JP2010200462A - Method of terminal welding, method of manufacturing brushless motor, and brushless motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a terminal welding method that facilitates suppressing a welding defect. <P>SOLUTION: Mutually bonded parts of a connection terminal 22 and a feeding terminal 32, which are formed of conductive metal materials, are overlapped. A pair of welding pawls 41 which extends to the feeding terminal 32 of an opposite side bonded along an overlap direction of the connection terminal 22 and the feeding terminal 32, and covers the feeding terminal 32 are arranged in the connection terminal 22. The connection terminal 22 and the feeding terminal 32 are bonded by welding the overlapped connection terminal 22 and feeding terminal 32 at a position close to the welding pawls 41 so as to weld the welding pawls 41. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a terminal welding method for joining terminals together by welding, a method for manufacturing a brushless motor for joining terminals to which end portions of coils are connected, and a brushless motor including the terminals. .

  2. Description of the Related Art Conventionally, in a brushless motor having a stator in which a plurality of coils are wound by concentrated winding, the end portions of the coils are connected to a substantially strip-shaped connection terminal (terminal) made of a conductive metal plate. Then, after the power supply connector for power supply is connected to the brushless motor, the connection terminal is joined to a substantially belt-shaped power supply terminal (terminal) made of a conductive metal plate provided on the power supply connector by welding. The connection terminal and the power supply terminal are joined by welding (for example, arc welding) to one end in the width direction in a state where one end in the longitudinal direction is overlapped in the thickness direction.

  By the way, as shown in FIG. 15 (a), when a gap G2 is generated between the connection terminal 101 and the power supply terminal 102, the arc 104 is divided into two from the welding electrode 103, and both terminals are connected. 101 and 102 may fly, and both terminals 101 and 102 may melt separately. When both terminals 101 and 102 are melted separately in this way, as shown in FIG. 15B, a melt 105 is formed in each of the connection terminal 101 and the power supply terminal 102, and the both terminals 101 and 102 are joined to each other. Inadequate welding called “melting” may occur.

  Further, as shown in FIG. 16A, when the connection terminal 101 and the power supply terminal 102 are displaced in the width direction and a step B2 is generated, the arc 104 jumps only to the connection terminal 101 closer to the welding electrode 103. The arc may not fly to the power supply terminal 102 far from the welding electrode 103. Then, as shown in FIG. 16B, a melt 105 may be formed only on one connection terminal 101, and a welding failure may occur in which the connection terminal 101 and the power supply terminal 102 are not joined.

  When these welding defects occur, poor continuity between the connection terminal and the power supply terminal occurs. Therefore, in order to suppress the occurrence of poor continuity between terminals due to poor welding, as described in Patent Document 1, after performing preliminary welding in which an arc is blown in advance on each of two terminals to be joined to each other. It is conceivable to perform full-scale welding that joins two terminals.

JP 2004-25303 A

  However, in the welding method described in Patent Document 1, since full-scale welding is performed after performing preliminary welding, the number of steps required for welding increases. Therefore, there is a concern about a decrease in productivity. Moreover, in addition to the equipment for performing full-scale welding, the equipment for performing preliminary welding increases, so that the equipment cost and the like increase.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a terminal welding method, a brushless motor manufacturing method, and a brushless motor that can easily suppress poor welding.

  In order to solve the above-mentioned problem, the invention according to claim 1 is characterized in that two terminals made of a conductive metal material are superposed on each other, and welding is performed from one direction orthogonal to the superposition direction to thereby form the two terminals. A terminal welding method for joining, wherein at least one of the terminals extends along the overlapping direction toward the mating terminal to be joined and covers at least one of the mating terminals to be joined. The gist of the present invention is to weld two claws that are formed and welded at a position close to the weld claws to join the two terminals while melting the weld claws.

  According to this method, the welding claw extends toward the mating terminal to be joined along the overlapping direction of the two terminals, and covers the mating terminal to be joined. At the time of welding the two terminals, welding is performed at a position close to the welding claws, and the welding claws are melted along with the welding. Therefore, even if the two terminals are separated in the overlapping direction and there is a gap between the two terminals, as long as the welding claw extends from one terminal and covers the other terminal, the two terminals are Joined via welding claws. In addition, even if the two terminals are offset in the direction perpendicular to the overlapping direction and have a step at the site where welding is performed, the welded claws are covered with the mating terminal to be joined. By attaching the welded claws to the mating terminal to be joined, the two terminals are joined via the weld claws. Furthermore, even if there is a gap in the overlapping direction between the two terminals and there is a step at the site where the welding is performed on the two terminals, it covers the mating terminal to which the welding claws are joined. Therefore, the two terminals are joined via the weld claws by adhering the molten weld claws to the mating terminal to be joined. In this way, by providing at least one welding claw on at least one terminal, it is possible to join the two terminals to each other by one welding at one welding location, and it is possible to easily suppress poor welding. In the present invention, the “position close to the welding nail” is a position where the welding nail can be melted along with the welding.

  According to a second aspect of the present invention, in the terminal welding method according to the first aspect, two welding claws are formed in total for the two terminals, and the welding electrode is close to the terminal during welding. Two welding claws are formed by bringing the welding electrode close to the center between the two welding claws with respect to the two terminals that are formed and spaced in the direction perpendicular to the direction and the overlapping direction. The gist is to join the two terminals while melting.

  According to this method, the welding electrode is brought close to the central portion between the two welding claws at the two superimposed terminals. Therefore, the two terminals can be easily joined by simultaneously melting the two welding claws substantially equally. In addition, since two welding claws are provided in total for the two terminals, the two terminals can be more firmly joined by these welding claws.

  According to a third aspect of the present invention, in the terminal welding method according to the first or second aspect, at least a pair of the weld claws are formed on at least one of the terminals, and the weld claws that form a pair are: It is connected by the connection part integrally formed in the front-end | tip part, and makes it the summary to join two said terminals, fuse | melting the said connection part with the said welding nail | claw.

  According to this method, when the two terminals are welded, the connecting portion is melted in addition to the welding claws, so that the two terminals are joined over a wider range. Accordingly, the two terminals can be joined more firmly.

  According to a fourth aspect of the present invention, in the terminal welding method according to any one of the first to third aspects, the center portion in the extending direction of the welding claw is wider than the distal end and the proximal end. The gist is that welding is performed at a position adjacent to a central portion in the extending direction of the weld claws to join the two terminals while melting the weld claws.

  According to this method, the welding claws extending in the overlapping direction of the two terminals are formed such that the central portion in the extending direction is wider than the proximal end portion and the distal end portion. At the time of welding, the welding electrode is brought close to a position adjacent to the central portion in the extending direction of the welding claws, that is, a position adjacent to a wide portion, with respect to the two overlapped terminals. Accordingly, the melt produced by melting the weld claws is more present between the two terminals to be joined to each other, so that the two terminals can be joined more firmly.

  The invention according to claim 5 is the terminal welding method according to any one of claims 1 to 4, wherein at least two of the welding claws are formed on one of the terminals. It is said.

  According to this method, since the welding claws are formed only on one terminal, it is not necessary to change the design of the other terminal. In addition, when two or more welding claws are provided, if the welding claws are provided only on one terminal, an error is unlikely to occur between the welding claws, and a desired interval is easily obtained. It is easy to make the height position constant. Therefore, it is possible to suppress the variation in the welding state of the welding location.

  The gist of the invention according to claim 6 is that, in the terminal welding method according to any one of claims 1 to 4, the welding claws are respectively formed on the two terminals. .

  According to this method, one terminal is joined to the other terminal via a welding claw provided on the terminal, and the other terminal is connected to one terminal via a welding claw provided on the terminal. To be joined. That is, the two terminals are joined to each other via the welding claws provided in each. When the welding claws are provided only on one terminal, the welding strength of the two terminals depends on the positional relationship between the welding claws provided on one terminal and the other terminal. In contrast, in the present invention, the welding strength of the two terminals is such that the positional relationship between the welding claw provided on one terminal and the other terminal, and the welding claw provided on the other terminal and the one terminal. Depends on the positional relationship. Therefore, the reliability of the part joined by welding can be improved.

  According to a seventh aspect of the present invention, in the terminal welding method according to any one of the first to sixth aspects, each of the terminals has a plate shape, and the one terminal and the other terminal are The gist is that the portions to be joined are overlapped so as to overlap in the thickness direction, and the weld claws extend along the thickness direction of the terminals.

According to this method, when joining plate-like terminals by welding, welding defects can be reduced by welding while welding the claws.
The invention according to claim 8 is provided with a stator formed by winding a plurality of coils around a stator core, and a plurality of connection terminals made of a conductive metal plate and having ends connected to the coils. A plurality of power supply terminals provided on a power supply connector for supplying power and a plurality of the connection terminals are respectively overlapped, and welding is performed from one direction orthogonal to the overlap direction, thereby the power supply terminals and the connection terminals. Each of the connection terminals and each of the power supply terminals has a plate shape, and at least one of the connection terminals and the power supply terminals is connected to the other side of the mating terminal. At least one welding claw is formed to cover the mating terminal to be joined extending along the thickness direction of the terminal toward the terminal, and the connection terminal and the feeding terminal are in contact with each other. The connection terminal and the power supply are overlapped so that the portions to be overlapped in the thickness direction are welded to the overlapped connection terminal and the power supply terminal at a position close to the weld claw to melt the weld claw. The gist is to join the terminals.

  According to this method, the welding claw extends toward the mating terminal to be joined along the overlapping direction of the connection terminal and the power feeding terminal, and covers the mating terminal to be joined. And at the time of welding of a connection terminal and an electric power feeding terminal, welding is performed in the position close | similar to a welding nail, and a welding nail is fuse | melted with welding. Therefore, even if the connection terminal and the power supply terminal are separated in the overlapping direction and there is a gap between the two terminals, as long as the welding claw extends from one terminal and covers the other terminal, The terminals are joined via welding claws. In addition, even if the connection terminal and the power supply terminal are shifted in the direction orthogonal to the overlapping direction and have a step at the site to be welded, the welding claw is covered with the mating terminal to be joined. When the molten weld claws are attached to the mating terminals to be joined, the connection terminals and the power supply terminals are joined via the weld claws. Furthermore, even when there is a gap in the overlapping direction between the connection terminal and the power supply terminal, and there is a step in the welded portion of the connection terminal and power supply terminal to be joined, the welding claws are joined. Since the melted welding claws adhere to the mating terminal to be joined, the connection terminal and the power supply terminal are joined via the welding claws. In this way, by providing at least one welding claw on at least one of the connection terminal and the power supply terminal, the connection terminal and the power supply terminal can be joined to each other by one welding per welding location, and easily welded. Defects can be suppressed. As a result, in the manufactured brushless motor, power can be satisfactorily supplied to the coil via the power supply terminal and the connection terminal. In the present invention, the “position close to the welding nail” is a position where the welding nail can be melted along with the welding.

  The invention according to claim 9 is provided with a stator formed by winding a plurality of coils around a stator core, and a plurality of connection terminals made of a conductive metal plate and having ends of the coils connected thereto. A plurality of power supply terminals provided in a power supply connector for supplying power and a plurality of the connection terminals are respectively overlapped and welded by welding, each of the connection terminals and each of the power supply terminals is The plate-shaped and joined portions are overlapped in the thickness direction, and further formed along at least one of the connection terminal and the power supply terminal along the overlapping direction of the connection terminal and the power supply terminal. The gist of the invention is that at least one welding claw that covers the mating terminal extending and overlapped is melted and joined.

  According to this configuration, the welding claws are formed so as to extend toward the mating terminal to be joined along the overlapping direction of the connection terminal and the power feeding terminal and to cover the mating terminal to be joined. Yes. The connection terminal and the power supply terminal are joined to each other by melting the welding claws. Therefore, even if the connection terminal and the power supply terminal are separated in the overlapping direction and there is a gap between the two terminals, as long as the welding claw extends from one terminal and covers the other terminal, The terminals are joined via welding claws. In addition, even if the connection terminal and the power supply terminal are shifted in the direction orthogonal to the overlapping direction and have a step at the site to be welded, the welding claw is covered with the mating terminal to be joined. When the molten weld claws are attached to the mating terminals to be joined, the connection terminals and the power supply terminals are joined via the weld claws. Furthermore, even when there is a gap in the overlapping direction between the connection terminal and the power supply terminal, and there is a step in the welded portion of the connection terminal and power supply terminal to be joined, the welding claws are joined. Since the melted welding claws adhere to the mating terminal to be joined, the connection terminal and the power supply terminal are joined via the welding claws. As described above, the connection terminal and the power supply terminal which are joined to each other by melting at least one welding claw provided on at least one of the connection terminal and the power supply terminal are suppressed in welding failure with a simple configuration called a welding claw. ing. Therefore, in the brushless motor of the present invention, the power supply to the coil is favorably performed via the power supply terminal and the connection terminal.

  According to the present invention, it is possible to provide a terminal welding method, a brushless motor manufacturing method, and a brushless motor that can easily suppress welding defects.

Schematic of a brushless motor. The partial enlarged view of a brushless motor. The top view of a stator. The side view of the stator to which the terminal holder was fixed. The perspective view of the junction part of a connection terminal and an electric power feeding terminal. The perspective view of the connection terminal at the time of welding and an electric power feeding terminal. (A) is a side view of the welding terminal and power supply terminal viewed from the thickness direction, (b) is a side view of the connection terminal and power supply terminal after welding viewed from the thickness direction, and (c) is during welding. Sectional drawing of a connection terminal and a power supply terminal, (d) is a cross-sectional view of the connection terminal and the power supply terminal after welding. (A) is sectional drawing of the connecting terminal and electric power feeding terminal during welding, (b) is sectional drawing of the connecting terminal and electric power feeding terminal after welding. (A) is sectional drawing of the connecting terminal and electric power feeding terminal during welding, (b) is sectional drawing of the connecting terminal and electric power feeding terminal after welding. (A) is sectional drawing of the connecting terminal and electric power feeding terminal during welding, (b) is sectional drawing of the connecting terminal and electric power feeding terminal after welding. The partial enlarged plan view of the wiring terminal of another form, and the electric power feeding terminal. The top view of the connection terminal provided with the welding nail | claw of another form, and the electric power feeding terminal. The top view of the connection terminal provided with the welding nail | claw of another form, and the electric power feeding terminal. The top view of the connection terminal provided with the welding nail | claw of another form, and the electric power feeding terminal. (A) is sectional drawing which shows the conventional terminal during welding, (b) is sectional drawing which shows the conventional terminal after welding. (A) is sectional drawing which shows the conventional terminal during welding, (b) is sectional drawing which shows the conventional terminal after welding.

DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, an embodiment of the invention will be described with reference to the drawings.
FIG. 1 shows a brushless motor of this embodiment. The bottomed cylindrical housing case 1 has a flange portion 1a extending radially outward at an opening thereof, and an annular stator 2 is fixed to an inner peripheral surface thereof. A rotor 3 (illustrated by a two-dot chain line in FIG. 1) is arranged inside the stator 2 so as to be rotatable in the circumferential direction. Note that the opening of the housing case 1 is closed by a substantially disc-shaped end frame (not shown).

  As shown in FIG. 3, the stator core 11 constituting the stator 2 is composed of a cylindrical fixing portion 11a and twelve teeth 11b extending radially inward from the inner peripheral surface of the fixing portion 11a. Yes. On the inner peripheral surface of the fixing portion 11a, fixing grooves 11c extending along the axial direction are formed at 24 locations that are equiangularly spaced in the circumferential direction, and each fixing groove 11c is directed radially outward. The circumferential width is wide. In addition, a fixed ridge portion 11d that protrudes radially outward is formed at the radially outer base end portion of each tooth 11b, and each fixed ridge portion 11d has a shape corresponding to the fixed groove 11c. The width in the circumferential direction becomes wider toward the outside in the radial direction. And each teeth 11b is each assembled | attached with respect to the fixing | fixed part 11a by inserting the fixing protrusion 11d from the one end side of the axial direction of the fixing | fixed part 11a to the fixing groove 11c of every other circumferential direction. Yes.

  An insulator 12 made of an insulating synthetic resin material is attached to each tooth 11b. Each insulator 12 has a substantially square cylindrical shape, and is externally inserted into each tooth 11b from the base end side of each tooth 11b to cover both end surfaces in the axial direction and both side surfaces in the circumferential direction of the teeth 11b. Each of the teeth 11b is wound with coils U1 to U4, V1 to V4, and W1 to W4 by winding the conductor 13 from the top of the insulator 12 by concentrated winding. These coils U1 to U4, V1 to V4, and W1 to W4 are electrically insulated from the stator core 11 by the insulator 12. In this embodiment, two coils of the same phase among coils U1 to U4, V1 to V4, and W1 to W4 are continuously wound while being connected by a jumper (not shown). One end of the winding start end and the winding end end of U1 to U4, V1 to V4, and W1 to W4 is drawn to one end side in the axial direction of the stator core 11.

  Each tooth 11b is assembled to the fixing portion 11a after the insulator 12 is mounted and the coils U1 to U4, V1 to V4, and W1 to W4 are wound respectively. Specifically, when the stator core 11 is viewed from one end side in the axial direction, each of the teeth 11b includes the coils U1 to U4, V1 to V4, and W1 to W4 in the clockwise direction, and the coils U4, V3, W3, and W3. U3, coil V2, coil W2, coil U2, coil V1, coil W1, coil U1, coil V4, and coil W4 are assembled to fixing portion 11a so as to be arranged in the circumferential direction in this order.

  As shown in FIG. 4, one end of the stator 2 in the axial direction on the side where the ends of the coils U1 to U4, V1 to V4, W1 to W4 are drawn (the end on the opening side of the housing case 1 in FIG. 1). Part) is fixed with a terminal holder 20 made of an insulating synthetic resin material. As shown in FIG. 1, the terminal holder 20 has a substantially annular shape, and its inner diameter is equal to the inner diameter of the stator 2 and its outer diameter is substantially equal to the outer diameter of the stator 2. The terminal holder 20 has an annular holder main body 20a. Extending fixing portions 20b extending outward in the radial direction are integrally formed at five locations on the outer peripheral edge of the holder main body 20a. A locking claw 20c that extends toward the stator 2 side (the back side in the drawing in FIG. 1) along the axial direction is integrally formed at the distal end portion of the fixing portion 20b. Further, an extended holding portion 20d extending outward in the radial direction is integrally formed on the outer peripheral edge of the holder main body 20a, and the stator 2 extends along the axial direction at the distal end portion of the extended holding portion 20d. A locking claw 20c extending to the side is integrally formed. Further, three holding grooves 20e to 20g are recessed in the surface of the extended holding portion 20d opposite to the stator 2. These holding grooves 20 e to 20 g are recessed in the axial direction, are formed so as to be substantially along the radial direction of the stator 2, and open to the radial inner side and the radial outer side of the terminal holder 20. As shown in FIGS. 1 and 4, the terminal holder 20 has a snap-fitting engagement with the insulator 12 on one end side in the axial direction of the stator 2, with the locking claw 20 c of the extended fixing portion 20 b and the extended holding portion 20 d. By being combined, the stator 2 is fixed.

On the end face of the terminal holder 20 opposite to the stator 2, a bus bar 21 and three connection terminals 22, 23, 24 are fixed.
The bus bar 21 fixed to the lower part of the terminal holder 20 in FIG. 1 is formed by bending a conductive metal plate (conductive metal material) punched in a substantially band shape in the longitudinal direction. Is substantially arc-shaped along the circumferential direction of the holder body 20a. The bus bar 21 is fixed to the terminal holder 20 so that the width direction (that is, the short direction) of the bus bar 21 coincides with the axial direction of the holder body 20a (the same as the axial direction of the stator 2). .

  In addition, six connection portions 21a are integrally provided at an end portion in the width direction of the bus bar 21 and on the end portion opposite to the holder main body 20a. The six connection portions 21 a are formed at both ends in the longitudinal direction of the bus bar 21 and at four places between the both ends, and are formed at equal intervals in the longitudinal direction of the bus bar 21. Each connecting portion 21a extends to the opposite side of the terminal holder 20 along the width direction of the bus bar 21, and a connecting claw whose shape viewed from the width direction of the bus bar 21 forms a substantially U shape at the tip portion thereof. 21b is integrally formed. One end of each of the coils U1, W1, V1, U2, W2, and V2 is connected to the connection claw 21b of each connection portion 21a. Specifically, after the ends of the coils U1, W1, V1, U2, W2, and V2 are respectively disposed in the U-shaped connection claw 21b, the ends of the coils U1, W1, V1, U2, W2, and V2 are The connection claws 21b are caulked so as to be sandwiched, and further, welding is performed, so that the ends of the coils U1, W1, V1, U2, W2, and V2 are electrically connected to the respective connection portions 21a. .

  The three connection terminals 22, 23, 24 are fixed to a portion of the terminal holder 20 on the extended holding portion 20 d side (upper side in FIG. 1). The connection terminal 22 arranged in the center is for supplying a U-phase current to the stator 2, and the connection terminal 23 arranged on the counterclockwise direction side (left side in FIG. 1) with respect to the connection terminal 22 is The remaining connection terminals 24 are for supplying a W-phase current to the stator 2. Each of the connection terminals 22 to 24 is formed by bending a conductive metal plate punched out in a substantially band shape. And the connection terminals 22-24 are being fixed with respect to the terminal holder 20 so that the width direction (namely, short direction) may correspond with the axial direction (same as the axial direction of the stator 2) of the holder main body 20a.

  Connection portions 22a, 23a, and 24a are formed at one end portions of the connection terminals 22, 23, and 24 in the longitudinal direction opposite to the extended holding portions 20d, respectively. Similarly to the connection portion 21a provided on the bus bar 21, the connection portions 22a to 24a extend from the connection terminals 22 to 24 on the opposite side of the terminal holder 20 along the width direction of the connection terminals 22 to 24, and Connection tips 22b, 23b, and 24b, each having a substantially U-shape when viewed from the width direction of the connection terminals 22 to 24, are integrally formed at the distal end portion. The ends of the coils U3 and U4 are electrically connected to the connection claw 22b of the connection terminal 22, and the ends of the coils V3 and V4 are electrically connected to the connection claw 23b of the connection terminal 23. Furthermore, the ends of the coils W3 and W4 are electrically connected to the connection claw 24b of the connection terminal 24. The ends of the coils U3, U4, V3, V4, W3, and W4 correspond to the connection of the ends of the coils U1, W1, V1, U2, W2, and V2 to the connection claw 21b of the bus bar 21. After being arranged in the connecting claws 22b to 24b, the connecting claws 22b to 24b are caulked so as to sandwich the ends of the coils U3, U4, V3, V4, W3 and W4, respectively, and further welded. Thus, the corresponding connection claws 22b to 24b are electrically connected.

  Moreover, the connection parts 22c, 23c, and 24c which make a substantially rectangular flat plate shape are provided in the edge part on the opposite side to the connection parts 22a-24a in each connection terminal 22-24, respectively. Each of the connection side joint portions 22c to 24c is disposed in each of the three holding grooves 20e to 20g formed in the extended holding portion 20d, and is substantially parallel to the radial direction of the holder body 20a. Yes.

  The housing case 1 is formed with an insertion portion 1b (not shown) that opens to the outside at a position facing the distal end portion of the extended holding portion 20d, and the brushless motor is supplied with power to the insertion portion 1b. A power supply connector 30 is inserted. A connector housing 31 of the power supply connector 30 is made of an insulating resin material, has a substantially cylindrical shape, and holds power supply terminals 32, 33, and 34 inside thereof. The three power supply terminals 32 to 34 are arranged at intervals in the circumferential direction of the stator 2 in a state where the power supply connector 30 is fitted into the insertion portion 1b. The central power supply terminal 32 is for supplying a U-phase current, and the power supply terminal 33 arranged on the counterclockwise direction side (the left side in FIG. 1) is a V-phase current. The remaining power supply terminal 34 is for supplying a W-phase current.

  Each of the power supply terminals 32 to 34 is formed of a conductive metal plate material punched into a predetermined shape, and a substantially band-like shape is formed at the distal end portion of the power supply terminals 32 to 34 on the central side in the radial direction of the brushless motor. Feeding-side joint portions 32c, 33c, and 34c having a flat plate shape are provided. And if the electric power feeding connector 30 is inserted by the insertion part 1b, the electric power feeding side junction parts 32c-34c will be inserted in the holding grooves 20e-20g, respectively from the radial direction outer side. Thereby, the power feeding side joint portion 32 c of the power feeding terminal 32 is overlapped with the connection side joint portion 22 c of the connection terminal 22 in the thickness direction, and the power feeding side joint portion 33 c of the power feeding terminal 33 is connected to the wiring side of the wiring terminal 23. The power supply terminal 34 is overlapped with the joint 23 c in the thickness direction, and the power supply side joint 34 c of the power supply terminal 34 is overlapped with the connection side joint 24 c of the connection terminal 24 in the thickness direction. Further, in a state where the power feeding connector 30 is fitted into the insertion portion 1b, the power feeding side joint portions 32c to 34c have the width direction (that is, the short direction) coincides with the axial direction of the stator 2, and each power feeding side joint portion. The width in the short direction of 32c to 34c is formed to be equal to the width in the short direction of the connection side joint portions 22c to 24c.

  The connection side joints 22c to 24c and the power supply side joints 32c to 34c overlapped with each other in the holding grooves 20e to 20g are overlapped with the connection side joints 22c to 24c and the power supply side joints 32c to 34c. Are joined by arc welding from one direction orthogonal to the axis direction, that is, the axial direction of the stator 2 (see FIG. 5).

  In the brushless motor configured as described above, the power supply terminals 32 to 34 that are electrically connected to an external power supply device are connected to the U phase, the V phase, and the W phase that are 120 ° different from each other via the connection terminals 22 to 24. Phase currents are supplied to coils U1-U4, V1-V4, W1-W4. Then, by supplying current to the coils U1 to U4, V1 to V4, and W1 to W4, a rotating magnetic field is generated in the stator 2, and the rotor 3 is rotated according to the rotating magnetic field.

Next, the manufacturing method of the brushless motor of this embodiment is demonstrated centering on the joining by welding with the connection terminals 22-24 and the electric power feeding terminals 32-34.
First, an overlapping process is performed in which the connection side joints 22c to 24c of the connection terminals 22 to 24 and the power supply side joints 32c to 34c of the power supply terminals 32 to 34 are respectively overlapped. Here, as shown in FIG. 2, a pair of welding claws 41 are integrally formed on the connection terminals 22 to 24 that are overlapped with the power supply terminals 32 to 34 in the overlapping step. In addition, in FIG. 2, the welding nail | claw 41 is illustrated with the dashed-two dotted line.

  The welding claw 41 will be described in detail by taking the connection terminal 22 as an example. As shown in FIG. 6, the pair of welding claws 41 are provided at the connection side joint portion 22 c that forms a rectangular flat plate shape in the connection terminal 22. The pair of welding claws 41 is one end portion in the width direction (short direction) of the connection side joint portion 22c and extends from the end portion opposite to the stator 2, and the thickness of the connection side joint portion 22c. It extends along the vertical direction. Further, the pair of welding claws 41 are formed so as to be separated from each other by a predetermined interval in the longitudinal direction of the connection-side joining portion 22c, and are parallel to each other. Further, each welding claw 41 has a rectangular shape as viewed from the width direction of the connection side joint portion 22c, and the length in the extending direction is determined by the thickness of the connection side joint portion 22c and the thickness of the power supply side joint portion 33c. The length is approximately equal to the sum of

  In order to form the connection terminal 22 having such welding claws 41, first, a conductive metal plate material is punched into a substantially flat plate shape. The strip-shaped plate material formed by punching is integrally provided with a pair of welding claws 41 extending in the width direction of the connection side joint portion 22c at a portion to be the connection side joint portion 22c. And when bending a strip | belt-shaped board | plate material by press work, the base end part of this welding nail | claw 41 is bent so that the welding nail | claw 41 may orthogonally cross the width direction of the connection side junction part 22c simultaneously. Thereby, the connection terminal 22 which has the welding nail | claw 41 is formed.

  6 shows the connection terminal 22 as a representative, but the welding claws 41 provided integrally with the connection side joints 23c and 24c of the remaining two connection terminals 23 and 24 are also provided on the connection terminal 22. It has the same shape as the welded claw 41 formed.

  As shown in FIG. 1 and FIG. 2, in the overlapping process, the power feeding connector is inserted from the radially outer side into the insertion portion 1 b of the housing case 1 to which the terminal holder 20 holding the bus bar 21 and the connection terminals 22 to 24 is fixed. 30 is inserted. Then, the power feeding side joint portions 32c to 34c are inserted into the holding grooves 20e to 20g, respectively, and the power feeding between the connection side joint portions 22c to 24c of the connection terminals 22 to 24 and the power feeding terminals 32 to 34 is performed in the holding grooves 20e to 20g. The side joint portions 32c to 34c are overlapped in the thickness direction. When the connection side joints 22c to 24c and the power supply side joints 32c to 34c are overlapped in the thickness direction, the welding claws 41 extending in the thickness direction of the connection side joints 22c to 24c are connected to the power supply side. Cover one end portion in the width direction of the joint portions 32c to 34c (the end portion on the side opposite to the stator 2 and the end portion on the opening side of the housing case 1). That is, in this state, each welding claw 41 extends along the overlapping direction of the connection side joints 22c to 24c and the power supply side joints 32c to 34c. In the same state, the pair of welding claws 41 are separated from each other in a direction perpendicular to the overlapping direction and perpendicular to a direction in which a welding electrode 51 (see FIG. 6) described later approaches. Furthermore, in the same state, the welding claw 41 has one end in the width direction (the end opposite to the stator 2) of the power feeding side joints 32 c to 34 c adjacent to the connection side joints 22 c to 24 c provided with the weld claw 41. And an end of the housing case 1 on the opening side.

  Next, a welding process is performed in which the connection side joints 22c to 24c and the power feeding side joints 32c to 34c overlapped with each other are joined by arc welding. In the welding process, the stator 2 fixed to the housing case 1 is arranged so that the terminal holder 20 is on the upper side. And the connection side joining parts 22c-24c and the electric power feeding side joining parts 32c-34c are sequentially welded and joined. For example, welding is performed in the order of the connection side joint 23c and the power supply side joint 33c, the connection side joint 22c and the power supply side joint 32c, and the connection side joint 24c and the power supply side joint 34c in the clockwise direction.

  The welding of the connection side joints 22c to 24c and the power supply side joints 32c to 34c will be described in detail with reference to the connection side joint 22c and the power supply side joint 32c as an example. As shown in FIG. Along the connection side joining portion 22c and the power feeding side joining portion 32c along a direction (the same as the axial direction of the stator 2 in this embodiment) perpendicular to the overlapping direction and perpendicular to the separating direction of the pair of welding claws 41. Then, the welding electrode 51 is approached from above. At this time, the tip of the welding electrode 51 is opposed to a position at the center between the pair of welding claws 41 at the joint of the connection side joint 22c and the power feeding side joint 32c. That is, the welding electrode 51 is arranged so as to perform welding with the aim of the center between the pair of welding claws 41. Then, as shown in FIGS. 7A and 7C, the welding electrode 51 is energized to generate an arc 52, thereby facing the welding electrode 51 at the connection side joining portion 22c and the power feeding side joining portion 32c. The periphery of the part to be melted is melted, and the pair of welding claws 41 are melted. That is, the distance between the pair of welding claws 41 and the volume of each welding claw 41 are set to values that can melt the welding claws 41 when the welding electrode 51 is energized. Further, the shape of the welding claw 41 is set in consideration of the amount of heat input to the welding claw 41 when the welding electrode 51 is energized. Then, as shown in FIGS. 5, 7B and 7D, the melted welding claw 41 is fused with the connection side joining portion 22c and the power feeding side joining portion 32c to form a melting portion 53. Thereafter, the melting part 53 is cooled and solidified, whereby the connection side joining part 22c and the feeding side joining part 32c are joined, and the connection terminal 22 and the feeding terminal 32 are electrically connected.

  The connection side joint 23c and the power supply side joint 33c, and the connection side joint 24c and the power supply side joint 34c are also welded in the same manner, and the connection terminal 23 and the power supply terminal 33, and the connection terminal 24 and The power supply terminals 34 are electrically connected to each other.

  Here, as shown in FIG. 8A, for example, the connection side joint 22c and the power supply side joint 32c are separated in the thickness direction, and the connection side joint 22c and the power supply side joint 32c are separated from each other. Even when there is a gap G1 between them, the welding claws 41 extending from the connection-side joint 22c cover the power-feed-side joint 32c. Therefore, when the arc 52 is generated by energizing the welding electrode 51 and the welding claw 41 is melted, as shown in FIG. 8B, the tip of the welding claw 41 is fused with the power feeding side joint portion 32c. Since the melting part 53 is formed over the connection side joining part 22c and the power feeding side joining part 32c, the connection side joining part 22c and the power feeding side joining part 32c are joined.

  Further, as shown in FIG. 9A, the power feeding side joint portion 32 c is shifted in a direction away from the welding claw 41 with respect to the connection side joint portion 22 c provided with the welding claws 41, and the power feeding side joint portion 22 c and the power feeding side are fed. Even when the side joint portion 32c has a step B1, the welding claw 41 extending from the connection side joint portion 22c covers the power feeding side joint portion 32c. Therefore, when the arc 52 is generated by energizing the welding electrode 51 and the welding claws 41 are melted, the molten welding claws 41 are lowered by gravity as shown in FIG. And fused with the power feeding side joint portion 32c. As a result, the melted portion 53 is formed across the connection side joining portion 22c and the power feeding side joining portion 32c, so that the connection side joining portion 22c is joined to the power feeding side joining portion 32c via the welding claws 41.

  Further, as shown in FIG. 10A, there is a gap G1 between the connection side joint 22c and the power supply side joint 32c, and the connection side joint 22c and the power supply side joint 32c form a step B1. Even if it has, the welding nail | claw 41 extended from the connection side junction part 22c covers the electric power feeding side junction part 32c. Therefore, when the arc 52 is generated by energizing the welding electrode 51 and the weld claw 41 extending above the power supply side joint 32c is melted, the melted weld claw 41 is lowered by gravity and adheres to the power supply side joint 32c. To do. As a result, as shown in FIG. 10B, the melted weld claw 41 and the power supply side joint portion 32c are fused, and a melted portion 53 is formed across the connection side joint portion 22c and the power supply side joint portion 32c. Therefore, the connection side joint 22c and the power feeding side joint 32c are joined via the welding claws 41.

  After the welding process, a substantially disc-shaped end frame (not shown) is assembled to the opening of the housing case 1 to complete the brushless motor. And in the completed brushless motor, as shown in FIG.2 and FIG.5, the connection terminals 22-24 and the electric power feeding terminals 32-34 were provided in the connection side junction part 22c-24c of the connection terminals 22-24. Since the weld claws 41 are joined while melting, they are fused and joined over a wider range. 2 and 5, the weld claw 41 before melting is illustrated by a two-dot chain line.

As described above, the present embodiment has the following effects.
(1) The pair of welding claws 41 provided in the connection side joints 22c to 24c are respectively connected to the connection side joints 22c to 24c of the connection terminals 22 to 24 and the power supply side joints 32c to 34c of the power supply terminals 32 to 34. While extending toward the mating power supply side joints 32c to 34c joined along the overlapping direction, the power supply side joints 32c to 34c are covered. At the time of welding the connection terminals 22 to 24 and the power supply terminals 32 to 34, a position close to the welding claw 41, that is, the joint of the connection side joints 22c to 24c and the power supply side joints 32c to 34c is paired. Welding is performed at the center of the welding claw 41, and the welding claw 41 is melted with the welding. Therefore, even when the connection side joints 22c to 24c and the power supply side joints 32c to 34c overlapped with each other are separated in the overlapping direction and the gap G1 exists, the welding claws 41 are connected to the connection side joints. As long as it extends from 22c to 24c and covers the power supply side joint portions 32c to 34c, the connection terminals 22 to 24 and the power supply terminals 32 to 34 are joined via the welding claws 41, respectively. In addition, even when the connection side joints 22c to 24c and the power feeding side joints 32c to 34c that are overlapped with each other are shifted in the direction orthogonal to the superposition direction and have a step B1 at the site to be welded, Since it covers the mating power supply side joints 32c to 34c to which the welding claws 41 are joined, by attaching the molten welding claws 41 to the mating terminals to be joined, the connection terminals 22 to 24 and the power feeding terminals 32-34 are joined through the welding nail | claw 41, respectively. Further, there is a gap G1 in the overlapping direction between the connection side joints 22c to 24c and the power supply side joints 32c to 34c overlapped with each other, and the connection side joints 22c to 24c and the power supply side joints overlapped with each other. Even if it has a level | step difference B1 in the site | part to which welding in 32c-34c is performed, since it has covered on the other party electric power feeding side junction part 32c-34c to which the welding nail | claw 41 is joined, the molten welding nail | claw 41 is melt | dissolved. The connection terminals 22 to 24 and the power supply terminals 32 to 34 are joined to each other via the welding claws 41 by adhering to the power supply side joints 32 c to 34 c on the mating side. In this way, by providing the pair of welding claws 41 to the connection terminals 22 to 24, respectively, the connection terminal 22 and the power supply terminal 32, the connection terminal 23 and the power supply terminal 33, and the connection terminal 24 and the power supply terminal 34 are welded once. Can be joined to each other, and welding defects can be easily suppressed. As a result, in the manufactured brushless motor, power can be satisfactorily supplied to the coils U1 to U4, V1 to V4, and W1 to W4 via the power supply terminals 32 to 34 and the connection terminals 22 to 24. And since it is not necessary to perform preliminary welding when joining the connection terminals 22-24 and the electric power feeding terminals 32-34 by welding, the fall of productivity is suppressed. Moreover, since the equipment for preliminary welding becomes unnecessary, the increase in equipment cost can be suppressed.

  (2) A pair of welding claws 41 are provided on each of the connection terminals 22 to 24, and the welding electrode 51 is close to the connection terminals 22 to 24 and the power supply terminals 32 to 34 during welding (that is, the axial direction of the stator 2). ) And the connection terminals 22 to 24 and the feeding terminals 32 to 34 are formed at intervals in a direction orthogonal to the overlapping direction. And at the time of welding, the welding nail | claw 41 which makes the welding electrode 51 adjoin to the center part between the welding claws 41 which make a pair with respect to the superimposed connection side junction parts 22c-24c and the electric power feeding side junction parts 32c-34c which make a pair. The connection side joining portions 22c to 24c and the power feeding side joining portions 32c to 34c are joined, respectively, while melting. Accordingly, it is possible to easily weld the connection terminals 22 to 24 and the power supply terminals 32 to 34 by simultaneously melting the paired welding claws 41 substantially equally. Further, since the pair of welding claws 41 are provided in each of the connection terminals 22 to 24, a wider range of the joints of the connection terminals 22 to 24 and the power supply terminals 32 to 34 can be provided by the melted pair of weld claws 41, respectively. Can be joined. Thus, the connection terminals 22 to 24 and the power supply terminals 32 to 34 can be joined more firmly.

  (3) A pair of welding claws 41 is provided only on one of the connection terminals 22 to 24 among the connection terminals 22 to 24 and the power supply terminals 32 to 34 to be joined to each other. Therefore, it is not necessary to change the design of the power supply terminals 32 to 34. In addition, when the pair of welding claws 41 are provided only in one of the connection terminals 22 to 24, an error is unlikely to occur between the pair of welding claws 41, and a desired interval can be easily obtained. It is easy to make the height position of the terminals 32 to 34 constant with respect to the power supply side joint portions 32c to 34c. Therefore, it is possible to suppress the variation in the welding state of the welding location.

In addition, you may change embodiment of this invention as follows.
In the above embodiment, the present invention has been described by taking the connection terminals 22 to 24 and the power supply terminals 32 to 34 included in the brushless motor as examples. However, the present invention may be applied to terminals used for other than the brushless motor as long as the terminals are joined to each other by welding.

  In the above embodiment, the connection terminals 22 to 24 and the power supply terminals 32 to 34 that are joined to each other are overlapped in the thickness direction with the connection side joints 22c to 24c and the power supply side joints 32c to 34c that are joined to each other. The However, the connection terminals 22 to 24 and the power supply terminals 32 to 34 to be joined to each other may be superposed as long as the parts to be joined to each other are superposed. For example, in the example illustrated in FIG. 11, the connection-side joining portion 22c and the power feeding-side joining portion 32c are overlapped in the width direction. In this case, the pair of welding claws 41 extend from the end on the power supply side joint portion 32c toward the power supply side joint portion 32c along the overlapping direction from one end in the width direction of the connection side joint portion 22c. The side joint 32c is covered. And at the time of welding, welding is performed aiming at the position which becomes the center part between a pair of welding claws 41 which is the joint of the connection side joining part 22c and the electric power feeding side joining part 32c. Then, the connection side joint 22c and the power supply side joint 32c merge with each other at the joint between the connection side joint 22c and the power supply side joint 32c, and the two welding claws 41 are melted together with welding, so that the power supply side It fuses with the joint part 32c, and the connection side joint part 22c and the power feeding side joint part 32c are joined to each other. Therefore, even in this case, the same effect as (1) of the above embodiment can be obtained.

  -The shape of the welding nail | claw 41 is not restricted to the shape of the said embodiment. The welding claws 41 may be formed so as to extend along the overlapping direction of the terminals toward the mating terminal to be joined and to be covered with the mating terminal to be joined, and to be meltable during welding. For example, the welding claw 61 shown in FIG. 12 extends from the connection side joint 22c toward the power supply side joint 32c along the overlapping direction of the connection side joint 22c and the power supply side joint 32c. The central part of the direction is formed wider than the front end part and the base end part. More specifically, the pair of welding claws 61 are in a direction orthogonal to the superposition direction from the distal end portion and the base end portion to the central portion in the extending direction, and the parallel welding direction of the two welding claws 61. It is formed so as to increase in width in a parallel direction. And at the time of welding, the front-end | tip part of the welding electrode 51 (refer FIG. 6) is a position which adjoins the center part of the extending direction of each welding nail | claw 61, and becomes a center part between a pair of welding nail | claw 61 (FIG. 12, facing and approaching, welding is performed aiming at the position. In the example shown in FIG. 12, the joint of the connection side joint 22 c and the power feeding side joint 32 c coincides with the central portion in the extending direction of the welding claws 61. Then, the connection side joint 22c and the power supply side joint 32c merge with each other at the joint of the connection side joint 22c and the power supply side joint 32c, and the two welding claws 61 are melted together with the welding to cause the power supply side. It fuses with the joint part 32c, and the connection side joint part 22c and the power feeding side joint part 32c are joined to each other. If it does in this way, at the time of welding, it formed in the position adjacent to the center part of the extending direction of the welding nail | claw 61 with respect to the superimposed connection side junction part 22c and the electric power feeding side junction part 32c, ie, the wide of the welding nail | claw 61. The welding electrode 51 is brought close to a position adjacent to the part. Accordingly, the melt produced by melting the weld claws 61 is more present in the joints of the connection side joint 22c and the power supply side joint 32c that are joined together. Therefore, the connection terminal 22 and the power supply terminal 32 are connected to each other. It is possible to join more firmly. Further, heat generated during welding is radiated from the connection side joint 22 c at the base end portion of the welding claw 61, and is radiated from the power feeding side joint portion 32 c at the distal end portion of the welding claw 61.

  Further, the pair of weld claws 41 provided in the connection side joint portions 22c to 24c may be connected to each other by a joint portion integrally provided at the distal ends of the weld claws 41. For example, as shown in FIG. 13, the distal ends of a pair of welding claws 71 that are provided apart from each other in a direction orthogonal to the overlapping direction of the connection side joining portion 22 c and the power feeding side joining portion 32 c are two welding claws 71. Are connected by a connecting portion 72 provided integrally with the front end portion. The pair of welding claws 71 and the connecting portion 72 have a shape viewed from the width direction of the connection-side joint portion 22c (in the direction perpendicular to the paper surface in FIG. 13) from the connection-side joint portion 22c toward the power supply-side joint portion 32c. It has a substantially arc shape curved so as to protrude. At the time of welding, the tip of the welding electrode 51 (see FIG. 6) is the joint between the connection-side joining portion 22c and the power-feeding-side joining portion 32c, and is the position that becomes the center between the pair of welding claws 71 (see FIG. The welding is performed aiming at the position. Then, the connection side joint 22c and the power supply side joint 32c merge with each other at the joint between the connection side joint 22c and the power supply side joint 32c, and the two weld claws 71 and the connection part 72 melt together with welding. Then, it fuses with the power supply side joint portion 32c, and the connection side joint portion 22c and the power supply side joint portion 32c are joined to each other. In this way, when the connection terminal 22 and the power supply terminal 32 are welded, the connection portion 72 is melted in addition to the pair of welding claws 71, so the connection terminal 22 and the power supply terminal 32 are joined over a wider range. Will be. Therefore, the connection terminal 22 and the power supply terminal 32 can be joined more firmly. Further, since the pair of welding claws 71 are integrated by connecting the distal ends thereof with the coupling portion 72, when the base end portion of the welding claws 71 is bent with respect to the connection side joining portion 22c, a pair of welding claws 71 are welded. The claws 71 can be easily bent at the same time, and the height positions of the two welding claws 71 forming a pair with respect to the power supply side joint portion 32c can be easily made uniform.

  Further, as in the example shown in FIG. 14, the pair of welding claws 41 of the above-described embodiment may be connected by a connecting portion 82 provided integrally at the tip end portion. 14 is a portion where the tip of the welding electrode 51 (see FIG. 6) is opposed at the time of welding. Even if it does in this way, the effect similar to the example shown in FIG. 13 can be acquired.

  In the above embodiment, the welding claws 41 are provided only on the connection terminals 22 to 24 among the connection terminals 22 to 24 and the power supply terminals 32 to 34 that are joined to each other. However, the welding claws 41 may be provided not only in the connection terminals 22 to 24 but also in the power supply terminals 32 to 34. In this case, for example, one welding claw 41 is provided for each of the connection terminals 22 to 24 and the power supply terminals 32 to 34. When the portions to be joined to each other in the connection terminals 22 to 24 and the power supply terminals 32 to 34 are overlapped, the weld claws 41 of the connection terminals 22 to 24 and the weld claws 41 of the power supply terminals 32 to 34 are overlapped. They are arranged apart from each other by a predetermined distance in a direction orthogonal to the mating direction (the overlapping direction of the connection terminals 22 to 24 and the power supply terminals 32 to 34). Note that this “predetermined distance” is a distance at which the two welding claws 41 can be melted when welding is performed aiming at the center of the two welding claws 41. In this way, the connection terminals 22 to 24 are joined to the power supply terminals 32 to 34 via the welding claws 41 provided on the terminals 22 to 24, respectively, and the power supply terminals 32 to 34 are connected to the terminals 32 to 34, respectively. 34 are joined to the connection terminals 22 to 24 through welding claws 41 provided respectively. That is, the connection terminals 22 to 24 and the power supply terminals 32 to 34 are joined to each other via the welding claws 41 provided in each. Moreover, when the welding nail | claw 41 is provided only in one connection terminal 22-24 among the connection terminals 22-24 and the electric power feeding terminals 32-34, the welding strength of each of the connection terminals 22-24 and the electric power feeding terminals 32-34 is as follows. Depends on the positional relationship between the welding claws 41 provided only in the connection terminals 22 to 24 and the power supply terminals 32 to 34. In contrast, when the welding claws 41 are provided in the connection terminals 22 to 24 and the power supply terminals 32 to 34, the welding strengths of the connection terminals 22 to 24 and the power supply terminals 32 to 34 are as follows. This depends on the positional relationship between the welding claws 41 and the power supply terminals 32 to 34 and the positional relationship between the welding claws 41 of the power supply terminals 32 to 34 and the connection terminals 22 to 24. Therefore, by providing the welding claws 41 in each of the connection terminals 22 to 24 and the power supply terminals 32 to 34, the stability of welding can be improved and the reliability of the parts joined by welding can be increased.

  In the above embodiment, each of the connection terminals 22 to 24 is provided with a pair of welding claws 41 (that is, two welding claws 41). However, at least one welding claw 41 may be formed in at least one of the connection terminals 22 to 24 and the power supply terminals 32 to 34 to be joined to each other.

  In the above-described embodiment, the tip of the welding electrode 51 is opposed to a position that is the joint between the connection-side joints 22c to 24c and the power feeding-side joints 32c to 34c and that is the center between the pair of welding claws 41. Then, welding is performed aiming at the position. However, if the connection side joints 22c to 24c and the power supply side joints 32c to 34c overlapped with each other at the time of welding can be partially melted and the welding claws 41 can be melted, the connection side joints 22c to 24c and the power supply are fed. You may make the front-end | tip part of the welding electrode 51 oppose to the position which is a joint with the side junction parts 32c-34c, and shifted | deviated from the position used as the center part between a pair of welding claws 41. FIG.

  In the above embodiment, the connection terminals 22 to 24 and the power supply terminals 32 to 34 that are joined to each other have a plate shape. However, the connection terminals 22 to 24 and the power supply terminals 32 to 34 may be rod-shaped or the like as long as they are made of a conductive metal material and can be joined to each other and the weld claws 41 can be formed.

  In the above-described embodiment, when the welding claws 41 are formed by bending the connection terminals 22 to 24 by pressing, the base end portions thereof are bent and extend in the thickness direction of the connection side joint portions 22c to 24c. Formed as follows. However, the bending of the base end portion of the welding claw 41 may be performed after the overlapping process.

  In the above embodiment, the connection terminals 22 to 24 and the power supply terminals 32 to 34 are joined by arc welding, but may be joined by melt welding (laser welding, electron beam welding, etc.) other than arc welding. .

The technical idea that can be grasped from the above embodiment and each of the above modifications will be described below.
(A) In the terminal welding method according to claim 1, a total of two welding claws are formed on the two terminals, and are formed at intervals in a direction orthogonal to the overlapping direction. A terminal welding method of joining the two terminals while melting the two weld claws by performing welding with respect to the two terminals that have been performed aiming at a central portion between the two weld claws. According to this method, the two terminals can be easily joined by simultaneously melting the two welding claws substantially equally. In addition, since two welding claws are provided in total for the two terminals, the two terminals can be more firmly joined by these welding claws.

  DESCRIPTION OF SYMBOLS 2 ... Stator, 11 ... Stator core, 22-24 ... Connection terminal as terminal and connection terminal, 30 ... Feeding connector, 32-34 ... Feeding terminal as terminal and feeding terminal, 41, 61, 71 ... Welding claw, 51 ... Welding electrodes, 72, 82 ... connecting portions, U1-U4, V1-V4, W1-W4 ... coils.

Claims (9)

A terminal welding method in which two terminals made of a conductive metal material are overlapped with each other, and the two terminals are joined by welding from one direction orthogonal to the overlapping direction,
At least one of the terminals is formed with at least one welding claw extending along the overlapping direction toward the mating terminal to be joined and covering the mating terminal to be joined.
A terminal welding method, wherein welding is performed at a position close to the welding claws on the two superimposed terminals, and the two terminals are joined while melting the welding claws. The terminal welding method according to claim 1,
The welding claws are formed in total for two of the terminals, and are formed at intervals in a direction close to the terminal of the welding electrode during welding and a direction orthogonal to the overlapping direction,
A terminal welding method characterized by joining the two terminals while melting the two welding claws by bringing the welding electrode close to a center portion between the two welding claws with respect to the two superimposed terminals. . In the terminal welding method according to claim 1 or 2,
The weld claws are formed in at least one pair with at least one of the terminals, and the pair of weld claws are connected to each other at a connecting portion formed integrally with a tip portion,
A terminal welding method characterized by joining the two terminals together while melting the connecting portion together with the welding claws. In the terminal welding method according to any one of claims 1 to 3,
The welding claw is formed such that the central portion in the extending direction is wider than the tip and the base end,
A terminal welding method characterized in that welding is performed at a position adjacent to a central portion in the extending direction of the welding claws to join the two terminals while melting the welding claws. The terminal welding method according to any one of claims 1 to 4,
At least two welding claws are formed on one of the terminals. The terminal welding method according to any one of claims 1 to 4,
The terminal welding method, wherein the welding claws are formed on the two terminals, respectively. In the terminal welding method according to any one of claims 1 to 6,
Each of the terminals has a plate shape, and one of the terminals and the other of the terminals are overlapped so that a portion to be joined overlaps in the thickness direction, and the welding claws extend along the thickness direction of the terminals. The terminal welding method characterized by the above-mentioned. A power supply connector for supplying a power to the coil, comprising a stator in which a plurality of coils are wound around a stator core, and a plurality of connection terminals made of a conductive metal plate and having ends connected to the ends of the coils. A method of manufacturing a brushless motor in which a plurality of provided power supply terminals and a plurality of connection terminals are overlapped and welded from one direction orthogonal to the overlapping direction to join the power supply terminals and the connection terminals Because
Each of the connection terminals and each of the power supply terminals has a plate shape, and at least one of the connection terminals and the power supply terminal extends in the thickness direction of the terminal toward the mating terminal. At least one welding claw is formed to cover the mating terminal to be joined;
The connection terminal and the power supply terminal are overlapped so that a portion to be joined is overlapped in the thickness direction, and the welded nail is welded to the overlapped connection terminal and the power supply terminal at a position close to the welding nail. A method of manufacturing a brushless motor, wherein the wire connection terminal and the power supply terminal are joined while melting the wire. A power supply connector for supplying a power to the coil, comprising a stator in which a plurality of coils are wound around a stator core, and a plurality of connection terminals made of a conductive metal plate and having ends connected to the ends of the coils. A brushless motor in which a plurality of provided power supply terminals and a plurality of connection terminals are respectively overlapped and joined by welding,
Each of the connection terminals and each of the power supply terminals has a plate-like shape and a portion to be joined to each other is overlapped in the thickness direction, and the connection terminals are formed on at least one of the connection terminals and the power supply terminals. A brushless motor characterized by melting and joining at least one welding claw covering a mating terminal extending along the overlapping direction of the terminal and the power supply terminal.

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