JP2009159782A - Terminal, connecting structure between terminal and coil, armature, stator, motor, method of joining terminal and coil, and method of manufacturing stator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a terminal which can reduce bad welding by controlling the shift of the connection end of a coil in welding in simple structure. <P>SOLUTION: The terminal 15 includes a band-shaped terminal body 31 and a connecting section 33 which has a shape of having turned up a part of the terminal body 31 so that it may have a pair of coil joints 33a and 33b which face each other and between which the connection ends 11a of coils are to be arranged. Then, the connecting section 33 is provided integratedly with a restricting section 36 which extends from one coil joint 33a to at least the other coil joint 33b so that it may cross the opening of the connecting section 33. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a terminal, a connection structure between the terminal and a coil, an armature including the terminal, a stator including the armature, a motor including the stator, a method for joining the terminal and the coil, and a method for manufacturing the stator. It is about.

Conventionally, a brushless motor has been provided with a terminal for connecting a plurality of coils wound around a stator core and a power supply device, and the terminals have winding start and winding end portions respectively. Connected. For example, the terminal described in Patent Document 1 is made of a band-shaped metal plate material, and has a connection portion formed by folding one end portion of the metal plate material in the longitudinal direction into a U shape. The connecting portion is provided with a restricting portion that protrudes toward the inside of the connecting portion, and this restricting portion is connected to the terminal of the coil (connection) to be connected to the terminal. It is formed on the opening side of the connecting portion with respect to the end portion. By this restricting portion, movement of the end portion of the coil arranged in the connecting portion to the opening side of the connecting portion is restricted.
JP 2005-328654 A

  By the way, in general, when joining the connection portion and the end portion of the coil by resistance welding, the connection portion in which the end portion of the coil is arranged on the inner side of the coil is connected to the connection portion by a pair of welding electrodes. Since it is clamped from both sides so as to sandwich the end portion, the movement of the end portion of the coil is suppressed by the action of the pressing force of these welding electrodes and the restricting portion, and welding can be performed satisfactorily. However, when clamping of the connection part by the welding electrode is insufficient, the end of the coil may move, resulting in poor welding.

  Moreover, generally the conducting wire which comprises a coil is comprised from the metal wire and the insulating coating | coated member which coat | covers the outer periphery of this metal wire, and is thick so that the diameter of a metal wire may be 1.2 mm or more When a conducting wire is used, it is difficult to ensure continuity by resistance welding, and thus the connection portion and the end portion of the coil may be joined by fusion welding such as arc welding. When joining the connection part and the end of the coil by fusion welding, the connection part is not sandwiched between a pair of electrodes as in resistance welding. Due to the action of the tension applied to the end of the wire, there is a problem that the opening of the connection portion opens or the end of the coil gets over the restricting portion. For this reason, the position of the end of the coil with respect to the connection portion may be shifted, or the end of the coil may jump out of the connection portion, which may cause poor welding. And if the welding defect of a terminal and a coil is one place, since the brushless motor will be inferior goods, reduction of a welding defect is desired.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a terminal that can reduce welding defects by suppressing movement of a connecting end of a coil during welding with a simple configuration. And coil connection structure, armature provided with the terminal, stator provided with the armature, motor provided with the stator, method for joining the terminal and coil, and method for manufacturing the stator provided with the terminal It is to provide.

  In order to solve the above-mentioned problem, the invention according to claim 1 is a terminal made of a metal plate having a connection part for connecting the connection end part of the coil provided in the armature, and is a belt-like terminal main body part The connection portion has a shape in which a part of the terminal body portion is folded back so as to form a pair of coil connection portions that face each other and the connection end portion is disposed between the connection portions. The gist of the invention is that a restricting portion that extends from one of the coil connection portions to at least the other coil connection portion is integrally provided so as to cross the opening of the connection portion.

  According to this configuration, since the restricting portion is provided so as to cross the opening of the connecting portion, the connecting end of the coil disposed in the connecting portion is connected to the connecting portion from the opening of the connecting portion by the restricting portion. Going out of is suppressed. Further, since the restricting portion is provided so as to cross the opening portion of the connection portion, even if the opening portion of the connection portion is opened due to a thermal shock during welding or a tension applied to the connection end portion, It is possible to suppress the connection end portion from coming out of the connection portion from the opening portion of the connection portion. In addition, the restricting portion is provided integrally with the connection portion, and has a simple configuration that is formed so as to extend from one coil connection portion to at least the other coil connection portion so as to cross the opening of the connection portion. is there. From these things, with a simple structure, the movement of the connection end part of the coil at the time of welding can be suppressed, and a welding defect can be reduced.

  According to a second aspect of the present invention, in the terminal according to the first aspect, the restricting portion is provided at one end in the width direction of the terminal main body portion in one of the coil connecting portions of the pair of coil connecting portions. The gist of the present invention is that they are provided integrally and have a width equal to or greater than the plate thickness of the terminal body in the direction from the bottom of the connection part toward the opening of the connection part.

  According to the same configuration, the regulating portion has a width equal to or greater than the thickness of the terminal main body in the direction from the bottom of the connecting portion toward the opening of the connecting portion, so that heat is generated when welding the connecting portion and the connection end. Further, it is possible to suppress melting to the end portion on the side away from the connection end portion in the restricting portion (that is, the end portion on the opening side of the connection portion). Therefore, it can suppress more that the connection end part of a coil goes out of this connection part from the opening part of a connection part at the time of welding.

  According to a third aspect of the present invention, in the terminal according to the first or second aspect, a gap between the connection end portion disposed in the connection portion and the regulating portion is 0.35 mm or less. Is the gist.

According to this configuration, it is possible to reduce the welding failure rate (the ratio at which welding failure occurs) to 0% by setting the gap between the connection end portion and the regulating portion to 0.35 mm or less.
According to a fourth aspect of the present invention, in the terminal according to any one of the first to third aspects, the restriction portion is the terminal body in one of the coil connection portions of the pair of coil connection portions. Is integrally provided at one end portion in the width direction of the portion, and its distal end portion is bent toward the other coil connection portion along the outer surface of the other coil connection portion outside the connection portion. The gist thereof is to have an overhang portion.

  According to this configuration, the overhang portion prevents the pair of coil connection portions from moving away from each other, that is, the opening of the connection portion is suppressed. Therefore, it can further suppress that the connection end part of a coil goes out of this connection part from the opening part of a connection part at the time of welding.

  According to a fifth aspect of the present invention, in the terminal according to the fourth aspect, a gap between the connection end portion disposed in the connection portion and the restriction portion is 0.6 mm or less, and the overhang portion The gist is that the length from the proximal end to the distal end is 0.8 mm or more.

  According to the same configuration, when the length of the overhang portion is 0.8 mm or more, the welding failure rate can be 0% if the gap between the connection end portion and the restriction portion is 0.6 mm or less. It becomes.

  According to a sixth aspect of the present invention, in the terminal according to the first aspect, the regulating portion includes an end portion on the opening side of the connection portion in one of the coil connection portions of the pair of coil connection portions. It is formed by bending toward the inside of the connection portion, and the gist thereof is that the tip of the restriction portion is pressed into contact with the other coil connection portion by the elastic force of the connection portion.

  According to the same configuration, the restricting portion has a simple configuration formed by bending an end portion on the opening side of the connection portion in one of the coil connection portions toward the inside of the connection portion. In addition, the opening of the connecting portion can be easily closed by the restricting portion. Moreover, the front-end | tip of a control part is press-contacted to the other coil connection part with the elastic force of a connection part. Therefore, since the restricting portion is difficult to move even when receiving an impact force from the connection end moved in the connection portion due to thermal shock or the like during welding, the connection end portion of the coil is not connected to the connection portion from the opening of the connection portion during welding. It is possible to further suppress going out.

  The invention according to claim 7 is a connection structure between a terminal and a coil, in which a connection end portion of a coil provided in an armature is connected to a connection portion provided in a terminal made of a metal plate, The terminal includes a band-shaped terminal main body, and the connection portion is formed by folding a part of the terminal main body so that a pair of coil connection portions facing each other is formed, and the pair of coil connection portions At least one of the coil connection portions from one of the coil connection portions so as to cross the opening of the connection portion, which is integrally provided at one end portion in the width direction of the terminal main body portion of the one of the coil connection portions. The gist of the invention is that the connecting end portion is disposed in the connection portion and melt-welded at the end portion of the connection portion on the side where the restriction portion is provided.

  According to this configuration, since the restricting portion is provided so as to cross the opening of the connecting portion, the connecting end of the coil disposed in the connecting portion is connected to the connecting portion from the opening of the connecting portion by the restricting portion. Going out of is suppressed. Further, since the restricting portion is provided so as to cross the opening portion of the connection portion, even if the opening portion of the connection portion is opened due to a thermal shock during welding or a tension applied to the connection end portion, It is possible to suppress the connection end portion from coming out of the connection portion from the opening portion of the connection portion. In addition, the restricting portion is provided integrally with the connection portion, and has a simple configuration that is formed so as to extend from one coil connection portion to at least the other coil connection portion so as to cross the opening of the connection portion. is there. From these things, with a simple structure, the movement of the connection end part of the coil at the time of welding can be suppressed, and a welding defect can be reduced. In addition, fusion welding is performed at the end of the connecting portion on the side where the restricting portion is provided. That is, since fusion welding is performed at the end portion of the connection portion on the side where the restriction portion is provided, the portion of the connection end portion on the opening portion side of the connection portion is also joined to the restriction portion. Therefore, since the connection end is joined to the terminal over the entire periphery, the connection between the terminal and the connection end can be made more reliable.

  The invention according to claim 8 is the armature core having a plurality of radially extending teeth portions, and the connection end portions wound around the teeth portions and at least one of the connection end portions at the start and end of winding. The gist of the present invention is that the armature includes a plurality of coils connected to the connection portion of the terminal according to any one of claims 1 to 6.

According to this configuration, since the welding failure rate between the terminal and the connection end of the coil is reduced, the number of defective armatures is reduced.
According to a ninth aspect of the present invention, there is provided a stator core having a plurality of radially extending tooth portions, and at least one of the connection end portions of the connection end portions at the start and end of winding. The gist of the present invention is a stator including a plurality of the coils connected to the connection portion of the terminal according to any one of Items 1 to 6.

According to this configuration, since the welding failure rate between the terminal and the connection end portion of the coil is reduced, defective products of the stator are reduced.
The invention described in claim 10 includes a stator having a plurality of teeth portions each wound with a coil, and a connection portion in which connection ends of the coils are connected. The gist of the present invention is a motor including the terminal according to the above section and a rotor that has a magnet disposed inside the stator and is rotated relative to the stator by energizing the coil. .

According to this configuration, since the welding failure rate between the terminal and the connection end of the coil is reduced, defective products of the motor are reduced.
The invention according to claim 11 is an arrangement step of arranging the connection end of the coil provided in the armature coil in the connection part provided in the terminal according to any one of claims 1 to 6. And a joining step of joining the connecting portion and the connecting end portion by welding to each other, and a gist thereof.

  According to the method, since the restricting portion provided integrally with the connecting portion is provided so as to cross the opening of the connecting portion, the connecting end portion of the coil arranged in the connecting portion in the joining process is The restriction part prevents the connection part from going out of the connection part. In addition, since the restriction part is provided so as to cross the opening part of the connection part, in the joining process, when the opening part of the connection part opens due to the thermal shock during welding or the action of the tension applied to the connection end part Even so, it is possible to suppress the connection end portion from coming out of the connection portion from the opening portion of the connection portion. From these things, generation | occurrence | production of a welding defect can be reduced.

  The invention according to claim 12 is the method of joining a terminal and a coil according to claim 11, wherein the restricting portion is a width of the terminal main body portion in one of the coil connecting portions of the pair of coil connecting portions. In the joining step, arc welding is performed at the end of the connection part on the side where the restriction part is provided, and the connection part and the connection end part are provided. Its gist is to be joined.

  According to this method, in the joining step, arc welding is performed at the end of the connecting portion on the side where the restricting portion is provided, so that the portion on the opening side of the connecting portion at the connecting end is also joined to the restricting portion. . Therefore, since the connection end is joined to the terminal over the entire periphery, the connection between the terminal and the connection end can be made more reliable.

  A thirteenth aspect of the present invention includes a stator core having a plurality of teeth portions extending radially, a plurality of coils wound around the teeth portions, and a connection portion to which connection ends of the coils are connected. A method for manufacturing a stator including a terminal made of a metal plate, wherein the connection end is disposed in a connection portion provided in the terminal according to any one of claims 1 to 6. The gist of the present invention is a method for manufacturing a stator including a step and a joining step of joining the connection portion and the connection end portion by welding.

  According to the method, since the restricting portion provided integrally with the connecting portion is provided so as to cross the opening of the connecting portion, the connecting end portion of the coil arranged in the connecting portion in the joining process is The restriction part prevents the connection part from going out of the connection part. In addition, since the restriction part is provided so as to cross the opening part of the connection part, in the joining process, when the opening part of the connection part opens due to the thermal shock during welding or the action of the tension applied to the connection end part Even so, it is possible to suppress the connection end portion from coming out of the connection portion from the opening portion of the connection portion. From these things, generation | occurrence | production of a welding defect can be reduced.

  A fourteenth aspect of the present invention is the stator manufacturing method according to the thirteenth aspect of the present invention, wherein the restricting portion is one side in the width direction of the terminal main body portion in one of the coil connecting portions of the pair of coil connecting portions. It is provided integrally at the end, and in the joining step, arc welding is performed at the end of the connection part on the side where the restriction part is provided, and the connection part and the connection end are joined. That is the gist.

  According to this method, in the joining step, arc welding is performed at the end of the connecting portion on the side where the restricting portion is provided, so that the portion on the opening side of the connecting portion at the connecting end is also joined to the restricting portion. . Therefore, since the connection end is joined to the terminal over the entire periphery, the connection between the terminal and the connection end can be made more reliable.

  According to the present invention, a terminal capable of reducing the welding failure by suppressing the movement of the connecting end portion of the coil during welding with a simple configuration, the connection structure between the terminal and the coil, and the armature including the terminal In addition, a stator including the armature, a motor including the stator, a method of joining the terminal and the coil, and a method of manufacturing a stator including the terminal can be provided.

(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
A brushless motor 1 shown in FIGS. 1A and 1B is used as a drive source of a power steering device that assists the operation of a vehicle steering shaft connected to a steering wheel of a vehicle (not shown). As shown in FIGS. 1 (a) and 1 (b), a substantially cylindrical stator 3 is fixed to the inner peripheral surface of the bottomed cylindrical housing 2, and inside the stator 3, The rotor 4 is rotatably arranged. The rotor 4 is connected to the vehicle steering shaft (not shown). A holder 5 made of an insulating synthetic resin material is fixed to an end of the housing 3 on the opening side of the stator 3, and the holder 5 covers one end of the stator 3 in the axial direction. .

  As shown in FIG. 2A, a stator core 6 as an armature core constituting the stator 3 includes a plurality of teeth portions 7 (this embodiment) extending radially toward the center at predetermined angles (30 ° in the figure). In the form, 12 ends) on the outer peripheral side are connected in the circumferential direction by the connecting member 8 to form a substantially annular shape. A bobbin 9 that covers both end surfaces in the axial direction and both side surfaces in the circumferential direction of each tooth portion 7 is attached to each tooth portion 7 from both sides in the axial direction, and a conductive wire 10 is concentrated on the bobbin 9. Each coil 11 is wound by being wound a plurality of times. The conducting wire 10 has a configuration in which a metal wire 10a made of a conductive metal material (copper in this embodiment) is covered with a covering member 10b made of an insulating resin material (see FIG. 5A). Each coil 11 has a U-phase coil 12, a V-phase coil 13, and a W-phase coil according to three-phase excitation currents (U-phase, V-phase, and W-phase) as drive power supplied to the brushless motor 1. 14

  The U-phase coil 12, the V-phase coil 13, and the W-phase coil 14 are each wound around a predetermined tooth portion 7, and are continuously connected to the tooth portion 7 that is separated (not adjacent) across the other phase coils. It is wound by one conducting wire 10. In the present embodiment, the U-phase coil 12, the V-phase coil 13, and the W-phase coil 14 are wound around two predetermined adjacent tooth portions 7 and straddle the tooth portions 7 corresponding to other phases. It is wound around two teeth portions 7 on the opposite sides of 180 °.

  Specifically, the U-phase coil 12 is wound around the tooth portion 7 from the start end portion 12s to the end portion 12e. 2b between the terminal portions 12e of the two U-phase coils 12 arranged on the upper side in the drawing and the start ends 12s of the two U-phase coils 12 arranged on the lower side in the drawing. ), The crossover line 12w is passed.

  Note that the start end 12s of the upper U-phase coil 12 in the drawing is drawn from the drawing position 12X indicated by the dotted line in the drawing, and the terminal end 12e of the lower U-phase coil 12 in the drawing is indicated by the dotted line in the drawing. It is pulled out from the pulling position 12Y.

  That is, the conducting wire 10 drawn from the drawing position 12X is wound as the U-phase coil 12 from the start end portion 12s to the end end portion 12e on the two teeth portions 7 arranged on the upper side in the drawing. Then, the crossover wires 12w are passed from each end portion 12e to the two tooth portions 7 arranged on the lower side in the drawing, and wound as the U-phase coil 12 from the start end portion 12s to each tooth portion 7. Further, the end portion 12e of each U-phase coil 12 is pulled out from the pulling position 12Y.

  Similarly, the conducting wire 10 drawn from the drawing position 13X is wound around the two tooth portions 7 as a V-phase coil 13 from the start end portion 13s to the end end portion 13e. Then, the crossover wires 13w are passed from each end portion 13e to the two tooth portions 7 disposed at opposing positions, and wound as the V-phase coil 13 from the start end portion 13s to each tooth portion 7. Furthermore, the terminal portion 13e of each V-phase coil 13 is pulled out from the pulling position 13Y.

  Similarly, the conducting wire 10 drawn from the drawing position 14X is wound around the two tooth portions 7 as a W-phase coil from the start end portion 14s to the end portion 14e. Then, the crossover wire 14w is passed from each end portion 14e to the two tooth portions 7 disposed at the opposing positions, and wound as a W-phase coil 14 from the start end portion 14s to each tooth portion 7. Further, the end portion 14e of each W-phase coil 14 is pulled out from the pull-out position 14Y.

  Each of the start ends 12s to 14s, the end portions 12e to 14e, and the connecting wires 12w to 14w are arranged on one side in the axial direction of the stator 3 (left side in FIG. 2B). The start end portions 12s to 14s and the end portions 12e to 14e correspond to the connection end portions 11a that are the end portions of the coil 11, and the connection end portions 11a are formed by removing the covering member 10b and the metal wires 10a. Exposed. Each start end part 12s-14s and each termination | terminus part 12e-14e (connection end part 11a) are pulled out to the surface on the opposite side to the stator 3 of the holder 5 (refer Fig.1 (a) and FIG.1 (b)), Wired to a plurality (four in this embodiment) of terminals 15 arranged on the surface of the holder 5 opposite to the stator 3. Moreover, each crossover line 12w-14w is arrange | positioned at the accommodation recessed part 24 formed in the holder 5 mentioned later.

  As shown in FIG. 2A, the rotating shaft 16 constituting the rotor 4 is pivotally supported by a bearing (not shown) provided in the housing 2. A cylindrical rotor core 17 is fixed to the rotating shaft 16, and a magnet 18 magnetized with different polarities (N pole, S pole) at predetermined angles is fixed to the outer peripheral surface of the rotor core 17. ing.

  In the brushless motor 1 configured as described above, U-phase, V-phase, and W-phase excitation currents having a phase difference of 120 ° from an excitation circuit (not shown) are respectively supplied to the U-phase coil 12, the V-phase coil 13, and the W-phase coil. 14 is supplied. Then, the U-phase coil 12, the V-phase coil 13, and the W-phase coil 14 are excited to generate a rotating magnetic field in the stator 3, and the rotor 4 rotates based on the rotating magnetic field.

  As shown in FIGS. 3A and 3B, the substantially cylindrical holder main body 21 constituting the holder 5 has substantially the same diameter as the stator core 6 (see FIG. 1B). A plurality of engagement pieces 23 project from the mounting surface 22 of the holder body 21 on the stator core 6 side along the outer peripheral edge of the mounting surface 22. Further, on the outer peripheral surface of the stator 3 described above, an engaging portion (not shown) is formed at a position corresponding to these engaging pieces 23, and the holder 5 moves toward the stator 3 along the axial direction. Then, the engagement piece 23 is engaged with the engagement portion, and the holder 5 is fixed to the stator 3.

  Further, the mounting surface 22 of the holder main body 21 is formed with a substantially arc-shaped accommodation recess 24 extending in the circumferential direction, and the accommodation recess 24 has the crossover wires 12w, 13w, 14w as described above. (See FIG. 2B) is accommodated. The accommodation recess 24 is formed at an appropriate location to accommodate the crossover wires 12w, 13w, and 14w, respectively.

  Further, at six locations in the circumferential direction of the holder main body portion 21, cutout portions 25 that are recessed from the outer peripheral edge of the holder main body portion 21 toward the radially inner side are formed. Each notch 25 is formed so as to penetrate in the axial direction of the brushless motor 1 (perpendicular to the plane of the drawing in FIG. 3A) and open radially outward. And the width | variety (width | variety of the circumferential direction) of each notch part 25 is made into the width | variety substantially the same as the diameter of the said conducting wire 10 (refer Fig.2 (a)) which comprises the coil 11. FIG. Each notch 25 is formed at a position corresponding to the pull-in positions 12X, 13X, 14X and the pull-out positions 12Y, 13Y, 14Y shown in FIG. 2 (a), and the U-phase coil 12, the V-phase coil 13, Two connection end portions 11a of the W-phase coil 14 are accommodated. The connection end portions 11a accommodated in the respective cutout portions 25 are held while the movement of the holder main body portion 21 in the circumferential direction is restricted. And each connection end part 11a accommodated in the notch part 25 is fixed to the connection part 33 of the terminal 15 mentioned later (refer FIG. 1).

  Further, on the installation surface 26 on which the terminal 15 opposite to the mounting surface 22 of the holder main body 21 is installed, engaging portions 27 are formed to protrude at a plurality of locations (four locations). As shown in FIG. 3C, the engaging portion 27 is formed with a locking surface 27a, and the terminal 15 is engaged with the engaging portion 27, respectively.

  As shown in FIG. 3A, each terminal 15 is formed by bending a plurality of portions of a conductive metal plate material. Of the four terminals 15, three terminals 15 a to 15 c arranged on the upper side in the drawing each have a band-shaped terminal body 31. And the terminal main-body part 31 of each terminal 15a-15c has the connector part 32 which can supply the electric power from the outside in the upper one end part in Fig.3 (a), respectively, and the said drawing-in position in the other end part Connection portions 33 are formed so as to correspond to 12X, 13X, and 14X (see FIG. 2A). Further, the strip-shaped terminal body 31 of the terminal 15d arranged on the lower side in the figure has both ends of the terminal body 31 corresponding to the drawing positions 12Y, 13Y, and 14Y (see FIG. 2A). The connection part 33 is integrally formed in three places of a part and a substantially center part. Then, each connection portion 33 is connected to the start end portions 12s to 14s and the end portions 12e to 14e (that is, the connection end portions 11a) of the coil 11 located at the drawing positions 12X to 14X and the drawing positions 12Y to 14Y. Thereby, the external electric power supplied from each connector part 32 is comprised so that it may be supplied to the U-phase coil 12, the V-phase coil 13, and the W-phase coil 14 via the terminal 15.

  The terminal 15a is formed with a fixed piece 34 so as to protrude toward the holder 5, and the fixed piece 34 is embedded in the holder body 21 as shown in FIG. The terminal 15 a is fixed to the holder 5. Similarly, a fixed piece 34 is formed in the terminal 15 d, and the fixed piece 34 is embedded in the holder main body 21.

  The terminal main body 31 of the terminal 15b is cut and raised at a position corresponding to the engaging portion 27 formed on the holder main body 21, as shown in FIGS. 4 (a) to 4 (c). Is formed. The terminal 15b is held by the engaging portion 27 and the cut-and-raised portion 35 is engaged when the terminal main body portion 31 is inserted into the engaging portion 27 formed in the holder main body portion 21 from the installation surface 26 side. It is locked to the stop surface 27a (see FIG. 3C) and fixed to the holder body 21. Similarly, a cut-and-raised portion 35 is also formed in each of the terminal main body portions 31 of the terminals 15c and 15d, and the cut-and-raised portion 35 is locked to the locking surface 27a of the engaging portion 27 so that the terminals 15c and 15d are It is fixed to the holder body 21.

  As described above, in the state where the terminals 15a to 15d are fixed to the holder 5, the connection portions 33 of the terminals 15a to 15d are arranged substantially concentrically as shown in FIG.

Here, the connection part 33 formed in each terminal 15a-15d is explained in full detail.
The connection part 33 is for connecting the connection end part 11 a of the coil 11 (that is, the U-phase coil 12, the V-phase coil 13, and the W-phase coil 14) wound around the stator (armature) 3 of the brushless motor 1. (See FIG. 2 (a) and FIG. 2 (b)). As shown in FIGS. 5 (a) and 5 (b), each connection portion 33 is connected to the end portion (or part) in the longitudinal direction of the terminal main body 31 at the connection end from which the covering member 10b has been removed in advance. It has a shape that is folded back into a substantially U shape so as to sandwich the portion 11a. And since the terminal main-body part 31 was folded in this way, each connection part 33 has a pair of coil connection parts 33a and 33b which mutually oppose.

  As shown in FIG. 3A, each connection portion 33 has a shape along the end portion (the radially inner end portion) of the cutout portion 25 formed in the holder main body portion 21, and the holder main body portion. When it is installed on the installation surface 26 of 21, it is formed so as to open toward the radially outer side. 5A and 5B, the pair of coil connection portions 33a and 33b are parallel to each other, and the width between the coil connection portions 33a and 33b is equal to the metal of the conductor 10. The value is substantially equal to the diameter d of the wire 10a. In the present embodiment, the diameter of the connection end portion 11a (that is, the diameter of the metal wire 10a from which the covering member 10b has been removed) d is 1.3 mm, and the plate thickness t of each terminal main body 31 is 0. 8 mm.

  Each connecting portion 33 is integrally provided with a restricting portion 36 for preventing the connecting end portion 11a of the coil 11 disposed in the connecting portion 33 from coming out of the connecting portion 33 from the opening of the connecting portion 33. Is formed. The restricting portion 36 has a width of the terminal main body 31 in one of the pair of coil connecting portions 33a and 33b (in this embodiment, a coil connecting portion corresponding to a portion where the terminal main body 31 is folded back). It extends from one end of the direction. The restricting portion 36 is formed such that the length from the base end to the tip end is longer than the interval between the pair of coil connecting portions 33a and 33b. Then, when the base end portion is bent so that the distal end portion comes into contact with the other coil connection portion 33b, the restriction portion 36 extends so as to cross the opening of the connection portion 33, and the distal end of the restriction portion 36 is It is arranged around the other coil connection portion 33b. Further, the width w of the restricting portion 36 in the direction from the bottom of the connecting portion 33 to the opening of the connecting portion 33 (left and right direction in FIG. 5B) is 1.2 mm. It is a value larger than the plate thickness t. Further, the restricting portion 36 has a gap G between the connecting end portion 33 and the connecting end portion 11 a arranged on the opening side of the connecting portion 33 of the two connecting end portions 11 a arranged in the connecting portion 33. It is formed at a position of 0.35 mm. In FIG. 5B, the gap G is exaggerated and enlarged.

  Two connecting end portions 11 a arranged in each connecting portion 33 are joined to the connecting portion 33 by arc welding. More specifically, as shown in FIG. 6, the base end portion of the restricting portion 36 is bent after the connecting end portion 11 a is disposed in the connection portion 33 (between the pair of coil connecting portions 33 a and 33 b), and the restricting portion 36 is bent. Is in a state of crossing the opening of the connection part 33. Thereafter, at the end portion of the connecting portion 33 on the side where the restricting portion 36 is provided, the connecting end portion 11a and the connecting portion 33 are melt-bonded by arc welding. In FIG. 6, a two-point difference is provided for a melted joint portion 37 (copper alloy of the terminal 15 and the coil 11) between the terminal 15 (connection portion 33) and the coil 11 (connection end portion 11 a) formed by performing arc welding. It is illustrated by a line. Each terminal 15 and the connection end portion 11 a of the coil 11 form a connection structure by the melt-bonded portion 37. In arc welding using a welding rod, the melt of the welding rod and the melt of the terminal 15 (connection portion 33) and the coil 11 (connection end portion 11a) serve as a melt joint portion.

Next, a method for manufacturing the stator 3 configured as described above will be described focusing on a method for joining the terminal 15 and the coil 11.
First, an arrangement step is performed, and two connection end portions 11a of the coils 11 wound around the tooth portions 7 of the stator core 6 are arranged in the corresponding connection portions 33, respectively (see FIG. 5A). ). At this time, the base end portion of each restriction portion 36 is not bent, and each connection end portion 11 a is inserted into the connection portion 33 from the opening of each connection portion 33. In addition, before an arrangement | positioning process is performed, each connection edge part 11a is in the state which the metal wire 10a was exposed by the coating | coated member 10b being removed.

  Next, a bending step is performed, and the base end portion of each regulating portion 36 is bent (see FIG. 5B). Thereby, each regulation part 36 will be in the state where the front-end | tip part contact | abuts to the one side edge part of the width direction of the terminal main-body part 31 in the other coil connection part 33b, and crossed the opening part of the connection part 33. FIG.

  Subsequently, a joining process is performed, and each connection part 33 and the connection end part 11a are joined by arc welding, respectively (refer FIG. 6). In the joining step, the end of the connecting portion 33 and the connecting end 11a on the side where the restricting portion 36 is provided are melted by arc welding, and both are joined as a copper alloy. At this time, the restricting portion 36 that crosses the opening of the connection portion 33 prevents the connection end portion 11 a disposed in the connection portion 33 from coming out of the connection portion 33 from the opening of the connection portion 33. .

  Here, FIG. 7 shows a result obtained by conducting an experiment in which the connection portion 33 and the connection end portion 11a are joined by arc welding and examining a ratio at which welding failure occurs (that is, a welding failure rate). In the experiment, a terminal having a thickness t of the terminal main body 31 of 0.8 mm and a width w of the restricting portion 36 of 1.2 mm is connected to the connecting end portion 11a (metal wire 10a) and the restricting portion. Seven types were prepared by changing the value of the gap G with respect to 36, and a metal wire 10a (connection end portion 11a) having a diameter d of 1.3 mm was actually joined to the connection portion 33 by arc welding. Also, seven types of terminals having a terminal thickness 31 of 0.8 mm and a width w of the restricting portion 36 of 1.5 mm are prepared by changing the value of the gap G, and a metal wire having a diameter d of 1.3 mm. 10a (connection end portion 11a) was actually joined to the connection portion 33 by arc welding. Furthermore, seven types of terminals having a terminal body 31 with a thickness t of 1.2 mm and a width w of the restricting portion 36 of 1.2 mm are prepared by changing the value of the gap G, and a metal wire having a diameter d of 2.0 mm. 10a (connection end portion 11a) was actually joined to the connection portion 33 by arc welding. Furthermore, seven types of terminals having a terminal body 31 having a plate thickness t of 1.2 mm and a width w of the restricting portion 36 of 1.5 mm are prepared by changing the value of the gap G, and a metal having a diameter d of 1.3 mm. The wire 10a (connection end portion 11a) was actually joined to the connection portion 33 by arc welding. In addition, the value of the gap G was changed into seven types of 0.3 mm, 0.35 mm, 0.45 mm, 0.5 mm, 0.6 mm, and 0.7 mm. And based on these experimental results, the welding defect rate was calculated. The calculated defect rate is a value within a thick frame in FIG. Further, in FIG. 8, as a representative, the gap G and the welding failure based on the experimental results when the terminal body portion 31 has a thickness t of 0.8 mm and the restriction portion 36 has a width w of 1.2 mm. The relationship with the rate is shown.

  7 and 8, the welding failure rate is 0% when the gap G between the connection end portion 11a and the restricting portion 36 is 0.35 mm or less, and the gap G is less than 0.35 mm. It can be seen that the value increases as the value of the gap G increases. If at least the width of the restricting portion 36 is 1.2 mm or more, the diameter d of the metal wire 10a is 1.3 mm and the plate thickness t of the terminal main body 31 is 0.8 mm. When the diameter d is 2.0 mm and the thickness t of the terminal body 31 is 1.2 mm, the gap G between the connection end 11a and the restricting portion 36 is set to 0.35 mm or less, It can be seen that the welding defect rate can be reduced to 0%.

  It can be considered as follows that the welding defect rate becomes 0% when the gap G is 0.35 mm or less. If the gap G between the restricting portion 36 and the connecting end portion 11a is narrow, the region surrounded by the connection portion 33 and the restricting portion 36 becomes narrow. Therefore, the connecting end portion 11a disposed in the region is welded. It becomes difficult to rampage by the impact of time. Accordingly, the impact force due to the ramping of the connection end portion 11a is reduced, so that poor welding is less likely to occur. Furthermore, if the gap G between the restricting portion 36 and the connecting end portion 11a is narrow, the restricting portion 36 and the connecting portion 33 and the connecting end portion 11a are closer to each other, so that poor welding is less likely to occur. From these facts, it is considered that when the gap G is 0.35 mm or less, the welding defect rate becomes 0%.

  In addition, when the diameter d of the metal wire 10a is in the range of 1.3 to 2.0 mm and the plate thickness t of the terminal main body 31 is in the range of 0.8 to 1.2 mm, the same applies. If the gap G is 0.35 mm or less, the welding failure rate is 0%. If the gap G is larger than 0.35 mm, the welding failure rate is considered to increase as the value of the gap G increases.

As described above, according to the first embodiment, the following operational effects are obtained.
(1) Since the restricting portion 36 is provided so as to cross the opening of the connecting portion 33, the connecting end portion 11 a of the coil 11 disposed in the connecting portion 33 is connected to the connecting portion 33 by the restricting portion 36. It is suppressed that it goes out of the connection part 33 from an opening part. Further, since the restricting portion 36 is provided so as to cross the opening portion of the connection portion 33, the opening portion of the connection portion 33 is caused by the thermal shock during welding and the tension applied to the connection end portion 11 a in the joining process. Even if it is a case where it opens, it can suppress that the connection end part 11a goes out of a connection part from the opening part of the connection part 33. FIG. Further, the restricting portion 36 is provided integrally with the connection portion 33 and is formed so as to extend from one coil connection portion 33a to the other coil connection portion 33b so as to cross the opening of the connection portion 33. It is a simple configuration. From these things, with a simple structure, the movement of the connection end part 11a of the coil 11 at the time of welding can be suppressed, and a welding defect can be reduced. And since the welding defect rate of the terminal 15 and the connection end part 11a of the coil 11 is reduced, the defective product of the stator (armature) 3 provided with the terminal 15 and the brushless motor 1 provided with the terminal 15 is reduced. The

  (2) The width w of the restricting portion 36 provided in the terminal 15 of the present embodiment is set to 1.2 mm, which is larger than the plate thickness t of the terminal main body portion 31. Generally, when welding the connection part 33 and the connection end part 11a, the part fuse | melted by the heat at the time of welding in the connection part 33 is a part within the range of plate | board thickness. As in the present embodiment, the regulation portion 36 having a width w larger than the plate thickness t of the terminal main body portion 31, that is, the thickness of the connection portion 33, is suppressed from being melted entirely. The connection end portion 11a is connected to the connecting portion at the time of welding by a portion that is not melted in 36 (that is, a portion far from the connection end portion 11a in the width direction of the restriction portion 36 and opposite to the connection end portion 11a). Further out of 33 is further suppressed.

  (3) In the terminal 15 of this embodiment in which the plate thickness t of the terminal body 31 is 0.8 mm and the width w of the restricting portion 36 is 1.2 mm, the gap G between the connection end 11 a and the restricting portion 36 is Since it is set to 0.35 mm, when connecting the connection end portion 11a having the diameter d of 1.3 mm to the connection portion 33, the welding defect rate can be set to 0%.

  (4) In the joining step, arc welding is performed at the end portion of the connection portion 33 on the side where the restricting portion 36 is provided, so the portion of the connection end portion 11a on the opening portion side of the connection portion 33 is also joined to the restricting portion 36. Is done. Therefore, since the connection end portion 11a is joined to the terminal 15 over the entire periphery, the joining of the terminal 15 and the connection end portion 11a can be made more reliable.

(Second Embodiment)
Hereinafter, a second embodiment of the present invention will be described with reference to the drawings. In addition, about the structure same as the said 1st Embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  As shown in FIGS. 9A and 9B, the terminal 41 of the second embodiment is provided in the brushless motor 1 instead of the terminal 15 of the first embodiment (FIG. 1 ( a)). Of the pair of coil connection portions 33a and 33b constituting the connection portion 33, one of the coil connection portions 33a (in this embodiment, the coil connection portion corresponding to the portion where the terminal main body portion 31 is folded back) of the terminal main body portion 31. The restricting portion 42 extends from one end portion in the width direction, and the restricting portion 42 includes an overhang portion 42a at the tip portion.

  The restriction portion 42 is formed such that the length from the proximal end to the distal end is longer than the distance between the outer surfaces of the pair of coil connection portions 33a and 33b, and the proximal end portion is directed toward the other coil connection portion 33b. When bent, it is in a state where it crosses the opening of the connecting portion 33 (that is, when it is in the state shown in FIGS. 9A and 9B). A portion bent toward the other coil connection portion 33b along the outer surface 33c of the other coil connection portion 33b outside the connection portion 33 at the front end portion of the restriction portion 42 becomes an overhang portion 42a. ing. The overhang portion 42 a is substantially orthogonal to a portion of the restricting portion 42 that crosses the opening of the connection portion 33.

  In the terminal 41 of the second embodiment, the thickness t of the terminal main body 31 is 0.8 mm, the width w of the restricting portion 42 is 1.2 mm, and the gap between the connection end portion 11a and the restricting portion 42. G is 0.6 mm, and the length L of the overhang portion 42a is 0.8 mm. Incidentally, the length L of the overhang portion 42a is the length from the base end to the tip end of the overhang portion 42a, and is the length along the width direction of the terminal main body portion 31 in this embodiment. And the diameter d of the connection end part 11a (metal wire 10a from which the coating | coated member 10b was removed) connected to the connection part 33 is 1.3 mm.

  The two connection end portions 11 a arranged in each connection portion 33 are joined to the connection portion 33 by performing the placement step, the bending step, and the joining step similarly to the first embodiment. That is, arc welding is performed at the end of the connection part 33 on the side where the restricting part 42 is provided, and the connection end part 11a and the connection part 33 are melt-bonded. In addition, each terminal 41 and the connection end part 11a of the coil 11 are the fusion | melting junction part (terminal 15 and the coil 11) of the terminal 41 (connection part 33) and the coil 11 (connection end part 11a) formed by arc welding. A copper alloy) forms a connection structure.

  Here, FIG. 10 is a graph showing the relationship between the length L of the overhang portion 42a and the welding failure rate when the terminal 41 having the restriction portion 42 having the overhang portion 42a and the connection end portion 11a are welded. Show. This graph shows a terminal 41 having an overhang portion 42a (the thickness t = 0.8 mm of the terminal main body portion 31, the width w of the restricting portion 42 = 1.2 mm, and the gap G between the connecting end portion 11a and the restricting portion 42. = 0.6 mm), and the length L of the overhang portion 42a was changed to produce the result based on the results of actual welding and experiments.

  Referring to FIG. 10, the welding failure rate decreases in a curved manner as the length L increases in the range where the length L of the overhang portion 42a is 0.0 to 0.8 mm. In the range where L is 0.8 mm or more, it is 0%. Therefore, by providing the overhang portion 42a and setting its length L to a value of 0.8 mm or more, even if the gap G is larger than 0.35 mm, the welding failure rate can be set to 0%. Is possible. At least when the gap G is 0.6 mm or less, the welding failure rate can be set to 0% by setting the length L of the overhang portion 42a to a value of 0.8 mm or more.

As described above, according to the second embodiment, in addition to the functions and effects of (1), (2), and (4) of the first embodiment, the following functions and effects are provided.
(1) The overhang portion 42a prevents the pair of coil connection portions 33a and 33b from moving away from each other, that is, the opening of the connection portion 33 is suppressed. Therefore, it can further suppress that the connection end part 11a of the coil 11 goes out of the connection part 33 from the opening part of the connection part 33 at the time of welding.

  (2) The terminal 41 of the present embodiment in which the plate thickness t of the terminal body 31 is 0.8 mm and the width w of the restricting portion 36 is 1.2 mm is connected to the overhang portion 42a having a length of 0.8 mm. The gap G between the end portion 11a and the restricting portion 42 is set to 0.6 mm or less. Therefore, in the case where the connection end portion 11a having the diameter d of 1.3 mm is connected to the connection portion 33, the welding failure rate can be set to 0%.

  (3) Since the overhang portion 42a is provided in the restriction portion 42, even if the gap G between the connection end portion 11a and the restriction portion 42 is larger than 0.35 mm, the welding failure rate is 0%. can do. When the gap G is set to a value larger than 0.35 mm and the restricting portion 42 and the connection end portion 11a are separated from each other, the base end portion of the restricting portion 42 is easily bent in the bending step. Therefore, it is possible to more easily join the terminal 41 and the coil 11 while reducing the welding defect rate.

In addition, you may change embodiment of this invention as follows.
In the joining process of the first embodiment, arc welding is performed so that the connection part 33 and the connection end part 11a of the coil 11 are melt-bonded at the end part of the connection part 33 on the side where the restriction part 36 is provided. Is called. However, in the joining process, the connection part 33 and the connection end part 11a of the coil 11 are connected to the end part of the connection part 33 in the width direction of the terminal main body part 31 where the restriction part 36 is not provided. Arc welding may be performed so as to be melt-bonded. The same applies to the case where the connection end portion 11a is joined to the connection portion 33 of the terminal 41 of the second embodiment.

  The shape of the restricting portion provided integrally with the connecting portion 33 in order to prevent the connection end portion 11a from coming out of the connecting portion 33 from the opening of the connecting portion 33 is the restricting portion 36 of each of the above embodiments. The shape is not limited to 42, and any shape that crosses the opening on the opening side of the connecting portion 33 relative to the connecting end 11a to be connected may be used. Regarding the restricting portion, “crossing the opening of the connecting portion” means from one coil connecting portion 33a to the other coil connecting portion 33b so as to cross the opening of the connecting end portion 11a in the connecting portion 33. In addition to the one extending, the one extending from one coil connection portion 33a to the other coil connection portion 33b around the opening of the connection portion 33 is also included. For example, the restricting portion 51 shown in FIG. 11 is extended from one end in the width direction of the terminal main body portion 31 in one coil connecting portion 33a of the pair of coil connecting portions 33a and 33b. The restricting portion 51 has a proximal end bent so that the distal end of the restricting portion 51 contacts the inner surface 33d of the other coil connecting portion 33b. And the front-end | tip of the control part 51 is press-contacted by the inner surface 33d of the coil connection part 33b with the elastic force of the connection part 33. FIG. Moreover, the restriction | limiting part 61 shown in FIG. 12 is an edge part by the side of the opening part of the connection part 33 in one coil connection part 33a applicable to the part which turned back the terminal main-body part 31 among a pair of coil connection parts 33a and 33b. Is bent toward the inner side of the connection portion 33. And the front-end | tip of the control part 61 is press-contacted by the inner surface 33d of the coil connection part 33b with the elastic force of the connection part 33. FIG.

  If comprised in this way, since the front-end | tip of the control parts 51 and 61 is press-contacted by the inner surface 33d of the other coil connection part 33b with the elastic force of the connection part 33, the control parts 51 and 61 are the connection part 33. Even when receiving an impact force from the connection end portion 11a that has moved in the connection portion 33 due to thermal shock or the like during welding to the connection end portion 11a, it becomes difficult to move. Therefore, it is possible to further suppress the connection end portion 11a of the coil 11 from coming out of the connection portion 33 from the opening portion of the connection portion 33 during welding. In addition, the restricting portion 61 is formed by bending the end portion on the opening side of the connection portion 33 in one of the coil connection portions 33a of the pair of coil connection portions 33a and 33b toward the inside of the connection portion 33. In addition, the restriction portion 61 can easily close the opening of the connection portion 33.

  In the terminal 41 of the second embodiment, the restricting portion 42 includes the two connecting end portions 11a arranged in the connection portion 33 so that the length L of the overhang portion 42a is 0.8 mm. It is formed so that the gap G between the connection end portion 11a disposed on the opening side of the connection portion 33 is 0.6 mm. However, the length L of the overhang portion 42a and the value of the gap G may be changed as appropriate.

  In the first embodiment, the restricting portion 36 includes the connecting end portion 11a disposed on the opening side of the connecting portion 33 of the two connecting end portions 11a disposed in the connecting portion 33 in the connecting portion 33. The gap G is formed at a position where the gap G becomes 0.35 mm. However, the value of the gap G is not limited to this. The restricting portion 36 may be formed at a position where the gap G is smaller than 0.35 mm in the connecting portion 33 or may be formed at a position larger than 0.35 mm. However, if the restricting portion 36 is formed so that the gap G is smaller than 0.35 mm, the welding defect rate can be reduced to 0%.

In each of the above embodiments, the width w of the restricting portions 36 and 42 is 1.2 mm. However, the width w of the restricting portions 36 and 42 may be set to a value other than this.
In each of the above embodiments, the restricting portions 36 and 42 are integrally provided in one of the pair of coil connection portions 33a and 33b and the one coil connection portion 33a corresponding to the portion where the terminal main body portion 31 is folded. Yes. However, the restriction portions 36 and 42 may be provided integrally with any one of the pair of coil connection portions 33a and 33b. In each of the above embodiments, the coil connection portion 33a is expressed as “one coil connection portion” and the coil connection portion 33b is expressed as “the other coil connection portion”, but “one coil connection portion”. May be regarded as the coil connection portion 33b, and the “other coil connection portion” may be regarded as the coil connection portion 33a.

  In each of the above embodiments, after the connection end portion 11a is arranged in the connection portion 33 in the arranging step, the restricting portions 36 and 42 are bent in the bending step so that the restricting portions 36 and 42 are bent. , 42 are in a state of crossing the opening of the connection portion 33. However, the bending step may be performed before the placement step is performed. In addition, when joining the connection end part 11a of the coil 11 to the connection part 33 of the terminal 41 of 2nd Embodiment, the gap G is set to a value larger than 0.35 mm, and the control part 42 and the connection end part 11a are spaced apart. Since the space surrounded by the connecting portion 33 and the restricting portion 42 is increased, the connecting end portion 11a can be more easily inserted into the connecting portion 33 in the arranging step after the bending step. Therefore, it is possible to more easily join the terminal 41 and the coil 11 while reducing the welding defect rate.

  As shown in FIG. 13, in the bending process, the connection portion 33 such that the pair of coil connection portions 33 a and 33 b are closer to each other on the opening side of the connection portion 33 than the connection end portion 11 a arranged in the connection portion 33. You may caulk. If it does in this way, the movement of the connection end part 11a in the connection part 33 will be controlled more, and it will suppress further that the connection end part 11a goes out of the connection part 33 from the opening part of the connection part 33 in a joining process. Is done. It should be noted that productivity can be improved by caulking the connecting portion 33 at the same time when the regulating portion 36 is bent.

  -In each above-mentioned embodiment, joining of connection part 33 and connecting end 11a is performed by arc welding, but it is not restricted to this. For example, you may join the connection part 33 and the connection end part 11a by any method, such as fusion welding (laser welding etc.) other than arc welding, resistance welding.

  In each of the above embodiments, the pair of coil connection portions 33a and 33b constituting the connection portion 33 are parallel to each other, but may be configured to face each other. Therefore, for example, the pair of coil connection portions 33 a and 33 b is not limited to being parallel, and may be configured such that the distance between the pair of coil connection portions 33 a and 33 b gradually increases toward the opening of the connection portion 33. Further, the pair of coil connection portions 33 a and 33 b may be configured such that the distance between the pair of coil connection portions 33 a and 33 b gradually decreases toward the opening of the connection portion 33.

  In the above embodiment, the connection portion 33 has a shape in which the end portion (or part) in the longitudinal direction of the terminal main body portion 31 is folded back into a U shape. However, the connecting portion 33 may have a shape other than the U shape, such as a U shape or a V shape, as long as the end portion (or part) in the longitudinal direction of the terminal main body portion 31 is folded back. .

In the above-described embodiment, two connection end portions 11a are connected to the connection portion 33, but one connection end portion 11a may be connected to the connection portion 33.
-The diameter d of the metal wire 10a of the conducting wire 10 which comprises the coil 11 is not restricted to the value of said each embodiment, You may change suitably.

  In each of the above embodiments, the connection portion 33 of the terminals 15 and 41 connects the coil 11 wound around the stator (armature) 3 of the brushless motor 1. However, the terminal concerning this invention is not limited to this, You may apply to the terminal provided with the connection part which connects the coil with which the armature of the motor with a brush was equipped.

  In each of the above embodiments, the present invention has been described by taking the brushless motor 1 provided in a power steering device for assisting the operation of the vehicle steering shaft as an example, but the present invention may be embodied in a brushless motor for other uses. Good.

The technical ideas that can be grasped from each of the above embodiments and each of the above modifications are described below.
(A) In the method of joining a terminal and a coil according to claim 11 or claim 12, the connection portion is disposed more than the connection end portion disposed in the connection portion between the placement step and the joining step. A method of joining a terminal and a coil, comprising a bending step of caulking the connection portion so that the pair of coil connection portions approach each other on the opening side. According to this method, the movement of the connection end portion in the connection portion is further restricted, and the connection end portion is further suppressed from coming out of the connection portion through the opening portion of the connection portion in the joining step.

  (B) In the stator manufacturing method according to claim 13 or claim 14, between the arrangement step and the joining step, the opening side of the connection portion is closer to the connection end portion arranged in the connection portion. A terminal and coil joining method, comprising: a bending step of caulking the connection portion so that the pair of coil connection portions approach each other. According to this method, the movement of the connection end portion in the connection portion is further restricted, and the connection end portion is further suppressed from coming out of the connection portion through the opening portion of the connection portion in the joining step.

(A) is a side view of a brushless motor, (b) is the sectional view on the AA line in Fig.1 (a). (A) is the side view which looked at the stator and the rotor from the holder side, (b) is a BB line sectional view in Drawing 2 (a) of a stator. (A) Side view of a holder provided with a terminal according to the first embodiment, (b) is a cross-sectional view taken along line CC in FIG. 3 (a), and (c) is a cross-sectional view taken along line DD in FIG. 3 (a). . (A) is a top view of the terminal of 1st Embodiment, (b) and (c) are side views of the terminal. (A) is a perspective view of the connection part vicinity in the terminal of 1st Embodiment, (b) is a top view of the connection part vicinity in the terminal. The perspective view which shows the joining state of the connection part and connection edge part in the terminal of 1st Embodiment. The table | surface which shows the relationship between the gap between the control part in the terminal of 1st Embodiment, and a connection edge part, and a welding defect rate. The graph which shows the relationship between the gap between the control part in the terminal of 1st Embodiment, and a connection edge part, and a welding defect rate. (A) is the top view of the connection part vicinity in the terminal of 2nd Embodiment, (b) is sectional drawing which looked at the connection part in the same terminal from the opening part side of this connection part. The graph which shows the relationship between the length of an overhang part, and a welding defect rate. (A) is a top view of the connection part vicinity in the terminal of another form, (b) is the EE sectional view taken on the line in Fig.11 (a). (A) is a top view of the connection part vicinity in the terminal of another form, (b) is the FF sectional view taken on the line in Fig.12 (a). (A) is a perspective view near the connection part in the terminal of another form, (b) is a top view near the connection part in the terminal.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 3 ... Stator as armature, 4 ... Rotor, 6 ... Stator core as armature core, 7 ... Teeth part, 11 ... Coil, 11a ... Connection end part, 15, 15a, 15b, 15c, 15d, 41 ... Terminal, 18 ... Magnet, 31 ... Terminal body part, 33 ... Connection part, 33a, 33b ... Coil connection part, 33c ... Outer surface, 36, 42, 51, 61 ... Restriction part, 42a ... Overhang part, G ... Gap, L ... The length of the overhang part, t ... the thickness of the terminal body part, w ... the width of the restriction part.

Claims (14)

A terminal made of a metal plate having a connection part for connecting the connection end part of a coil provided in the armature,
It has a belt-like terminal body,
The connection portion is formed by folding a part of the terminal main body portion so as to form a pair of coil connection portions opposed to each other and having the connection end portion disposed therebetween,
A terminal provided integrally with a restriction portion extending from one coil connection portion to at least the other coil connection portion so as to cross the opening of the connection portion in the connection portion. The terminal according to claim 1,
The restriction portion is integrally provided at one end portion in the width direction of the terminal main body portion in one of the coil connection portions of the pair of coil connection portions, and from the bottom portion of the connection portion to the opening portion of the connection portion. A terminal having a width equal to or greater than a thickness of the terminal main body in a direction toward the terminal. In the terminal according to claim 1 or claim 2,
The terminal characterized by the gap between the said connection end part arrange | positioned in the said connection part and the said control part being 0.35 mm or less. The terminal according to any one of claims 1 to 3,
The restricting portion is integrally provided at one end portion in the width direction of the terminal main body portion in one of the coil connection portions of the pair of coil connection portions, and the tip portion thereof is provided outside the connection portion on the other side. A terminal having an overhang portion that is bent toward the other coil connection portion along the outer surface of the coil connection portion. The terminal according to claim 4,
The gap between the connection end portion and the restriction portion arranged in the connection portion is 0.6 mm or less,
A terminal characterized in that a length from a base end to a tip end of the overhang portion is 0.8 mm or more. The terminal according to claim 1,
The restricting portion is formed by bending an end portion of the connection portion in one of the coil connection portions on the opening portion side toward the inside of the connection portion. A terminal characterized in that the tip of the restricting portion is pressed against the other coil connecting portion by an elastic force. A connection structure between a terminal and a coil, in which a connection end portion of a coil provided in an armature is connected to a connection portion provided in a terminal made of a metal plate,
The terminal includes a belt-like terminal body,
The connection portion is formed by folding back part of the terminal body so that a pair of coil connection portions facing each other is formed, and the terminal in one of the coil connection portions of the pair of coil connection portions. A regulation portion provided integrally with one end portion in the width direction of the main body portion and extending from one coil connection portion to at least the other coil connection portion so as to cross the opening of the connection portion;
A connection structure of a terminal and a coil, wherein the connection end portion is disposed in the connection portion, and fusion welding is performed at an end portion of the connection portion on the side where the restriction portion is provided. An armature core having a plurality of teeth extending radially;
7. Each of the connection ends is wound around the teeth portion, and at least one of the connection end portions at the start and end of winding is connected to the connection portion of the terminal according to claim 1. A plurality of coils,
An armature characterized by comprising: A stator core having a plurality of teeth extending radially;
7. Each of the connection ends is wound around the teeth portion, and at least one of the connection end portions at the start and end of winding is connected to the connection portion of the terminal according to claim 1. A plurality of said coils;
A stator comprising: A stator having a plurality of teeth each wound with a coil;
The terminal according to any one of claims 1 to 6, wherein the terminal has a connection portion connected to the connection end of the coil.
A rotor that has a magnet disposed inside the stator and is rotated relative to the stator by energizing the coil;
A motor comprising: An arrangement step of arranging a connection end portion of the coil provided in the armature coil in the connection portion provided in the terminal according to any one of claims 1 to 6,
A joining step of joining the connection part and the connection end part by welding;
A method of joining a terminal and a coil, characterized by comprising: In the joining method of the terminal and coil according to claim 11,
The restricting portion is integrally provided at one end portion in the width direction of the terminal main body portion in one of the coil connection portions of the pair of coil connection portions,
In the joining step, arc welding is performed at the end of the connection part on the side where the restriction part is provided, and the connection part and the connection end part are joined together. Joining method. A stator core having a plurality of teeth extending radially;
A plurality of the coils respectively wound around the teeth portion;
A terminal made of a metal plate having a connection portion to which the connection end of the coil is connected;
A method for manufacturing a stator comprising:
An arrangement step of arranging the connection end portion in a connection portion provided in the terminal according to any one of claims 1 to 6,
A joining step of joining the connection part and the connection end part by welding;
A stator manufacturing method comprising: The method of manufacturing a stator according to claim 13,
The restricting portion is integrally provided at one end portion in the width direction of the terminal main body portion in one of the coil connection portions of the pair of coil connection portions,
In the joining step, a method for manufacturing a stator is characterized in that arc welding is performed at an end portion of the connection portion on the side where the restricting portion is provided to join the connection portion and the connection end portion.

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