JP2017123727A

JP2017123727A - Method for manufacturing electric motor and bus ring for the same

Info

Publication number: JP2017123727A
Application number: JP2016001524A
Authority: JP
Inventors: 健一江上; Kenichi Egami; 太一岡; Taichi Oka
Original assignee: Hitachi Metals Ltd
Current assignee: Proterial Ltd
Priority date: 2016-01-07
Filing date: 2016-01-07
Publication date: 2017-07-13
Anticipated expiration: 2036-01-07
Also published as: JP6657969B2

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing an electric motor and a bus ring for an electric motor which can reliably perform connection with an end portion of a winding and improve work efficiency.SOLUTION: The method of manufacturing an electric motor includes: a bus ring forming step of plastically deforming a conductor wire having a circular cross section so that a winding connecting portion 411 is formed by processing a contact surface with a winding 32 facing across an end portion 321 of the winding 32 into a flat surface 411d; an inserting step of inserting the end portion 321 of the winding 32 into the winding connecting portion 411; a deforming step of deforming the winding connecting portion 411 so as to press the winding connecting portion 411 in the circumferential direction of the bus ring so that the flat surface 411d and the end portion 321 of the winding 32 are in contact with each other; and a welding step of energizing the winding connecting portion 411 in a state where the winding connecting portion 411 is deformed and welding the winding connecting portion 411 and the end portion 321 of the winding 32.SELECTED DRAWING: Figure 6

Description

本発明は、複数の磁性体コアに巻線を巻き回してなるステータと、ステータに対して回転するロータと、巻線が接続されるバスリングとを備えた電動機の製造方法、及び電動機用バスリングに関する。 The present invention relates to a method for manufacturing an electric motor including a stator formed by winding a winding around a plurality of magnetic cores, a rotor rotating with respect to the stator, and a bus ring to which the winding is connected, and an electric motor bus. Regarding the ring.

従来、例えば電気自動車や所謂ハイブリッド車等に搭載され、車両の駆動力を発生する電動機として、バスリングを介して巻線に駆動電流が供給されるものが知られている（例えば、特許文献１参照）。 2. Description of the Related Art Conventionally, as an electric motor that is mounted on, for example, an electric vehicle or a so-called hybrid vehicle and generates a driving force of the vehicle, a motor that supplies a driving current to a winding via a bus ring is known (for example, Patent Document 1). reference).

特許文献１に記載の電動機は、環状に配置された複数の磁極を有する磁性体コアと、複数の素線を束ねて形成された巻線を磁性体コアの複数の磁極ごとに巻き回してなるステータと、ステータに対して回転するロータと、ステータと同心状に配置され、巻線の端部が接続される複数の環状のバスリングとを備えている。 The electric motor described in Patent Document 1 is formed by winding a magnetic core having a plurality of magnetic poles arranged in an annular shape and a winding formed by bundling a plurality of strands around the plurality of magnetic poles of the magnetic core. A stator, a rotor that rotates with respect to the stator, and a plurality of annular bus rings that are arranged concentrically with the stator and to which ends of the windings are connected.

上記のバスリングは、断面円形の導体の表面を絶縁体で被覆し、絶縁体から露出させた複数の導体の部分に巻線の端部が接続される巻線接続部を形成している。巻線接続部は、一箇所に所定の開口を有する環状に形成されている。バスリングの巻線接続部に巻線の端部を接続する際は、巻線接続部に巻線の端部を挿通し、巻線接続部と巻線の端部とが接触するように巻線接続部を加圧し、巻線接続部を加圧した状態で巻線接続部に通電して巻線接続部と巻線の端部とを溶着させる。巻線接続部の加圧時には、開口の開口幅が巻線の素線の太さよりも狭くなるように巻線接続部を周方向に押圧する。 In the above-described bus ring, the surface of a conductor having a circular cross section is covered with an insulator, and a winding connection portion is formed in which ends of the winding are connected to a plurality of conductor portions exposed from the insulator. The winding connection part is formed in an annular shape having a predetermined opening at one place. When connecting the winding end to the winding connection of the bus ring, insert the winding end into the winding connection so that the winding connection and the end of the winding are in contact. The wire connection portion is pressurized, and the winding connection portion is energized while the winding connection portion is pressurized to weld the winding connection portion and the end of the winding. When pressurizing the winding connection portion, the winding connection portion is pressed in the circumferential direction so that the opening width of the opening is narrower than the thickness of the wire of the winding.

国際公開第２０１５／１４０９５５号International Publication No. 2015/140955

特許文献１に記載の電動機では、巻線接続部と巻線の端部とを接続する際、巻線接続部は断面円形であるため、巻線接続部を加圧するときに巻線の端部と巻線接続部とが線接触となり、接続部の接触面積が十分でないことから、接続不良の原因となる可能性があった。この場合には、接続作業のやり直しが必要となり、作業効率向上の妨げとなっていた。 In the electric motor described in Patent Document 1, when connecting the winding connection portion and the end portion of the winding, the winding connection portion is circular in cross section. The winding connection portion is in line contact, and the contact area of the connection portion is not sufficient, which may cause connection failure. In this case, it is necessary to redo the connection work, which hinders improvement in work efficiency.

そこで、本発明は、巻線の端部との接続を確実に行うことができ、もって作業効率の向上を図ることが可能な電動機の製造方法及び電動機用バスリングを提供することを目的とする。 Accordingly, an object of the present invention is to provide a method of manufacturing an electric motor and a bus ring for the electric motor that can reliably connect the end of the winding and can improve the working efficiency. .

本発明は、上記課題を解決することを目的として、環状に配置された複数の磁極を有する磁性体コアに、複数の素線を束ねて形成された巻線を前記複数の磁極ごとに巻き回してなるステータと、前記ステータに対して回転するロータと、前記ステータと同心状に配置され、前記巻線の端部が接続される複数の環状のバスリングとを備えた電動機の製造方法であって、前記バスリングの素材となる断面円形状の導体線を塑性変形させ、前記巻線の端部を挟んで向かい合う前記巻線との接触面が平坦面に加工された巻線接続部を形成するバスリング形成工程と、前記バスリングの前記巻線接続部に前記巻線の端部を挿通させる挿通工程と、前記巻線接続部を前記バスリングの周方向に押圧して前記平坦面と前記巻線の端部とが接触するように前記巻線接続部を変形させる変形工程と、前記巻線接続部が変形された状態で前記巻線接続部に通電し、前記巻線接続部と前記巻線の端部とを溶着する溶着工程とを有する、電動機の製造方法を提供する。 In order to solve the above-mentioned problems, the present invention winds a winding formed by bundling a plurality of strands around a plurality of magnetic poles around a magnetic core having a plurality of magnetic poles arranged in an annular shape. And a plurality of annular bus rings arranged concentrically with the stator and connected to the ends of the windings. Then, the conductor wire having a circular cross section as a material for the bus ring is plastically deformed to form a winding connection portion in which a contact surface facing the winding across the end of the winding is processed into a flat surface. A bus ring forming step, an insertion step of inserting an end portion of the winding into the winding connection portion of the bus ring, and pressing the winding connection portion in a circumferential direction of the bus ring and the flat surface So that the end of the winding contacts A deformation step of deforming the wire connection portion, and a welding step of energizing the winding connection portion in a state where the winding connection portion is deformed and welding the winding connection portion and the end of the winding. A method for manufacturing an electric motor is provided.

また、本発明は、上記課題を解決することを目的として、複数の素線を束ねて形成された巻線が接続される複数の巻線接続部、及び前記複数の巻線接続部の間の複数の円弧部を有し、前記巻線を磁性体コアに巻き回してなる電動機のステ―タと同心状に配置される電動機用バスリングであって、前記複数の円弧部は、少なくとも一部が絶縁体で被覆された断面円形状の芯線を円弧状に湾曲してなり、前記複数の巻線接続部は、前記巻線の端部を挟んで向かい合う前記巻線との接触面が平坦面に加工されている、電動機用バスリングを提供する。 In addition, for the purpose of solving the above-described problems, the present invention provides a plurality of winding connection portions to which windings formed by bundling a plurality of strands are connected, and between the plurality of winding connection portions. An electric motor bus ring having a plurality of arc portions and arranged concentrically with a motor stator formed by winding the winding around a magnetic core, wherein the arc portions are at least partially The core wire having a circular cross section covered with an insulator is curved in an arc shape, and the plurality of winding connection portions have flat contact surfaces with the windings facing each other across the end portions of the windings. An electric motor bus ring is provided.

本発明に係る電動機の製造方法及び電動機用バスリングによれば、巻線の端部との接続を確実に行うことができ、もって作業効率の向上を図ることが可能である。 According to the method for manufacturing an electric motor and the bus ring for an electric motor according to the present invention, the connection with the end of the winding can be reliably performed, and thus the working efficiency can be improved.

本発明の実施の形態に係る電動機の構成例の概略について説明する模式図である。It is a schematic diagram explaining the outline of the structural example of the electric motor which concerns on embodiment of this invention. 第１乃至第３のバスリングが組み付けられたステータをシャフトの回転軸方向から見た平面図である。It is the top view which looked at the stator with which the 1st thru | or 3rd bus ring was assembled | attached from the rotating shaft direction of the shaft. 磁性体コア組立体の構成例を示す斜視図である。It is a perspective view which shows the structural example of a magnetic body core assembly. 第１乃至第３のバスリングを示し、端子部及びその周辺部の拡大斜視図である。FIG. 5 is an enlarged perspective view of the terminal portion and its peripheral portion, showing the first to third bus rings. （ａ）は、第１のバスリングの巻線接続部を途中まで形成した状態を示す断面図、（ｂ）は、（ａ）のＡ−Ａ線断面図、（ｃ）は、第１のバスリングの巻線接続部及び一対の延在部を形成した状態を示す正面図である。(A) is sectional drawing which shows the state which formed the winding connection part of the 1st bus ring to the middle, (b) is the sectional view on the AA line of (a), (c) is the 1st It is a front view which shows the state which formed the coil | winding connection part and pair of extension part of a bus ring. （ａ）は、第１のバスリングの巻線接続部とＵ相の巻線の一方の端部との接続過程の一部を示し、一方の巻線の端部が巻線接続部に挿通した状態を示す説明図、（ｂ）は、第１のバスリングの巻線接続部とＵ相の巻線の一方の端部との接続過程の一部を示し、巻線接続部が加圧されている状態を示す説明図、（ｃ）は、（ｂ）のＢ−Ｂ線断面図、（ｄ）は、第１のバスリングの巻線接続部とＵ相の巻線の一方の端部との接続過程の一部を示し、巻線接続部と一方の巻線の端部とが溶着している状態を示す説明図である。(A) shows a part of connection process between the winding connection portion of the first bus ring and one end portion of the U-phase winding, and the end portion of one winding is inserted into the winding connection portion. FIG. 4B is a diagram illustrating a part of the connection process between the winding connection portion of the first bus ring and one end portion of the U-phase winding, and the winding connection portion is pressurized. (C) is a cross-sectional view taken along the line BB of (b), (d) is one end of the winding connection portion of the first bus ring and the U-phase winding. It is explanatory drawing which shows a part of connection process with a part, and shows the state which the coil | winding connection part and the edge part of one coil | winding are welded.

［実施の形態］
本発明の実施の形態に係る電動機について、図１乃至図６を参照して説明する。 [Embodiment]
An electric motor according to an embodiment of the present invention will be described with reference to FIGS.

（電動機１の構成）
まず、電動機１の構成について、図１を参照して説明する。 (Configuration of electric motor 1)
First, the configuration of the electric motor 1 will be described with reference to FIG.

図１は、本実施の形態に係る電動機１の構成例の概略について説明する模式図である。 FIG. 1 is a schematic diagram for explaining an outline of a configuration example of an electric motor 1 according to the present embodiment.

この電動機１は、固定子であるステータ３と、ステータ３に対して回転するロータ２と、複数の素線（後述する図６参照）３２０が撚られて束になって形成された巻線３２が接続される第１乃至第４のバスリング４１〜４４とを備えている。巻線３２を構成する素線は、銅線がエナメルで被覆されたエナメル線を用いることが可能である。 The electric motor 1 includes a stator 3 that is a stator, a rotor 2 that rotates with respect to the stator 3, and a plurality of windings 32 that are formed by twisting a plurality of strands (see FIG. 6 described later) 320. Are connected to the first to fourth bus rings 41 to 44. As the element wire constituting the winding 32, an enameled wire in which a copper wire is covered with enamel can be used.

ロータ２は、図略の軸受によってステータ３と同軸上で回転可能に支持されたシャフト２１と、シャフト２１の外周面に固定されてＮ極及びＳ極が周方向に交互に着磁された円筒状の磁石２２とを有している。 The rotor 2 includes a shaft 21 that is rotatably supported on the same axis as the stator 3 by a bearing (not shown), and a cylinder that is fixed to the outer peripheral surface of the shaft 21 and has N and S poles alternately magnetized in the circumferential direction. Shaped magnet 22.

ステータ３は、シャフト２１の回転軸Ｏを中心として環状に配置された複数（本実施の形態では２４個）の磁性体コア３１に巻線３２を巻き回して構成される。本実施の形態では、２４個の磁性体コア３１が、８個のＵ相の磁性体コア３１Ｕ、８個のＶ相の磁性体コア３１Ｖ、及び８個のＷ相の磁性体コア３１から構成され、ロータ２の回転方向Ｒに沿って、Ｕ相の磁性体コア３１Ｕ、Ｖ相の磁性体コア３１Ｖ、Ｗ相の磁性体コア３１Ｗの順に並んで配置されている。複数の磁性体コア３１は、本発明の「複数の磁極を有する磁性体コア」の一態様である。複数の磁性体コア３１は、複数の磁極を有する一体物の磁性体コアでもよい。 The stator 3 is configured by winding a winding 32 around a plurality (24 in the present embodiment) of magnetic cores 31 arranged in an annular shape around the rotation axis O of the shaft 21. In the present embodiment, the 24 magnetic cores 31 are composed of eight U-phase magnetic cores 31U, eight V-phase magnetic cores 31V, and eight W-phase magnetic cores 31. Along with the rotation direction R of the rotor 2, the U-phase magnetic core 31U, the V-phase magnetic core 31V, and the W-phase magnetic core 31W are arranged in this order. The plurality of magnetic cores 31 are an aspect of the “magnetic core having a plurality of magnetic poles” of the present invention. The plurality of magnetic cores 31 may be integrated magnetic cores having a plurality of magnetic poles.

Ｕ相の磁性体コア３１Ｕには、巻線３２としてＵ相の巻線３２Ｕが巻き回されている。このＵ相の巻線３２Ｕは、その両端部のうち一方の端部３２１Ｕが第１のバスリング４１に電気的に接続され、他方の端部３２２Ｕが第４のバスリング４４に電気的に接続されている。 A U-phase winding 32U is wound as a winding 32 around the U-phase magnetic core 31U. The U-phase winding 32 U has one end 321 U that is electrically connected to the first bus ring 41 and the other end 322 U that is electrically connected to the fourth bus ring 44. Has been.

Ｖ相の磁性体コア３１Ｖには、巻線３２としてＶ相の巻線３２Ｖが巻き回されている。このＶ相の巻線３２Ｖは、その両端部のうち一方の端部３２１Ｖが第２のバスリング４２に電気的に接続され、他方の端部３２２Ｖが第４のバスリング４４に電気的に接続されている。 A V-phase winding 32V is wound as a winding 32 around the V-phase magnetic core 31V. The V-phase winding 32 V has one end 321 V electrically connected to the second bus ring 42, and the other end 322 V electrically connected to the fourth bus ring 44. Has been.

Ｗ相の磁性体コア３１Ｗには、巻線３２としてＷ相の巻線３２Ｗが巻き回されている。このＷ相の巻線３２Ｗは、その両端部のうち一方の端部３２１Ｗが第３のバスリング４３に電気的に接続され、他方の端部３２２Ｗが第４のバスリング４４に電気的に接続されている。 A W-phase winding 32 W is wound around the W-phase magnetic core 31 W as the winding 32. The W-phase winding 32 W has one end 321 W electrically connected to the third bus ring 43 and the other end 322 W electrically connected to the fourth bus ring 44. Has been.

したがって、第４のバスリング４４は、Ｕ相の巻線３２Ｕの他方の端部３２２Ｕ、Ｖ相の巻線３２Ｖの他方の端部３２２Ｖ、及びＷ相の束３２Ｗの他方の端部３２２Ｗが電気的に接続された中性相のバスリングとして機能している。 Therefore, the fourth bus ring 44 is electrically connected to the other end 322U of the U-phase winding 32U, the other end 322V of the V-phase winding 32V, and the other end 322W of the W-phase bundle 32W. It functions as a neutrally connected neutral phase bus ring.

Ｕ相の巻線３２Ｕの一方の端部３２１Ｕは、ステータ３の周方向におけるＶ相の巻線３２Ｖ側に位置し、他方の端部３２２Ｕは、ステータ３の周方向におけるＷ相の巻線３２Ｗ側に位置している。Ｖ相の巻線３２Ｖの一方の端部３２１Ｖは、ステータ３の周方向におけるＷ相の巻線３２Ｗ側に位置し、他方の端部３２２Ｖは、ステータ３の周方向におけるＵ相の巻線３２Ｕ側に位置している。Ｗ相の巻線３２Ｗの一方の端部３２１Ｗは、ステータ３の周方向におけるＵ相の巻線３２Ｕ側に位置し、他方の端部３２２Ｗは、ステータ３の周方向におけるＶ相の巻線３２Ｖ側に位置している。 One end 321U of the U-phase winding 32U is located on the V-phase winding 32V side in the circumferential direction of the stator 3, and the other end 322U is a W-phase winding 32W in the circumferential direction of the stator 3. Located on the side. One end 321V of the V-phase winding 32V is located on the W-phase winding 32W side in the circumferential direction of the stator 3, and the other end 322V is a U-phase winding 32U in the circumferential direction of the stator 3. Located on the side. One end 321W of the W-phase winding 32W is located on the U-phase winding 32U side in the circumferential direction of the stator 3, and the other end 322W is a V-phase winding 32V in the circumferential direction of the stator 3. Located on the side.

第１乃至第３のバスリング４１〜４３には、それぞれ給電端子４１０，４２０，４３０が接続され、この給電端子４１０，４２０，４３０を介して図略のインバータから１２０°ずつ位相がずれた正弦波状の駆動電流が第１乃至第３のバスリング４１〜４３に供給される。この駆動電流によってステータ３に回転磁界が形成され、磁石２２がこの回転磁界による吸引力及び反発力により回転力を受けてシャフト２１を回転軸Ｏを中心として回転させる。 The first to third bus rings 41 to 43 are connected to power supply terminals 410, 420, and 430, respectively, and the sine whose phase is shifted by 120 ° from the inverter (not shown) via the power supply terminals 410, 420, and 430. A wavy drive current is supplied to the first to third bus rings 41 to 43. A rotational magnetic field is formed in the stator 3 by this driving current, and the magnet 22 receives the rotational force by the attractive force and the repulsive force due to the rotational magnetic field and rotates the shaft 21 around the rotational axis O.

（ステータ３の構成）
次に、ステータ３の構成について、図２及び図３を参照して説明する。 (Configuration of stator 3)
Next, the structure of the stator 3 is demonstrated with reference to FIG.2 and FIG.3.

図２は、第１乃至第３のバスリング４１〜４３が組み付けられたステータ３をシャフト２１の回転軸Ｏ方向から見た平面図である。図３は、磁性体コア組立体３０の構成例を示す斜視図である。 FIG. 2 is a plan view of the stator 3 assembled with the first to third bus rings 41 to 43 as viewed from the direction of the rotation axis O of the shaft 21. FIG. 3 is a perspective view illustrating a configuration example of the magnetic core assembly 30.

ステータ３は、図２に示すように、磁性体コア３１に巻線３２を巻き回してなる複数（本実施の形態では２４個）の磁性体コア組立体３０が環状に配置されることにより構成されている。より具体的には、磁性体コア組立体３０は、図３に示すように、複数の電磁鋼板３１０を積層してなる磁性体コア３１に絶縁性のインシュレータ３３を装着し、インシュレータ３３を介して磁性体コア３１の外側に巻線３２を巻き回してなる。 As shown in FIG. 2, the stator 3 is configured by arranging a plurality (24 in this embodiment) of magnetic core assemblies 30 formed by winding a winding 32 around a magnetic core 31 in an annular shape. Has been. More specifically, as shown in FIG. 3, the magnetic core assembly 30 has an insulating insulator 33 mounted on a magnetic core 31 formed by laminating a plurality of electromagnetic steel plates 310, and the insulator 33 is interposed via the insulator 33. A winding 32 is wound around the outside of the magnetic core 31.

インシュレータ３３は、磁性体コア３１と巻線３２との間に介在する絶縁部３３６（図３において破線で示す）と、絶縁部３３６をロータ２（図１参照）の径方向に挟んで対向する第１の壁部３３１及び第２の壁部３３２と、第１の壁部３３１からシャフト２１の回転軸Ｏ（図１参照）側に向かって張り出した内鍔部３３４と、第２の壁部３３２から第１の壁部３３１とは反対側に向かって張り出した外鍔部３３５と、外鍔部３３５の端部から第２の壁部３３２に対向するように立設された第３の壁部３３３とを一体に有している。 The insulator 33 is opposed to an insulating portion 336 (shown by a broken line in FIG. 3) interposed between the magnetic core 31 and the winding 32 with the insulating portion 336 sandwiched in the radial direction of the rotor 2 (see FIG. 1). A first wall portion 331 and a second wall portion 332; an inner flange portion 334 protruding from the first wall portion 331 toward the rotation axis O (see FIG. 1) of the shaft 21; and a second wall portion An outer flange 335 projecting from 332 toward the opposite side of the first wall 331, and a third wall erected so as to face the second wall 332 from the end of the outer flange 335 It has the part 333 integrally.

第１乃至第３の壁部３３１〜３３３は、シャフト２１の回転軸Ｏ側からロータ２の径方向に沿って第１の壁部３３１、第２の壁部３３２、第３の壁部３３３の順に立設されている。 The first to third wall portions 331 to 333 are formed on the first wall portion 331, the second wall portion 332, and the third wall portion 333 along the radial direction of the rotor 2 from the rotation axis O side of the shaft 21. They are erected in order.

第２の壁部３３２には、巻線３２の一方の端部３２１を挿通させる第２の挿通部３３２ａが形成され、巻線３２の一方の端部３２１は、挿通部３３２ａからシャフト２１の回転軸Ｏ方向に平行な方向に沿って引き出されている。第１の壁部３３１には、巻線３２の他方の端部３２２を挿通させる第１の挿通部３３１ａが形成され、巻線３２の他方の端部３２２は、第１の挿通部３３１ａからシャフト２１の回転軸Ｏ側に向かって引き出されている。 The second wall portion 332 is formed with a second insertion portion 332a through which one end portion 321 of the winding 32 is inserted, and the one end portion 321 of the winding 32 is rotated from the insertion portion 332a to the shaft 21. It is pulled out along a direction parallel to the axis O direction. The first wall portion 331 is formed with a first insertion portion 331a through which the other end portion 322 of the winding 32 is inserted, and the other end portion 322 of the winding 32 is connected to the shaft from the first insertion portion 331a. 21 is drawn toward the rotation axis O side.

また、インシュレータ３３は、第１乃至第３のバスリング４１〜４３を保持する保持部３３０を有している。保持部３３０は、図３に示すように、第２の壁部３３２の一部、第３の壁部３３３、及び第２の壁部３３２の一部と第３の壁部３３３との間を連結する外鍔部３３５によって構成されている。外鍔部３３５は、保持部３３０の底部として機能する。本実施の形態では、保持部３３０は、巻線３２（Ｕ相の巻線３２Ｕ，Ｖ相の巻線３２Ｖ，Ｗ相の巻線３２Ｗ）の外周側に設けられている。第３の壁部３３３には、第１乃至第３のバスリング４１〜４３を固定する固定部材４０が嵌合される嵌合凹部３３３ａが形成されている。 The insulator 33 has a holding portion 330 that holds the first to third bus rings 41 to 43. As shown in FIG. 3, the holding unit 330 includes a part of the second wall part 332, a third wall part 333, and a part of the second wall part 332 and the third wall part 333. It is comprised by the outer collar part 335 to connect. The outer flange portion 335 functions as the bottom portion of the holding portion 330. In the present embodiment, holding section 330 is provided on the outer peripheral side of winding 32 (U-phase winding 32U, V-phase winding 32V, and W-phase winding 32W). The third wall portion 333 is formed with a fitting recess 333a into which the fixing member 40 for fixing the first to third bus rings 41 to 43 is fitted.

（第１乃至第３のバスリング４１〜４３の構成）
次に、第１乃至第３のバスリング４１〜４３の構成について、図２及び図４を参照して説明する。 (Configuration of the first to third bus rings 41 to 43)
Next, the configuration of the first to third bus rings 41 to 43 will be described with reference to FIGS.

図４は、第１乃至第３のバスリング４１〜４３を示し、端子部４１ａ，４２ａ，４３ａ及びその周辺部の拡大斜視図である。 FIG. 4 shows the first to third bus rings 41 to 43, and is an enlarged perspective view of the terminal portions 41a, 42a, 43a and their peripheral portions.

図２に示すように、第１乃至第３のバスリング４１〜４３は、シャフト２１の回転軸Ｏ（図１参照）方向に沿って並んで配置され、複数（本実施の形態では２４個）の固定部材４０によって一括して固定された状態でステータ３の保持部３３０に保持されている。 As shown in FIG. 2, the first to third bus rings 41 to 43 are arranged side by side along the direction of the rotation axis O (see FIG. 1) of the shaft 21, and a plurality (24 in the present embodiment) are arranged. Are held by the holding portion 330 of the stator 3 while being fixed together by the fixing member 40.

第１乃至第３のバスリング４１〜４３は、例えば銅等の良電導性の金属からなる断面円形状の中心導体４００ａを樹脂からなる絶縁体４００ｂで被覆した線状の絶縁電線４００を屈曲して形成されている。中心導体４００ａは、本発明の「導体線」の一態様である。 The first to third bus rings 41 to 43 are formed by bending a linear insulated wire 400 in which a central conductor 400a having a circular cross section made of a highly conductive metal such as copper is covered with an insulator 400b made of resin. Is formed. The center conductor 400a is an embodiment of the “conductor wire” in the present invention.

第１のバスリング４１は、ステータ３の径方向内側に突出し、Ｕ相の巻線３２Ｕの一方の端部３２１Ｕが接続される複数（本実施の形態では８個）の端子部４１ａと、ステータ３の周方向に沿って並ぶ複数（本実施の形態では８個）の円弧部４１２とを有している。複数の端子部４１ａは、複数の円弧部４１２の間に設けられている。また、第１のバスリング４１の両端部では、絶縁体４００ｂから中心導体４００ａが露出し、この露出した中心導体４００ａに給電端子４１０が圧着又は加締めにより接続されている。 The first bus ring 41 protrudes inward in the radial direction of the stator 3, and a plurality (eight in this embodiment) of terminal portions 41 a to which one end 321 U of the U-phase winding 32 U is connected, and the stator 3 (eight in the present embodiment) arcuate portions 412 arranged along the circumferential direction. The plurality of terminal portions 41 a are provided between the plurality of arc portions 412. Further, at both ends of the first bus ring 41, the central conductor 400a is exposed from the insulator 400b, and the power supply terminal 410 is connected to the exposed central conductor 400a by crimping or crimping.

第１のバスリング４１は、中心導体４００ａを塑性変形させ、巻線３２の端部を挟んで向かい合う巻線３２との接触面が平坦面４１１ｄに加工された複数の巻線接続部４２ａを有している。円弧部４１２は、少なくとも一部が絶縁体４００ｂで被覆された断面円形状の芯線を円弧状に湾曲して形成されている。本実施の形態では、端子部４１ａの近傍を除く円弧部４１２の一部が絶縁体４００ｂで被覆されているが、円弧部４１２の全体が縁体４００ｂで被覆されていてもよい。 The first bus ring 41 has a plurality of winding connection portions 42a whose contact surfaces with the windings 32 facing each other across the ends of the windings 32 are plastically deformed and the flat surfaces 411d are processed. doing. The arc portion 412 is formed by curving a circular core wire having a circular cross section, at least a portion of which is covered with the insulator 400b. In the present embodiment, a part of the arc part 412 except the vicinity of the terminal part 41a is covered with the insulator 400b, but the whole arc part 412 may be covered with the edge body 400b.

第１のバスリング４１と同様にして、第２のバスリング４２は、Ｖ相の巻線３２Ｖの一方の端部３２１Ｖが接続される複数（本実施の形態では８個）の端子部４２ａと、複数（本実施の形態では８個）の円弧部４２２とを有している。また、第２のバスリング４２の両端部には、給電端子４２０が接続されている。 Similarly to the first bus ring 41, the second bus ring 42 includes a plurality of (in this embodiment, eight) terminal portions 42a to which one end portion 321V of the V-phase winding 32V is connected. , And a plurality (eight in this embodiment) of arc portions 422. In addition, power supply terminals 420 are connected to both ends of the second bus ring 42.

第１及び第２のバスリング４１，４２と同様にして、第３のバスリング４３は、Ｗ相の巻線３２Ｗの一方の端部３２１Ｗが接続される複数（本実施の形態では８個）の端子部４３ａと、複数（本実施の形態では８個）の円弧部４３２とを有している。また、第３のバスリング４３の両端部には、給電端子４３０が接続されている。 Similarly to the first and second bus rings 41 and 42, the third bus ring 43 includes a plurality of (eight in the present embodiment) to which one end 321W of the W-phase winding 32W is connected. Terminal portion 43a and a plurality (eight in this embodiment) of arc portions 432 are provided. In addition, power supply terminals 430 are connected to both ends of the third bus ring 43.

第１乃至第３のバスリング４１〜４３は、シャフト２１の回転軸Ｏ方向に沿って並べて配置したときに、第１のバスリング４１の端子部４１ａがＵ相の巻線３２Ｕの一方の端部３２１Ｕの引き出し位置に、第２のバスリング４２の端子部４２ａがＶ相の巻線３２Ｖの一方の端部３２１Ｖの引き出し位置に、第３のバスリング４３の端子部４３ａがＷ相の巻線３２Ｗの一方の端部３２１Ｗの引き出し位置に、それぞれ対応するようにステータ３の周方向に沿って等間隔に配置されている。 When the first to third bus rings 41 to 43 are arranged side by side along the direction of the rotation axis O of the shaft 21, the terminal portion 41a of the first bus ring 41 is one end of the U-phase winding 32U. The terminal portion 42a of the second bus ring 42 is at the pulling position of one end 321V of the V-phase winding 32V, and the terminal portion 43a of the third bus ring 43 is W-phase winding. It arrange | positions at equal intervals along the circumferential direction of the stator 3 so as to correspond to the drawing position of one end 321W of the line 32W.

Ｕ相の巻線３２Ｕ、Ｖ相の巻線３２Ｖ、及びＷ相の巻線３２Ｗの一方の端部３２１Ｕ，３２１Ｖ，３２１Ｗは、ステータ３側からシャフト２１の回転軸Ｏに平行な方向に沿って第１乃至第３のバスリング４１〜４３の端子部４１ａ，４２ａ，４３ａにそれぞれ挿通されている。なお、図４では、一方の端部３２１Ｕ，３２１Ｖ，３２１ＷのうちＶ相の巻線３２Ｖの一方の端部３２１Ｖが端子部４２ａに挿通されている様子を示す。 One end portions 321U, 321V, and 321W of the U-phase winding 32U, the V-phase winding 32V, and the W-phase winding 32W extend along a direction parallel to the rotation axis O of the shaft 21 from the stator 3 side. The first to third bus rings 41 to 43 are inserted into the terminal portions 41a, 42a and 43a, respectively. FIG. 4 shows a state where one end 321V of the V-phase winding 32V among the one end 321U, 321V, 321W is inserted into the terminal portion 42a.

（バスリングの巻線接続部の形成方法）
次に、１乃至第３のバスリング４１〜４３における端子部４１ａ，４２ａ，４３ａの巻線接続部４１１，４２１，４３１の形成方法について、図５を参照して説明する。 (Method of forming winding connection part of bus ring)
Next, a method of forming the winding connection portions 411, 421, 431 of the terminal portions 41a, 42a, 43a in the first to third bus rings 41-43 will be described with reference to FIG.

なお、第１乃至第３のバスリング４１〜４３における端子部４１ａ，４２ａ，４３ａの巻線接続部４１１，４２１，４３１の構造は全て同一であるため、第１のバスリング４１における端子部４１ａの巻線接続部４１１の形成方法を例にとって、以下説明する。 In addition, since all the structure of the coil | winding connection part 411,421,431 of the terminal parts 41a, 42a, 43a in the 1st thru | or 3rd bus rings 41-43 is the same, the terminal part 41a in the 1st bus ring 41 is used. The method for forming the winding connection portion 411 will be described below as an example.

図５（ａ）〜（ｃ）は、第１のバスリング４１の形成工程（バスリング形成工程）を示す説明図である。図５（ａ）は、巻線接続部４１１の形成工程（巻線接続部形成工程）を示す断面図、図５（ｂ）は、図５（ａ）のＡ−Ａ線断面図、図５（ｃ）は、巻線接続部４１１及び一対の延在部４１３，４１４を含む端子部４１ａの形成工程（端子部形成工程）を示す正面図である。 FIGS. 5A to 5C are explanatory views showing a process of forming the first bus ring 41 (bus ring forming process). 5A is a cross-sectional view showing a step of forming the winding connection portion 411 (winding connection portion forming step), FIG. 5B is a cross-sectional view taken along line AA of FIG. (C) is a front view showing a forming step (terminal portion forming step) of the terminal portion 41a including the winding connection portion 411 and the pair of extending portions 413 and 414.

このバスリング形成工程では、バスリングの素材となる断面円形状の導体線を塑性変形させ、巻線３２の端部３２１を挟んで向かい合う巻線３２との接触面が平坦面４１１ｄに加工された巻線接続部４１１を形成し、その後に、巻線絶縁部４１１を一箇所に開口４１１ａを有する環状に形成する。 In this bus ring forming step, a conductor wire having a circular cross section as a material of the bus ring is plastically deformed, and a contact surface with the winding 32 facing the end portion 321 of the winding 32 is processed into a flat surface 411d. The winding connection part 411 is formed, and then the winding insulation part 411 is formed in an annular shape having an opening 411a at one place.

まず、芯線としての中心導体４００ａを絶縁体４００ｂで被覆した絶縁電線４００を用意する。次に、絶縁電線４００のうち巻線接続部４１１となる部分及びその周辺部の絶縁体４００ｂを除去する。この絶縁体４００ｂを除去する工程は、例えばカッタ等の刃具を用いて除去する範囲の絶縁体４００ｂの両端部に周方向の切れ込みを入れると共に、その両端部間における絶縁体４００ｂに絶縁電線４００の長手方向に沿う切れ込みを入れ、その後に絶縁体４００ｂを取り除くことにより行うことができる。絶縁電線４００から絶縁体４００ｂを除去すると、中心導体４００ａが露出する。 First, an insulated wire 400 in which a central conductor 400a as a core wire is covered with an insulator 400b is prepared. Next, the part which becomes the coil | winding connection part 411 among the insulated wires 400, and the insulator 400b of the peripheral part are removed. In the step of removing the insulator 400b, for example, notches in the circumferential direction are made at both ends of the insulator 400b in a range to be removed by using a cutter such as a cutter, and the insulator 400b between the both ends is inserted into the insulator 400b. This can be done by making a cut along the longitudinal direction and then removing the insulator 400b. When the insulator 400b is removed from the insulated wire 400, the central conductor 400a is exposed.

次に、図５（ａ）に示すように、絶縁体４００ｂから露出している中心導体４００ａのうち第１のバスリング４１の巻線接続部４１１となる領域を受けダイス１１と押しダイス１２で挟むよう配置し、押しダイス１２を受けダイス１１に向けて加圧して巻線接続部４１１を形成する（巻線接続部形成工程）。 Next, as shown in FIG. 5 (a), a region that becomes the winding connection portion 411 of the first bus ring 41 in the central conductor 400 a exposed from the insulator 400 b is received by the die 11 and the pressing die 12. It arrange | positions so that it may pinch | interpose, receives the press die 12 and pressurizes it toward the die | dye 11, and forms the coil | winding connection part 411 (winding connection part formation process).

受けダイス１１は、所定の間隔を設けて形成された直線状の一対の第１の受け面１１ａ，１１ａと、互いに逆方向に傾斜した直線状の一対の第３の受け面１１ｃ，１１ｃと、第１の受け面１１ａと第３の受け面１１ｃとを接続する弧状の一対の第２の受け面１１ｂ，１１ｂと、一対の第３の受け面１１ｃ，１１ｃを接続する弧状の第４の受け面１１ｄとを有する。第１乃至第４の受け面１１ａ〜１１ｄは、図５（ａ）の紙面に垂直な断面において中心導体４００ａの外径に対応させて弧状に形成されている。 The receiving die 11 includes a pair of linear first receiving surfaces 11a, 11a formed at a predetermined interval, and a pair of linear third receiving surfaces 11c, 11c inclined in opposite directions. A pair of arcuate second receiving surfaces 11b, 11b connecting the first receiving surface 11a and the third receiving surface 11c, and an arcuate fourth receiving member connecting the pair of third receiving surfaces 11c, 11c. A surface 11d. The first to fourth receiving surfaces 11a to 11d are formed in an arc shape corresponding to the outer diameter of the central conductor 400a in a cross section perpendicular to the paper surface of FIG.

押しダイス１２は、先端側に弧状の先端面１２ａを有する。この先端面１２ａは、図５（ｂ）に示す断面において平坦に形成されている。 The push die 12 has an arcuate tip surface 12a on the tip side. The tip surface 12a is formed flat in the cross section shown in FIG.

受けダイス１１に対して押しダイス１２を加圧すると、図５（ｂ）に示すように、中心導体４００ａは、受けダイス１１の第４の受け面１１ｄによって弧状が保たれ、押しダイス１２の先端面１２ａによって巻線３４に面する面にロータ２の回転軸と略平行な平坦面４１１ｄが形成され（後述する図６（ｃ）参照）、かつ内側に平坦面４１１ｄを有する巻線接続部４１１が形成される。すなわち、本実施の形態では、巻線接続部４１１の形成工程において、中心導体４００ａの曲げと平坦面４１１ｄの形成とが同時に行われる。ただし、中心導体４００ａの曲げ工程と、平坦面４１１ｄの形成工程とを、別々の工程で行ってもよい。この場合、加工の容易性を考慮すると、中心導体４００ａの一部を塑性変形させて平坦面４１１ｄを形成した後に、中心導体４００ａをＶ字状乃至Ｕ字状に曲げ加工することが望ましい。 When the pressing die 12 is pressed against the receiving die 11, the center conductor 400 a is maintained in an arc shape by the fourth receiving surface 11 d of the receiving die 11 as shown in FIG. A winding surface 411d having a flat surface 411d substantially parallel to the rotation axis of the rotor 2 is formed on the surface facing the winding 34 by the surface 12a (see FIG. 6C described later), and the winding connection portion 411 has a flat surface 411d on the inner side. Is formed. That is, in the present embodiment, in the step of forming the winding connection part 411, the bending of the center conductor 400a and the formation of the flat surface 411d are performed simultaneously. However, the step of bending the central conductor 400a and the step of forming the flat surface 411d may be performed in separate steps. In this case, considering the ease of processing, it is desirable that the central conductor 400a is bent into a V shape or a U shape after a part of the central conductor 400a is plastically deformed to form the flat surface 411d.

次に、図５（ｃ）に示すように、受けダイス１３を巻線接続部４１１の中心に対応させて配置し、中心導体４００ａを一対の押しダイス１４で斜めの方向に加圧する。 Next, as shown in FIG. 5C, the receiving die 13 is disposed so as to correspond to the center of the winding connection portion 411, and the center conductor 400 a is pressed in a diagonal direction by the pair of pushing dies 14.

受けダイス１３は、後述する図６（ａ）に示す巻線接続部４１１の開口４１１ａに対応した幅を有する凸部１３ａを備えている。押しダイス１４，１５は、先端側に互いに直交する直交面１４ａ，１５ａを有する。 The receiving die 13 includes a convex portion 13a having a width corresponding to an opening 411a of a winding connecting portion 411 shown in FIG. The push dies 14, 15 have orthogonal surfaces 14a, 15a orthogonal to each other on the tip side.

受けダイス１３に対して一対の押しダイス１４を加圧すると、隣り合う一対の円弧部４１２ａ，４１２ｂと開口部４１１ａを挟む巻線接続部４１１の両端部４１１ｂ，４１１ｃとの間に介在する一対の延在部４１３，４１４が形成される。すなわち、巻線接続部４１１は、一箇所に開口４１１ａを有する環状に形成される。 When a pair of pressing dies 14 are pressed against the receiving die 13, a pair of adjacent arcs 412a, 412b and a pair of winding connecting portions 411 sandwiching the opening 411a are interposed between a pair of ends 411b, 411c. Extension portions 413 and 414 are formed. That is, the winding connection part 411 is formed in an annular shape having an opening 411a at one place.

以上のようにして第１のバスリング４１に巻線接続部４１１、及び一対の延在部４１３，４１４を有する端子部４１ａが形成される。その後、第１のバスリング４１は、図２に示すように、曲げ加工により環状に形成される。 As described above, the terminal portion 41 a having the winding connection portion 411 and the pair of extending portions 413 and 414 is formed in the first bus ring 41. Thereafter, as shown in FIG. 2, the first bus ring 41 is formed into an annular shape by bending.

（巻線接続部と巻線の端部との接続方法）
次に、第１乃至第３のバスリング４１〜４３における端子部４１ａ，４２ａ，４３ａの巻線接続部４１１，４２１，４３１とＵ相の巻線３２Ｕ，Ｖ相の巻線３２Ｖ，Ｗ相の巻線３２Ｗの一方の端部３２１Ｕ，３２１Ｖ，３２１Ｗとの接続方法について、図６（ａ）〜（ｄ）を参照して説明する。 (Connection method between winding connection and winding end)
Next, the winding connection portions 411, 421, 431 of the terminal portions 41a, 42a, 43a in the first to third bus rings 41-43, the U-phase winding 32U, the V-phase winding 32V, and the W-phase winding A connection method with one end 321U, 321V, 321W of the winding 32W will be described with reference to FIGS.

なお、第１乃至第３のバスリング４１〜４３における端子部４１ａ，４２ａ，４３ａの巻線接続部４１１，４２１，４３１とＵ相の巻線３２Ｕ，Ｖ相の巻線３２Ｖ，Ｗ相の巻線３２Ｗの一方の端部３２１Ｕ，３２１Ｖ，３２１Ｗとの接続方法は全て同一であるため、第１のバスリング４１における端子部４１ａの巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとの接続方法を例にとって、以下説明する。 It should be noted that the terminal portions 41a, 42a, 43a of the first to third bus rings 41-43, the winding connection portions 411, 421, 431, the U-phase winding 32U, the V-phase winding 32V, and the W-phase winding. Since all the connection methods of the one end portions 321U, 321V, and 321W of the line 32W are the same, the winding connection portion 411 of the terminal portion 41a in the first bus ring 41 and one end of the U-phase winding 32U. The connection method with the unit 321U will be described below as an example.

図６（ａ）〜（ｄ）は、第１のバスリング４１の巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとの接続過程を示す説明図であり、図６（ａ）は、Ｕ相の巻線４２Ｕの一方の端部３２１Ｕが巻線接続部４１１に挿通された状態、図６（ｂ）は、巻線接続部４１１が加圧されている状態、図６（ｃ）は、図６（ｂ）のＢ−Ｂ線断面図、図６（ｄ）は、巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとが溶着している状態を示す。なお、図６（ｄ）では、Ｕ相の巻線３２Ｕの一方の端部３２１Ｕを破線で示している。 FIGS. 6A to 6D are explanatory views showing a connection process between the winding connection portion 411 of the first bus ring 41 and one end portion 321U of the U-phase winding 32U. FIG. 6A shows a state in which one end 321U of the U-phase winding 42U is inserted through the winding connection portion 411. FIG. 6B shows a state in which the winding connection portion 411 is pressurized. 6C is a cross-sectional view taken along the line BB of FIG. 6B, and FIG. 6D is a state where the winding connection portion 411 and one end portion 321U of the U-phase winding 32U are welded. Indicates. In FIG. 6D, one end 321U of the U-phase winding 32U is indicated by a broken line.

図６（ａ）に示すように、端子部４１ａは、一箇所に開口４１１ａを有する環状に形成された巻線接続部４１１と、隣り合う一対の円弧部４１２ａ，４１２ｂと開口４１１ａを挟む巻線接続部４１１の両端部４１１ｂ，４１１ｃとの間に介在する一対の延在部４１３，４１４とを有している。 As shown in FIG. 6A, the terminal portion 41a includes a winding connection portion 411 formed in an annular shape having an opening 411a at one location, and a winding sandwiching the pair of adjacent arc portions 412a and 412b and the opening 411a. It has a pair of extension parts 413 and 414 interposed between both ends 411b and 411c of the connection part 411.

本実施の形態では、一対の延在部４１３，４１４は、隣り合う一対の円弧部４１２ａ，４１２ｂのそれぞれの端部からステータ３（図２参照）の径方向内側に向かって平行に延在している。図６（ａ）に示すように、一対の延在部４１３，４１４の延在方向の長さＬ_１は、例えば円弧部４１２ａ，４１２ｂから巻線接続部４１１における第１のバスリング４１の径方向の先端までの距離Ｌ_２の３０〜６０％である。 In the present embodiment, the pair of extending portions 413 and 414 extend in parallel from the respective end portions of the pair of adjacent arc portions 412a and 412b toward the radially inner side of the stator 3 (see FIG. 2). ing. As shown in FIG. 6 (a), the diameter of the first bus ring 41 in the pair of the extending direction of the length _{L 1} of the extending portion 413 and 414, for example, a circular arc portion 412a, the winding connecting portion 411 from 412b 30 to 60% of the distance _{L 2} to the direction of the distal end.

端子部４１ａの巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとの接続方法は、巻線接続部４１１にＵ相の巻線３２Ｕの一方の端部３２１Ｕを挿通させる挿通工程（図６（ａ）参照）と、巻線接続部４１１を第１のバスリング４１の周方向に押圧して巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとが接触するように巻線接続部４１１を変形させる変形工程（図６（ｂ）参照）と、巻線接続部４１１に通電して巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとを溶着する溶着工程（図６（ｄ）参照）とを有する。 The connection method between the winding connection portion 411 of the terminal portion 41a and the one end portion 321U of the U-phase winding 32U is to insert the one end portion 321U of the U-phase winding 32U into the winding connection portion 411. The step (refer to FIG. 6A) and the winding connection portion 411 are pressed in the circumferential direction of the first bus ring 41 so that the winding connection portion 411 and one end portion 321U of the U-phase winding 32U are A deformation step (see FIG. 6B) for deforming the winding connection portion 411 so as to come into contact with the winding connection portion 411 and one end portion of the winding connection portion 411 and the U-phase winding 32U And a welding step (see FIG. 6D) for welding 321U.

図６（ｂ）に示すように、変形工程では、巻線接続部４１１の開口４１１ａの開口幅ｄがＵ相の巻線３２Ｕの素線３２０の太さよりも狭くなるように、一対の電極１６，１７で巻線接続部４１１を挟んで図６（ｂ）の矢印の方向（バスリングの周方向）に向かって押圧する。 As shown in FIG. 6B, in the deformation process, the pair of electrodes 16 is formed so that the opening width d of the opening 411a of the winding connection portion 411 is narrower than the thickness of the strand 320 of the U-phase winding 32U. , 17 with the winding connection portion 411 interposed therebetween, and is pressed toward the direction of the arrow in FIG. 6B (the circumferential direction of the bus ring).

本実施の形態では、図６（ｂ）及び図６（ｄ）に示すように、開口４１１ａの開口幅ｄと一対の延在部４１３，４１４の対向面４１３ａ，４１４ａ間の距離とが等しく形成されている。したがって、変形工程によって、一対の延在部４１３，４１４の対向面４１３ａ，４１４ａ間の距離は、Ｕ相の巻線３２Ｕの素線３２０の太さ寸法よりも短い距離まで近づく。 In the present embodiment, as shown in FIGS. 6B and 6D, the opening width d of the opening 411a and the distance between the opposing surfaces 413a and 414a of the pair of extending portions 413 and 414 are formed to be equal. Has been. Therefore, the distance between the opposing surfaces 413a and 414a of the pair of extending portions 413 and 414 approaches the distance shorter than the thickness of the strand 320 of the U-phase winding 32U by the deformation process.

巻線接続部４１１のＵ相の巻線３２Ｕに面する面に平坦面４１１ｄが形成されているので、図６（ｃ）に示すように、巻線３２Ｕと巻線接続部４１１の平坦面４１１ｄとの接触面積が断面が円形の場合と比べて増やすことができる。 Since the flat surface 411d is formed on the surface of the winding connection portion 411 facing the U-phase winding 32U, as shown in FIG. 6C, the flat surface 411d of the winding 32U and the winding connection portion 411 is formed. The contact area can be increased compared to the case where the cross section is circular.

図６（ｄ）に示すように、溶着工程では、巻線接続部４１１が加圧された状態で一対の電極１１，１２により巻線接続部４１１に電流を流し、巻線接続部４１１とＵ相の巻線３２Ｕの一方の端部３２１Ｕとを溶着させて電気的に接続させる。この溶着工程では、例えばヒュージングによる溶接が用いられる。 As shown in FIG. 6D, in the welding process, a current is passed through the winding connection portion 411 by the pair of electrodes 11 and 12 while the winding connection portion 411 is pressurized, and the winding connection portion 411 and U The one end 321U of the phase winding 32U is welded and electrically connected. In this welding process, for example, welding by fusing is used.

以上より、電動機１は、巻線接続部４１１の開口４１１ａの開口幅ｄがＵ相の巻線３２Ｕの素線３２０の太さよりも狭い状態で、巻線接続部４１１とＵ相の巻線３２Ｕの端部３２１Ｕとが電気的に接続される。 As described above, in the electric motor 1, the winding connection portion 411 and the U-phase winding 32 U are formed in a state where the opening width d of the opening 411 a of the winding connection portion 411 is narrower than the thickness of the strand 320 of the U-phase winding 32 U. The end portion 321U is electrically connected.

（実施の形態の作用及び効果）
以上説明した本実施の形態によれば、以下のような作用及び効果が得られる。 (Operation and effect of the embodiment)
According to the present embodiment described above, the following operations and effects can be obtained.

（１）バスリング形成工程において、巻線接続部４１１の巻線３２に面する面に平坦面４１１ｄを形成するため、巻線３２と巻線接続部４１１の平坦面４１１ｄとの接触面積を、断面が円形の巻線接続部の場合と比べて増やすことができる。これにより、素線３２０同士及び巻線３２と巻線接続部４１１との間の接続を確実に行うことができる。 (1) In the bus ring forming step, in order to form the flat surface 411d on the surface facing the winding 32 of the winding connection portion 411, the contact area between the winding 32 and the flat surface 411d of the winding connection portion 411 is This can be increased compared to the case of a winding connection portion having a circular cross section. Thereby, the connection between the strands 320 and between the winding 32 and the winding connection portion 411 can be reliably performed.

（２）変形工程において、巻線接続部４１１の開口４１１ａの開口幅ｄが巻線３２の太さよりも狭くなるように巻線接続部４１１を加圧するため、溶着工程の際に巻線３２が開口４１１ａを介して巻線接続部４１１から抜け出すことがなく、巻線接続部４１１と巻線３２の一方の端部３２１との接続を確実に行うことができ、作業効率の向上につながる。 (2) In the deformation step, the winding connection portion 411 is pressurized so that the opening width d of the opening 411a of the winding connection portion 411 is narrower than the thickness of the winding 32. The winding connection part 411 and the one end 321 of the winding 32 can be reliably connected without coming out of the winding connection part 411 through the opening 411a, which leads to an improvement in work efficiency.

（３）バスリング形成工程では、巻線３２との接触面を平坦面４１１ｄに加工した後に、巻線絶縁部４１１を一箇所に開口４１１ａを有する環状に形成するので、平坦面４１１ｄの加工を容易に精度よく行うことができる。 (3) In the bus ring forming step, the contact surface with the winding 32 is processed into the flat surface 411d, and then the winding insulating portion 411 is formed in an annular shape having an opening 411a at one location. Therefore, the flat surface 411d is processed. It can be done easily and accurately.

（４）第１乃至第３のバスリング４１〜４３の複数の円弧部４１２，４２２，４３２は、少なくとも一部が絶縁体４００ｂで被覆されているので、第１乃至第３のバスリング４１〜４３のそれぞれの中心導体４００ａ間の沿面距離が長くなり、絶縁性を高めることができる。つまり、中心導体４００ａが断面円形状であることによって、中心導体４００ａを絶縁体４００ｂによって被覆した絶縁電線４００を容易に得ることができ、この絶縁電線４００の中心導体４００ａの屈曲により形成される巻線接続部４１１の巻線３２との接触面を平坦面４１１ｄとして第１乃至第３のバスリング４１〜４３を形成することにより、絶縁性が高められ、かつ巻線３２と巻線接続部４１１との間の接続の確実性が高められた電動機１を容易に製造することができる。 (4) Since the plurality of arc portions 412 422 432 of the first to third bus rings 41 to 43 are at least partially covered with the insulator 400b, the first to third bus rings 41 to 41 are covered. The creepage distance between the 43 central conductors 400a becomes longer, and the insulation can be improved. That is, since the center conductor 400a has a circular cross section, the insulated wire 400 in which the center conductor 400a is covered with the insulator 400b can be easily obtained, and the winding formed by the bending of the center conductor 400a of the insulated wire 400. By forming the first to third bus rings 41 to 43 with the contact surface of the wire connection portion 411 with the winding 32 as a flat surface 411d, the insulation is improved, and the winding 32 and the winding connection portion 411 are formed. Can be easily manufactured.

（実施の形態のまとめ）
次に、以上説明した実施の形態から把握される技術思想について、実施の形態における符号等を援用して記載する。ただし、以下の記載における各符号は、特許請求の範囲における構成要素を実施の形態に具体的に示した部材等に限定するものではない。 (Summary of embodiment)
Next, the technical idea grasped from the embodiment described above will be described with reference to the reference numerals in the embodiment. However, each reference numeral in the following description does not limit the constituent elements in the claims to members or the like specifically shown in the embodiment.

［１］環状に配置された複数の磁極を有する磁性体コア（３１）に、複数の素線（３２０）を束ねて形成された巻線（３２）を前記複数の磁極ごとに巻き回してなるステータ（３）と、前記ステータ（３）に対して回転するロータ（２）と、前記ステータ（３）と同心状に配置され、前記巻線（３２）の端部が接続される複数の環状のバスリング（４１〜４３）とを備えた電動機（１）の製造方法であって、前記バスリング（４１〜４３）の素材となる断面円形状の導体線（中心導体４００ａ）を塑性変形させ、前記巻線（３２）の端部を挟んで向かい合う前記巻線（３２）との接触面が平坦面（４１１ｄ）に加工された巻線接続部（４１１）を形成するバスリング形成工程と、前記バスリング（４１）の前記巻線接続部（４１１）に前記巻線（３２）の端部を挿通させる挿通工程と、前記巻線接続部（４１１）を前記バスリング（４１）の周方向に押圧して前記平坦面（４１１ｄ）と前記巻線（３２）の端部とが接触するように前記巻線接続部（４１１）を変形させる変形工程と、前記巻線接続部（４１１）が変形された状態で前記巻線接続部（４１１）に通電し、前記巻線接続部（４１１）と前記巻線（３２）の端部とを溶着する溶着工程とを有する、電動機（１）の製造方法。 [1] A winding (32) formed by bundling a plurality of strands (320) around a magnetic core (31) having a plurality of magnetic poles arranged in an annular shape is wound for each of the plurality of magnetic poles. A stator (3), a rotor (2) rotating with respect to the stator (3), and a plurality of annular members arranged concentrically with the stator (3) and connected to an end of the winding (32) A method of manufacturing an electric motor (1) having a bus ring (41-43), wherein a conductor wire (center conductor 400a) having a circular cross section as a material of the bus ring (41-43) is plastically deformed. A bus ring forming step of forming a winding connection portion (411) in which a contact surface with the winding (32) facing each other across an end portion of the winding (32) is processed into a flat surface (411d); The winding is connected to the winding connection part (411) of the bus ring (41). An insertion step of inserting the end of (32), and the end of the flat surface (411d) and the end of the winding (32) by pressing the winding connecting portion (411) in the circumferential direction of the bus ring (41). A step of deforming the winding connection portion (411) so that the winding contact portion is in contact with the coil connection portion (411), and energizing the winding connection portion (411) in a state where the winding connection portion (411) is deformed. The manufacturing method of an electric motor (1) which has a welding process of welding a wire connection part (411) and the edge part of the said coil | winding (32).

［２］前記バスリング形成工程では、前記巻線接続部（４１１）を、一箇所に開口（４１１ａ）を有する環状に形成し、前記変形工程では、前記開口（４１１ａ）の開口幅（ｄ）が前記素線（３２０）の太さよりも狭くなるように前記巻線接続部（４１１）を変形させる、前記［１］に記載の電動機（１）の製造方法。 [2] In the bus ring forming step, the winding connection portion (411) is formed in an annular shape having an opening (411a) at one location, and in the deformation step, the opening width (d) of the opening (411a). The method for manufacturing the electric motor (1) according to the above [1], wherein the winding connection portion (411) is deformed so that is smaller than a thickness of the element wire (320).

［３］前記バスリング形成工程では、前記巻線（３２）との接触面を平坦面（４１１ｄ）に加工した後に、前記巻線接続部（４１１）を一箇所に開口（４１１ａ）を有する環状に形成する、前記［２］に記載の電動機（１）の製造方法。 [3] In the bus ring forming step, the contact surface with the winding (32) is processed into a flat surface (411d), and then the winding connection portion (411) has an opening (411a) at one place. The manufacturing method of the electric motor (1) according to [2], wherein the electric motor (1) is formed.

［４］前記導体線（４００ａ）は、絶縁体（４００ｂ）で被覆された絶縁電線（４００）の芯線であり、前記バスリング形成工程は、前記巻線接続部（４１１）となる部分の前記絶縁体（４００ｂ）を除去する工程を含む、前記［１］乃至［３］の何れか１つに記載の電動機（１）の製造方法。 [4] The conductor wire (400a) is a core wire of an insulated wire (400) covered with an insulator (400b), and the bus ring forming step includes the step of forming a portion of the wire connection portion (411). The method for manufacturing an electric motor (1) according to any one of [1] to [3], including a step of removing the insulator (400b).

［５］複数の素線（３２０）を束ねて形成された巻線（３２）が接続される複数の巻線接続部（４１１）、及び前記複数の巻線接続部（４１１）の間の複数の円弧部（４１２）を有し、前記巻線（３２）を磁性体コア（３１）に巻き回してなる電動機のステータ（３）と同心状に配置される電動機用バスリング（４１）であって、前記複数の円弧部（４１２）は、少なくとも一部が絶縁体（４００ｂ）で被覆された断面円形状の芯線（４００ａ）を円弧状に湾曲してなり、前記複数の巻線接続部（４１１）は、前記巻線（３２）の端部を挟んで向かい合う前記巻線（３２）との接触面が平坦面（４１１ｄ）に加工されている、電動機用バスリング（４１）。 [5] A plurality of winding connection portions (411) to which a winding (32) formed by bundling a plurality of strands (320) is connected, and a plurality of winding connections (411) between the plurality of winding connection portions (411). The motor bus ring (41) is arranged concentrically with the stator (3) of the electric motor having a circular arc portion (412) and the winding (32) wound around the magnetic core (31). The plurality of arc portions (412) are formed by curving a circular core wire (400a) having a circular cross section, at least a portion of which is covered with an insulator (400b), and the plurality of winding connection portions ( 411) is a motor bus ring (41) in which the contact surface with the winding (32) facing each other across the end of the winding (32) is processed into a flat surface (411d).

（付記）
以上、本発明の実施の形態を説明したが、上記に記載した実施の形態は特許請求の範囲に係る発明を限定するものではない。また、実施の形態の中で説明した特徴の組合せの全てが発明の課題を解決するための手段に必須であるとは限らない点に留意すべきである。 (Appendix)
While the embodiments of the present invention have been described above, the embodiments described above do not limit the invention according to the claims. In addition, it should be noted that not all the combinations of features described in the embodiments are essential to the means for solving the problems of the invention.

１…電動機
２…ロータ
３…ステータ
３１，３１Ｕ，３１Ｖ，３１Ｗ…磁性体コア
３２，３２Ｕ，３２Ｖ，３２Ｗ…巻線
４１〜４４…第１乃至第４のバスリング
３２０…素線
４１１，４２１，４３１…巻線接続部
４１１ａ…開口
４１１ｄ…平坦面、
４１２，４２２，４３２…円弧部 DESCRIPTION OF SYMBOLS 1 ... Electric motor 2 ... Rotor 3 ... Stator 31, 31U, 31V, 31W ... Magnetic-material core 32, 32U, 32V, 32W ... Winding | winding 41-44 ... 1st thru | or 4th bus ring 320 ... Wire 411,421 431 ... Winding connection part 411a ... Opening 411d ... Flat surface,
412, 422, 432 ... arc portions

Claims

A stator formed by winding a winding formed by bundling a plurality of strands around a magnetic core having a plurality of magnetic poles arranged in a ring for each of the plurality of magnetic poles, and a rotor rotating with respect to the stator A method of manufacturing an electric motor comprising a plurality of annular bus rings arranged concentrically with the stator and connected to ends of the windings,
A bus forming a winding connection portion in which a conductor wire having a circular cross section as a material of the bus ring is plastically deformed and a contact surface with the winding facing each other across an end of the winding is processed into a flat surface. A ring forming step;
An insertion step of inserting an end portion of the winding into the winding connection portion of the bus ring;
A deformation step of deforming the winding connection portion so that the flat surface and the end of the winding are in contact with each other by pressing the winding connection portion in the circumferential direction of the bus ring;
Energizing the winding connection portion in a state where the winding connection portion is deformed, and welding the winding connection portion and an end portion of the winding.
A method for manufacturing an electric motor.

In the bus ring forming step, the winding connection part is formed in an annular shape having an opening in one place,
In the deformation step, the winding connection portion is deformed so that an opening width of the opening is narrower than a thickness of the strand.
The manufacturing method of the electric motor of Claim 1.

In the bus ring forming step, after processing the contact surface with the winding into a flat surface, the winding connection portion is formed in an annular shape having an opening in one place.
A method for manufacturing the electric motor according to claim 2.

The conductor wire is a core wire of an insulated wire covered with an insulator,
The bus ring forming step includes a step of removing the insulator in a portion to be the winding connection portion.
The method for manufacturing an electric motor according to any one of claims 1 to 3.

A plurality of winding connection portions to which windings formed by bundling a plurality of strands are connected, and a plurality of arc portions between the plurality of winding connection portions, and the windings as magnetic cores A motor bus ring arranged concentrically with a stator of a wound motor,
The plurality of arc portions are formed by curving a circular core wire having a circular cross section at least partially covered with an insulator,
The plurality of winding connection portions, the contact surface with the winding facing each other across the end of the winding is processed into a flat surface,
Bus ring for electric motor.