the diameter direction. In a state of the welding objects being aligned at the prescribed position by the aligning jig 46, the aligning jig is removed by sandwiching and fixing the vicinity of the tip of the coil segment per alignment using a support claw 52. The welding objects are welded in this state, thus allowing the accurate positioning of the welding objects at the prescribed position by the aligning jig, to improve the accuracy of welding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a coil of a rotary electric machine by welding, a jig used at this time, and a welding method.

[0002]

2. Description of the Related Art As a method of forming a coil in a core of a rotating electric machine such as an electric motor or a generator, each U-shaped side of a substantially U-shaped coil segment is inserted into different slots of the core to form a U-shaped side. There is known a method in which the tip of the coil is bent into a predetermined shape and the U-shaped tips of predetermined coil segments are welded to each other to obtain a coil. This method is disclosed in
No. 000-350422.

[0003]

In the above-described method of welding coil segments to form a coil, it is necessary to weld many points and ensure sufficient insulation between the coil segments that are not to be welded. There was a problem. Further, if there are many welding points, there is a problem in that it takes a lot of time to weld one by one.

The present invention has been made in view of the above problems, and an object thereof is to provide a jig and a welding method for forming a segment coil with high quality, high accuracy and high speed. To do.

[0005]

In order to solve the above-mentioned problems, the present invention provides a jig for effectively positioning a welding target portion during welding. That is, an alignment jig for aligning the bent U-shaped tip portions of the coil segments in the radial direction of the rotating electric machine, and the U of the aligned coil segments.
And a support jig including support claws that are located between the rows of the character tip portions and that clamp and support the vicinity of the tip ends of these coil segments.

The aligning jig includes a plurality of rings, each ring corresponding to a welding pair which is a pair of tips of coil segments to be welded, and is arranged concentrically with respect to the axis of the rotating electric machine. Further, each ring can be separately moved in the axial direction of the rotating electric machine. Further, the ring has a spacer for aligning the circumferential positions of the tip ends of the coil segments to be welded and a spacer for ensuring a gap between the welding pairs adjacent in the radial direction.

Since the position of the welding pair is accurately fixed by the alignment jig and the support jig, the welding accuracy is improved.

The support claw can be inserted between the rows of the coil segment tips aligned from the outside in the radial direction of the core. By making the tip of this support claw into a shape of a tip and expanding this at the final stage of insertion, it is possible to reliably sandwich the tip of the coil segment between adjacent support claws.

Further, the surface of the support claw opposite to the core may be an arc transfer surface for receiving a welding arc from the tip of the coil segment and passing it to the next tip. The arc passing surface is spaced apart from the adjacent welding pair by a predetermined distance. With this arc passing surface, continuous welding can be performed. That is, the core and the welding electrode can be continuously moved relative to each other, and the arc can be successively transferred from the welding pair to the transfer surface and from the transfer surface to the welding pair. At this time, the arc transfer surface is made of a material having high thermal conductivity such as copper or a copper alloy, so that the wear resistance of this surface is improved.

When forming a coil using the above-mentioned jig, first, the positions of the welding pairs, which are the pairs to be welded at the ends of the coil segments, are aligned with the aligning jig. The alignment jig includes a plurality of concentrically arranged rings, and these rings are provided corresponding to the welding pairs. The circumferential position of the weld pair is defined by the protrusion provided on the ring. The distance between the welding pairs that are adjacent to each other in the radial direction is defined by a spacer that is also provided on the ring.

When aligned by the aligning jig, it is clamped from both sides of the row of the welding pair by the supporting claws of the supporting jig to fix the position. Then, the alignment jig is removed and the welding pair is welded.

During welding of the welding pair, the welding electrode and the core are continuously moved relative to each other so that the welding electrode moves in the circumferential direction with respect to the core. At this time, the welding arc is performed so that the welding arc is passed from the welding pair to the surface of the supporting claw and further to the next welding pair.

Further, according to another aspect of the present invention, there is provided a method for welding objects to be welded arranged at intervals. That is, a dummy jig is placed between the welding targets, the welding electrode is continuously moved in the welding target array direction, and the welding arc is generated from the welding target to the dummy jig and from the dummy jig to the next welding target. Welding is done so that it moves from one to the next.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention (hereinafter referred to as embodiments) will be described below with reference to the drawings. Figure 1
It is a figure which shows a part of manufacturing process of a segment coil type rotary electric machine stator, especially the process before the coil segment welding process concerning this embodiment. Electromagnetic steel plates each having a substantially annular plate shape and having a comb tooth shape formed inside are laminated, and the outer peripheral portion is welded to form the stator core 10 (a). As shown in the figure, the stator core 10 has a substantially cylindrical outer shape, and on the inner peripheral side thereof, a magnetic pole 12 formed in a comb tooth shape in the circumferential direction.
have. The space between the magnetic poles 12 is called a slot 14.

An insulating member 16 is arranged on the inner peripheral surface of the slot 14 (b). The detailed shape and the like of the insulating member 16 will be described later. On the other hand, the conducting wire 18 serving as a coil is bent into a substantially U-shape as shown in the drawing to produce a coil segment 20 (c). The coil segment 20 is inserted into the slot 14 in the cylindrical axis direction of the stator core 10 from the tip of the U-shaped conductor. That is, the leading end of the conductor is inserted from one end (downward in the drawing) of the slot 14 in the axial direction of the rotating electric machine, and is projected to the other end (upper) (d). Then, the tip of the conductive wire 18 is bent. An outline of the folded state is shown in FIG.

Thereafter, the tips of the adjacent coil segments are welded to each other to form a coil. However, the tips of the coil segments 20 are not necessarily aligned as shown in FIG. Become. This happens when,
If there is a gap, a shift, or a step between the tips of the coil segments to be welded, welding failure will occur. Further, if the tips of the adjacent coil segments, which are not to be welded, are too close to each other, they may be welded and may become conductive. In this case, the current path does not have a regular spiral shape, and the desired performance cannot be obtained.

A jig described below is used to align the tips of the coil segments. FIG. 3 is a diagram showing an outline of a jig for positioning the tip of the coil segment 20. The stator core 10 with the coil segments 20 inserted therein is placed on the support base 30. Support stand 3
0 is fixed on the lower base 32 of the jig. In addition, the lower base 32 has a segment base 3 that supports and supports the U-shaped spine of the coil segment 20.
4, a support column 38 that supports the inner superstructure 36, and a support cylinder 42 that supports the outer superstructure 40 are fixed. Further, the stator core 10 is pressed and fixed toward the support base 30 from above by a core pressing ring 44.

The inner superstructure 36 includes an alignment jig 4 for aligning the tips of the coil segments 20 at appropriate positions for welding.
Including 6. The alignment jig 46 includes a plurality of alignment rings 48 that are positioned concentrically with the central axis of the stator core 10. One alignment ring 48 is provided corresponding to the pair of coil segments 20 to be welded, which exist in the same circumferential shape. The alignment ring 48 is individually movable in the axial direction of the stator core (vertical direction in the drawing). Details of the structure and function of the alignment jig 46 will be described later.

The outer upper structure 40 includes a support jig for fixing and supporting the tips of the coil segments 20 aligned by the alignment jig 46 in the aligned state and position. The outer upper structure 40 includes a slide base 50 fixed to the end surface of the support cylinder 42, a plurality of support claws 52 movable on the slide base 50 in the radial direction of the stator core 10, and a sliding direction of the support claws 52. It includes a support claw press 54 having a guide for radially defining. Details of the configuration and functions of the upper structure 40 will be described later.

FIG. 4 is a diagram showing a more detailed structure of the alignment jig 46. Further, the alignment jig 46 is fixedly arranged on the outer peripheral portion of the alignment jig base 56 which can be fixed to the support column 38 (see also FIG. 3). Coil segment 20
Are paired from the inside by two, and the pairs are welded in a later process. This pair is hereinafter referred to as weld pair 58. The welding pairs are arranged in the circumferential direction of the end surface of the stator core in correspondence with the number of coils of the stator. One alignment ring 48 is provided for each welding pair 58 located on one circumference. A fixed alignment ring 60 fixedly arranged on the outer periphery of the alignment jig base 56 corresponds to the innermost weld pair 58. From the inner weld pair 58, there is a corresponding alignment ring 48, which is movable in the axial direction of the stator core. As shown in FIG. 5, a welding pair 58 is formed on the surface of the alignment ring 48 facing the tip of the coil segment 20.
Alignment projections 62 for aligning the positions of the welds, and spacers 64 for ensuring a space between the welding pairs 58 adjacent in the radial direction.
Are arranged. Note that FIG. 5 shows a state where one of the alignment rings 48 is viewed from the outside of the ring. Two of the alignment protrusions 62 that are adjacent to each other in the circumferential direction form a set.
A pair of welding pairs 58 are engaged between them to perform circumferential positioning. The spacer 64 is provided on the inner peripheral side of the alignment protrusion 62, and secures a gap between the welding pair 58 engaged with this protrusion and the welding pair 58 corresponding to the ring inside the alignment ring 48.

Corresponding to each of the alignment rings 48, a pushing bolt 66 for pushing them is provided.
When the pushing bolt 66 is tightened, the alignment ring 48 is pushed via the pushing ring 68, moves in the axial direction of the stator core, and abuts on the tip of the coil segment 20. At this time, the welding pair 58 engages with the corresponding alignment protrusion 62, and positioning is performed in the circumferential direction. In addition, the spacer 6
4 is inserted between the welding pair 58 corresponding to the alignment ring 48 on which it is provided and the welding pair 58 inside thereof.
The space between these welding pairs 58 is secured. Next, as shown in FIG. 6, the outer alignment ring 48 next to the moved alignment ring 48 is pushed in by a corresponding pushing bolt 66. Repeating this, the outermost alignment ring 48
Move to. Each weld pair 58 engages the alignment protrusion 62 of each corresponding alignment ring for circumferential positioning. At the same time, the welding pair 58 is also aligned in the radial direction.
This is because each alignment ring 48 has such a position.
This is because the position of the alignment protrusions 62 is determined.

7 and 8 are views showing a more detailed structure of the outer superstructure 40. The inner superstructure 36 is omitted. The support claws 52 are inserted between the tip ends of the coil segments maintained in alignment by the alignment jig 46 from the radially outer side of the stator core (left side in FIGS. 7 and 8). As best shown in FIG. 8, the support claws 52 are
The tip is split into two parts, and a tip end sloped surface 72 is formed on the surfaces of the respective claw tips 70 that face each other. Grooves 74 are formed on the lower surface of the claw tip 72 in FIG. 7 and the rear surface in FIG. 8 (represented by a broken line in FIG. 8). An inner sloped surface 76 is provided at the end of the groove 74 on the base side of the claw tip 70 (left end in the figure). Further, a hole 78 having a shape of a skirt is formed in a portion of the support claw 52 corresponding to the upper portion of the support cylinder 42.

The tip side pin 8 corresponds to the tip of the support claw 52.
0 is fixedly arranged on the support column 38. Also, the groove 74
A root-side pin 82 is fixed on the slide base 50 so as to correspond to the vicinity of the base end of the claw tip 70. Also,
A pawl feed bolt 84 is screw-connected to the support pawl presser 54 at a position corresponding to the burial hole 78. The tip of the claw feed bolt 84 is provided with a tapered taper portion 86,
It is adapted to engage with the burrs holes of the support pawls.

After the tips of the coil segments are aligned by the aligning jig 46, the support claws 52 are inserted from the outside in the radial direction between the rows of the tip ends of the coil segments. After the insertion to the position shown in FIG. 7, when the pawl feed bolt 84 is tightened, the support pawl 5 is supported by the action of the taper portion 86 of the bolt and the slot 78.
2 is sent further into the back. When the support claw 52 is inserted until it abuts on the tip side pin 80, the tip slope 72 of the support claw comes into contact with the tip side pin 80, and the two claw tips 70 are
They are acted upon by pins 80 so that they open. At the same time point, the pin 82 on the base side is engaged with the beveled surface 76 in the groove and the base side of the claw tip 70 is widened.
More affected. By the adjacent support claws 52, the tips of the segment coils aligned at the positions sandwiched by these are clamped and fixedly supported. Then, the alignment jig 46 is removed and the tip of the coil segment is opened upward. Further, since the tip of the coil segment is firmly supported by the support claw 52, it is held at the position aligned by the alignment jig 46.

The welding electrode 88 is arranged at a position corresponding to the welding pair 58 from the opened upper side, and the stator core 10 is rotated together with the jig to perform welding. As the welding method, for example, tungsten inert gas (TIG) welding can be adopted. At this time, the support claw 52 is grounded.

FIG. 9 is an explanatory view of the process of welding the tip of the coil segment 20, that is, the welding pair 58. The state where the tip of the coil segment 20 and the support claw 52 are viewed from the radial direction is shown. The welding electrode 88 moves relative to the circumferential direction of the stator core. This movement is continuous, and is not intermittent in that it temporarily stops at the welding target portion and moves to the next welding target portion after the completion of welding. In order to realize this, a transfer surface 90 having substantially the same height as the upper end of the coil segment 20 is provided on the surface (upper surface in the drawing) of the support claw 52 opposite to the surface facing the stator core 10. The transfer surface 90 is formed by the left and right coil segments 2.
It is provided with a certain distance from the zero tip.

When the welding electrode 88 and the tip of the coil segment face each other, an arc is generated as shown by A in the figure, and welding is performed. Even if the welding electrode 88 moves to some extent, an arc is formed between the coil segment 20 and the electrode 88 at an angle, as shown by B in the figure, because of the gap between the coil segment 20 and the transfer surface 90. It When the welding electrode 88 moves further, the arc jumps to the transfer surface 90, as indicated by C in the figure. Further, the arc jumps from the transfer surface 90 to the next coil segment 20, and by repeating this, the welding of each welding pair 58 is continuously performed. That is, by arranging the welding pairs 58, which are the welding targets arranged with a gap, between the welding pairs, a dummy (in the present embodiment, which corresponds to the transfer surface 90 of the support claw) for transferring the arc is arranged. It is possible to perform welding while continuously moving the welding electrode 88.

Since the support claw 52 has to support the coil segment 20, high rigidity is required. In addition, the transfer surface 90 is required to have high thermal conductivity in order to prevent deformation and wear due to welding. Therefore, the lower portion of the support claw shown in FIG. 9 represented by a substantially rectangular shape is made of steel, and the upper portion of the support claw including the transfer surface 90 is made of copper or a copper alloy. When the transfer surface 90 is made of a metal such as copper, the heat conductivity is good and the temperature rise is suppressed, so that the deformation and wear due to melting can be suppressed. Also, by making it possible to replace the part made of copper or copper alloy,
When abrasion or the like due to melting occurs, the running cost can be suppressed by exchanging only this portion.

[Brief description of drawings]

FIG. 1 is a process diagram of a stator coil forming process before welding a coil segment.

FIG. 2 is a diagram showing a state where a coil segment is inserted in a stator core.

FIG. 3 is a diagram showing a schematic configuration of a jig used for welding a tip of a stator core.

FIG. 4 is an explanatory diagram of a detailed structure of an alignment jig.

FIG. 5 is a diagram showing a schematic configuration near an alignment protrusion of an alignment ring.

FIG. 6 is an operation explanatory view of the alignment jig.

FIG. 7 is an explanatory diagram of a detailed structure of a support jig.

FIG. 8 is an explanatory diagram of a detailed structure of a support jig.

FIG. 9 is an explanatory diagram regarding continuous welding.

[Explanation of symbols]

10 stator cores, 20 coil segments, 46
Alignment jig, 48 alignment ring, 52 support claw, 58 welding pair, 62 alignment protrusion, 64 spacer, 88 welding electrode.

Continued front page    (72) Inventor Shigetaka Nagamatsu             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. F term (reference) 5H603 AA03 AA09 BB01 BB02 BB12                       CA01 CB03 CB18 CB19 CC17                       CD22 CD33 CE02 EE01                 5H604 AA08 BB01 BB03 BB14 CC01                       CC05 CC14 QB14 QB15                 5H615 AA01 BB01 BB02 BB14 PP01                       PP08 PP14 QQ02 QQ05 QQ12                       QQ27 SS04 SS16

Claims (8)

[Claims] 1. A coil is formed by bending a tip portion of a substantially U-shaped coil segment inserted into a slot of a core of a rotary electric machine, the tip portion projecting from the core end, and welding the tips of predetermined coil segments to each other. A positioning jig used in the process, wherein an alignment jig for aligning the bent coil segment tips in the radial direction of the rotating electric machine and the coil segment located between the aligned coil segment tip rows. A supporting jig having a supporting claw for clamping and supporting the vicinity of the tip, and the aligning jig corresponds to a welding pair, which is a pair of coil segment tips to be welded, with respect to the axis of the rotating electric machine. It includes a plurality of rings that are arranged concentrically and are individually movable in the axial direction of the rotating electric machine, and the rings align the circumferential positions of the tips of the coil segments that form the welding pair. It has a force, and a spacer to secure a distance between the welding adjacent pairs in the radial direction, and the positioning jig welded. 2. The welding positioning jig according to claim 1, wherein the support claw is inserted between the rows of the tip ends of the coil segment from the radially outer side of the core, and the support claw is cracked. It is shaped and at the end of the insertion,
A welding positioning jig in which the tip crack portion spreads to clamp and fix the tip of the coil segment together with the adjacent support claw. 3. The welding positioning jig according to claim 1, wherein an arc passing surface, which is a surface opposite to the core of the support claw, has a predetermined distance from the tip end of the coil segment. A welding positioning jig that receives a welding arc moving in the circumferential direction at the arc passing surface and passes the work to the tip of the next welding pair to be welded. 4. The welding positioning jig according to claim 3, wherein the arc transfer surface of the support claw is made of copper or a copper alloy. 5. A coil is formed by bending a tip portion of a substantially U-shaped coil segment inserted into a slot of a core of a rotating electric machine, the tip portion projecting from the core end, and welding the tips of predetermined coil segments to each other. A welding pair, which is a pair of the coil segment tips to be welded, has a protrusion for aligning the circumferential positions of the coil segment tips with each other, and a spacer for ensuring an interval between the welding pairs adjacent in the radial direction. A step of aligning the coil segment tips in the radial direction of the rotating electric machine by an aligning jig having a plurality of rings arranged concentrically with respect to the axis of the rotating electric machine; and a coil segment tip aligned by the aligning jig,
There is a step of supporting with a support jig having a support claw that is located between the rows and sandwiched from the side thereof, a step of removing the alignment jig, and a step of welding a welding pair of the coil segments. Coil forming method. 6. The coil forming method according to claim 5, wherein in the step of welding, the welding electrode and the core are continuously moved relative to each other so that the welding electrode moves in the circumferential direction with respect to the core.
A method of forming a coil, wherein welding is performed so that an arc of welding travels from the welding pair at the tip of the coil segment to the surface of the support claw and further to the next welding pair. 7. A method for welding objects to be welded arranged at intervals, wherein a dummy jig is arranged between the objects to be welded, and the welding electrode is continuously moved in the welding object arrangement direction to perform welding. Welding method, in which the arc of sig- nal moves from the welding target to the dummy jig and from the dummy jig to the next welding target one after another. 8. The welding method according to claim 7, wherein a surface of the dummy jig facing the welding electrode is located at a distance from an object to be welded, and the surface is made of copper or copper alloy.
Welding method.