WO2022038746A1

WO2022038746A1 - Welding jig and method for manufacturing rotating electrical machine

Info

Publication number: WO2022038746A1
Application number: PCT/JP2020/031471
Authority: WO
Inventors: 昌和黄川田; 哲男坂井; 光夫佐々木
Original assignee: 株式会社東芝; 東芝インフラシステムズ株式会社
Priority date: 2020-08-20
Filing date: 2020-08-20
Publication date: 2022-02-24
Also published as: JPWO2022038746A1

Abstract

This welding jig according to one embodiment is configured so that one end section of a first segment and one end section of a second segment that is adjacent to the first segment are retained in an overlapping state. The welding jig is provided with: a first ring-shaped member that is ring-shaped and can come into contact with the one end section of the first segment; and a second ring-shaped member that is ring-shaped, is disposed on the outer side of the first ring-shaped member with the first segment and the second segment sandwiched therebetween, and can come into contact with the one end section of the second segment. The first ring-shaped member is provided with a first recessed section that can come into contact with the one end section of the first segment, and/or the second ring-shaped member is provided with a second recessed section that can come into contact with the one end section of the second segment.

Description

How to manufacture welding jigs and rotary electric machines

An embodiment of the present invention relates to a welding jig and a method for manufacturing a rotary electric machine.

For example, a rotating electric machine such as a motor or a generator is provided with a coil wound around a core. Since the coil is formed by winding a copper wire a plurality of times, the flexibility is poor, and if the formed coil is inserted into the slot of the core, the workability is significantly deteriorated. Therefore, after inserting a plurality of segments into the slots, the end faces of the segments and the end faces of the segments adjacent thereto are irradiated with laser light to form a coil wound around the core. In this case, if there is a gap between the end faces of the segment, the weld cross-sectional area may become small, or the laser beam may leak from the gap between the end faces.

Therefore, a first annular member provided with a plurality of first insertion windows and a second annular member provided on the first annular member and provided with a plurality of second insertion windows are provided. Welding jigs to have have been proposed. In this welding jig, when the first annular member and the second annular member provided so as to be stacked in the vertical direction are rotated in opposite directions, the end portion of the segment becomes the first insertion window and the second insertion. You are invited to the inside of the window. Since each of the first insertion window and the second insertion window is provided with an inclined surface, the end portion of the segment provided at a position overlapping in the circumferential direction of the core due to the inclined surface invading from the circumferential direction of the core. Are pushed in directions close to each other in the radial direction of the core.

However, when the end of the segment is pushed by the inclined surface, the force in the direction in which the ends of the segment are brought close to each other becomes small. Therefore, a gap is likely to occur between the end faces of the segments, and the welding strength may decrease. Further, since the end portion of the segment and the inclined surface of the welding jig are in point contact, it becomes difficult for heat during welding to be transferred to the jig. Therefore, the heat during welding is easily transferred to the insulating film on the outer surface of the segment, and the insulating film may be damaged.
Therefore, it has been desired to develop a technique capable of improving the quality of the welded portion.

Japanese Patent No. 4114588

An object to be solved by the present invention is to provide a welding jig capable of improving the quality of a welded portion and a method for manufacturing a rotary electric machine.

The welding jig according to the embodiment is a welding jig that holds one end of the first segment and one end of the second segment adjacent to the first segment in an overlapped state. Is. The welding jig exhibits an annular shape and exhibits a first annular member that can contact one end of the first segment and an annular shape that sandwiches the first segment and the second segment. It has a second annular member provided outside the first annular member and accessible to one end of the second segment. The first annular member has a first recess accessible to one end of the first segment, and the second annular member is at one end of the second segment. At least one of having a second recess that can be contacted.

It is a schematic perspective view for exemplifying a stator. It is a schematic diagram for exemplifying a segment before being attached to a core. It is a schematic diagram for exemplifying a coil attached to a core. It is a schematic perspective view for exemplifying a welding jig. It is a schematic enlarged plan view of the part A in FIG. It is a schematic perspective view for exemplifying the attachment of a welding jig. It is a schematic plan view of the part B in FIG. It is a schematic cross-sectional view for exemplifying the contact between an annular member and an end portion of a segment. It is a schematic perspective view for exemplifying the welding jig which concerns on other embodiment. It is a schematic plan view for exemplifying the welding jig which concerns on other embodiment. It is a schematic enlarged plan view of the part C in FIG. It is a schematic perspective view for exemplifying the attachment of a welding jig. It is a schematic perspective view for exemplifying the welding jig which concerns on other embodiment. It is a schematic perspective view for exemplifying the welding jig which concerns on other embodiment. It is a schematic perspective view for exemplifying the welding jig which concerns on other embodiment. (A) is a schematic cross-sectional view for exemplifying a curved surface. (B) is a schematic cross-sectional view for exemplifying a slope. (A) and (b) are schematic perspective views for exemplifying a process of welding the ends of a plurality of segments. (A) and (b) are schematic perspective views for exemplifying a process of welding the ends of a plurality of segments. (A) and (b) are schematic perspective views for exemplifying a process of welding the ends of a plurality of segments. (A) and (b) are schematic perspective views for exemplifying a process of welding the ends of a plurality of segments. It is a schematic perspective view for exemplifying the process of welding the end portions of a plurality of segments.

The welding jig according to the present embodiment can be used, for example, when forming a coil provided in a rotary electric machine such as a motor or a generator. In the following, the welding jig used in the manufacture of the stator will be described as an example, but the welding jig according to the present embodiment can also be used in the manufacture of the rotor, for example.

Hereinafter, embodiments will be illustrated with reference to the drawings. In each drawing, similar components are designated by the same reference numerals and detailed description thereof will be omitted as appropriate.
(Stator 1)
First, the stator 1 manufactured by the method for manufacturing a rotary electric machine according to the present embodiment will be described.
FIG. 1 is a schematic perspective view for illustrating the stator 1.
As shown in FIG. 1, the stator 1 is provided with a core 2 and a coil 3.

The core 2 may have a plurality of annular magnetic members laminated in the axial direction of the stator 1 (Z direction in FIG. 1). The magnetic member can be formed from, for example, an electromagnetic steel sheet (silicon steel sheet). The core 2 has a yoke 21 and a plurality of teeth 22. The yoke 21 has a cylindrical shape and is located on the outer peripheral side of the core 2. The plurality of teeth 22 are provided on the inner peripheral surface of the yoke 21 at equal intervals. Each of the plurality of teeth 22 projects from the inner peripheral surface of the yoke 21 toward the center of the core 2 and has a form extending in the axial direction of the stator 1. Further, the groove provided between the teeth 22 and the teeth 22 becomes the slot 23. The shape, number, and size of the teeth 22 are not limited to those illustrated, and can be appropriately changed according to the application, size, specifications, and the like of the rotary electric machine provided with the stator 1.

The coil 3 includes a plurality of segments 31.
FIG. 2 is a schematic diagram for illustrating the segment 31 before being attached to the core 2.
As shown in FIG. 2, the segment 31 has a conductor portion 31a and an insulating film 31b. The external shape of the conductor portion 31a before being attached to the core 2 can be substantially U-shaped. The conductor portion 31a can be formed of a material having high conductivity. The conductor portion 31a can be formed from, for example, so-called pure copper or a material containing copper as a main component. Further, the conductor portion 31a can be formed from a flat wire. A flat wire is a wire rod having a quadrangular cross section.

The insulating film 31b covers the outer surface of the conductor portion 31a. However, the insulating film 31b is not provided in the vicinity of the ends on both sides of the conductor portion 31a, and the conductor portion 31a is exposed. The insulating film 31b contains, for example, enamel and the like.

FIG. 3 is a schematic diagram for illustrating the coil 3 attached to the core 2.
As shown in FIG. 3, the segment 31 is provided inside the slot 23. Both ends of the segment 31 project from one end face of the core 2. The portion of the segment 31 protruding from one end face of the core 2 extends in a direction approaching the adjacent segment 31.

Further, the vicinity of the portion of the segment 31 where the conductor portion 31a is exposed extends in the axial direction of the core 2 (Z direction in FIG. 3). In the circumferential direction of the core 2 (direction around the central axis of the core 2), the portion of the segment 31 where the conductor portion 31a is exposed is overlapped with the portion of the adjacent segment 31 where the conductor portion 31a is exposed. ing.

The end faces of the conductor portion 31a are irradiated with laser light, and the end faces are laser welded to each other. Therefore, since the plurality of segments 31 are electrically connected via the welded portion 31c, the coil 3 is configured.

In this case, a plurality of coils 3 can be provided side by side in the radial direction of the core 2 (the direction that passes through the central axis of the core 2 and is orthogonal to the Z direction). For example, as shown in FIG. 1, a U-phase coil 3, a V-phase coil 3, and a W-phase coil 3 can be provided side by side in the radial direction of the core 2. The appearance shape, number, size, etc. of the coil 3 and the segment 31 are not limited to those illustrated, and may be appropriately changed according to the application, size, specifications, etc. of the rotary electric machine provided with the stator 1. can do. For example, as shown in FIG. 6 described later, four coils 3 may be provided side by side in the radial direction of the core 2.

Here, when the end faces of the conductor portion 31a are irradiated with laser light, if there is a gap between the end faces, the weld cross-sectional area may become small and the welding strength may decrease. Further, if the gap is large, when the laser light is scanned, the laser light may be applied to the member below the stator 1 through the gap.

Therefore, in the method for manufacturing the stator according to the present embodiment, when laser welding is performed, the welding jig 100 is used to bring the end faces of the conductor portions 31a into contact with each other.

(Welding jig 100)
Next, the welding jig 100 according to the present embodiment will be described. The welding jig 100 has one end of a segment 31 (corresponding to an example of the first segment) and one end of a segment 31 (corresponding to an example of the second segment) adjacent to the segment 31. And can be held in a superposed state.
FIG. 4 is a schematic perspective view for illustrating the welding jig 100.
FIG. 5 is a schematic enlarged plan view of part A in FIG.
FIG. 6 is a schematic perspective view for exemplifying the attachment of the welding jig 100.
FIG. 7 is a schematic plan view of part B in FIG.
The welding jig 100 shown in FIGS. 4 to 7 is used when forming four coils 3 arranged substantially concentrically.

As shown in FIG. 4, the welding jig 100 includes an annular member 101 (corresponding to an example of a first annular member), an annular member 102 (corresponding to an example of a second annular member), an annular member 103, and an annular member. It has a member 104 and an annular member 105. Since the welding jig 100 is used when forming four coils, it has five annular members, but the number of annular members is larger than the number of coils 3 arranged substantially concentrically. You can add one more.

As shown in FIG. 5, the annular member 101 exhibits an annular shape (for example, a substantially annular shape). The outer surface side of the annular member 101 can contact one end of a plurality of segments 31 arranged on the innermost side of the core 2. A plurality of recesses 101a1 (corresponding to an example of the first recess) may be provided on the outer side surface 101a of the annular member 101. The plurality of recesses 101a1 can be provided at substantially equal intervals. The number of the plurality of recesses 101a1 can be the same as the number of slots 23 provided in the core 2.

The annular member 102 exhibits an annular shape (for example, a substantially circular annular shape). The annular member 102 is provided on the outside of the annular member 101 with the plurality of segments 31 arranged on the innermost side of the core 2 interposed therebetween. The inner side surface side of the annular member 102 can contact the other end of the plurality of segments 31 arranged on the innermost side of the core 2. The outer surface side of the annular member 102 can come into contact with one end of a plurality of segments 31 that are secondarily arranged from the inside of the core 2. A plurality of recesses 102a1 may be provided on the outer side surface 102a of the annular member 102. The plurality of recesses 102a1 can be provided at substantially equal intervals. The number of recesses 102a1 can be the same as the number of recesses 101a1.

The annular member 103 exhibits an annular shape (for example, a substantially circular annular shape). The annular member 103 is provided on the outside of the annular member 102 with the plurality of segments 31 secondarily arranged from the inside of the core 2 interposed therebetween. The inner side surface side of the annular member 103 can contact the other end of the plurality of segments 31 arranged second from the inside of the core 2. The outer surface side of the annular member 103 can come into contact with one end of a plurality of segments 31 arranged third from the inside of the core 2. A plurality of recesses 103a1 can be provided on the outer side surface 103a of the annular member 103. The plurality of recesses 103a1 can be provided at substantially equal intervals. The number of recesses 103a1 can be the same as the number of recesses 101a1.

The annular member 104 exhibits an annular shape (for example, a substantially circular annular shape). The annular member 104 is provided on the outside of the annular member 103 with the plurality of segments 31 arranged third from the inside of the core 2 interposed therebetween. The inner side surface side of the annular member 104 can contact the other end of the plurality of segments 31 arranged third from the inside of the core 2. The outer surface side of the annular member 103 can contact one end of a plurality of segments 31 arranged fourth from the inside of the core 2. A plurality of recesses 104a1 may be provided on the outer side surface 104a of the annular member 104. The plurality of recesses 104a1 can be provided at substantially equal intervals. The number of recesses 104a1 can be the same as the number of recesses 101a1.

The annular member 105 exhibits an annular shape (for example, a substantially circular annular shape). The annular member 105 is provided on the outside of the annular member 104 with the plurality of segments 31 arranged fourth from the inside of the core 2 interposed therebetween. The inner side surface side of the annular member 105 can contact the other end of the plurality of segments 31 arranged fourth from the inside of the core 2.

When viewed from the direction along the central axis of the core 2, a set of recesses 101a1 to 104a1 can be arranged on a line passing through the center of the core 2.
The annular members 101 to 105 are preferably formed of a material having a certain degree of rigidity and high thermal conductivity. The annular members 101 to 105 can be formed of, for example, a metal such as stainless steel.

As shown in FIGS. 6 and 7, when the welding jig 100 is attached to the ends of the plurality of segments 31 attached to the slots 23 of the core 2, the annular member 101 is arranged on the innermost side of the core 2. It can be provided inside a plurality of segments 31. The annular member 102 can be provided between the plurality of segments 31 arranged on the innermost side of the core 2 and the plurality of segments 31 arranged second from the inside of the core 2. The annular member 103 can be provided between the plurality of segments 31 arranged second from the inside of the core 2 and the plurality of segments 31 arranged third from the inside of the core 2. The annular member 104 can be provided between the plurality of segments 31 arranged third from the inside of the core 2 and the plurality of segments 31 arranged fourth from the inside of the core 2. The annular member 105 can be provided on the outside of the plurality of segments 31 arranged fourth from the inside of the core 2.

At this time, one end of a plurality of segments 31 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted inside the recess 101a1 of the annular member 101. The inner side surface 102b of the annular member 102 is in contact with the other end of the plurality of segments 31 arranged on the innermost side of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed).

Further, one end of a plurality of segments 31 arranged second from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted into the inside of the recess 102a1 of the annular member 102. The other end of the plurality of segments 31 arranged second from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) comes into contact with the inner side surface 103b of the annular member 103.

Further, inside the recess 103a1 of the annular member 103, one end of a plurality of segments 31 arranged third from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted. The other end of the plurality of segments 31 arranged third from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) comes into contact with the inner side surface 104b of the annular member 104.

Further, one end of a plurality of segments 31 arranged fourth from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted into the recess 104a1 of the annular member 104. The other end of the plurality of segments 31 arranged fourth from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) comes into contact with the inner side surface 105b of the annular member 105.

When the annular members 101 to 105 are attached, the annular members arranged inside the plurality of segments 31 arranged in the circumferential direction of the core 2 move one end of each of the plurality of segments 31 to the outside of the core 2. Press toward. An annular member arranged outside the plurality of segments 31 arranged in the circumferential direction of the core 2 presses the other end of each of the plurality of segments 31 toward the inside of the core 2.

FIG. 8 is a schematic cross-sectional view for illustrating the contact between the annular member and the end of the segment. In FIG. 8, the contact between the

annular members

101 and 102 and the end portion of the segment 31 will be described as an example, but the same can be applied to the other annular members 103 to 105.

As shown in FIG. 8, the portion of the segment 31 where the conductor portion 31a is exposed comes into contact with the bottom surface of the recess 101a1 of the annular member 101. In this case, since the bottom surface of the recess 101a1 is a flat surface, the side surface of the conductor portion 31a having a substantially quadrangular cross-sectional shape and the bottom surface of the recess 101a1 can be in line contact or surface contact. Further, the side surface 102b of the annular member 102 is in contact with the portion of the adjacent segment 31 where the conductor portion 31a is exposed.

Further, the annular member 101 is provided at a position separated from the end surface of one end of the segment 31. The annular member 102 is provided at a position separated from the end surface of one end of the segment adjacent to the segment 31. When performing laser welding, the end faces of the abutted segments 31 are irradiated with laser light.

In this case, if the distance L between the end surface of the segment 31 and the upper surface of the

annular members

101 and 102 is small, the end surface of the segment 31 and the upper surface of the

annular members

101 and 102 may be joined. Therefore, the distance L is preferably 2 mm or more.

According to the present embodiment, as shown in FIG. 8, one of the segments 31 is formed by the annular member provided inside the plurality of segments 31 arranged in the circumferential direction of the core 2 and the annular member provided outside. And the other end of the segment 31 adjacent to the segment 31 are pushed in a direction close to each other. Therefore, since the force in the direction in which the ends of the segments 31 are brought close to each other can be increased, it is possible to suppress the formation of a gap between the end faces of the segments 31. Further, since the end portion of the segment 31 is provided inside the recess of the annular member, it is possible to suppress the position of the end portion of the segment 31 from being displaced.

Further, since the end portion of the segment 31 (the portion of the segment 31 where the conductor portion 31a is exposed) is in line contact or surface contact with the bottom surface of the concave portion of the annular member, the heat generated by laser welding is transferred to the annular member. It becomes easier to convey. Therefore, the heat transferred to the insulating film 31b containing enamel and the like can be reduced, so that damage to the insulating film 31b can be suppressed.
As described above, if the welding jig 100 according to the present embodiment is used, the quality of the welded portion can be improved.

Furthermore, if the annular members 101 to 105 are made of a material having high thermal conductivity, the heat generated by laser welding is more easily transferred to the annular members 101 to 105. Therefore, it becomes easier to prevent the insulating film 31b from being damaged.

FIG. 9 is a schematic perspective view for exemplifying the welding jig 110 according to another embodiment.
As shown in FIG. 9, the welding jig 110 has an annular member 111, an annular member 112, an annular member 113, an annular member 114, and an annular member 115.
When the welding jig 110 is attached to the ends of the plurality of segments 31 attached to the slots 23 of the core 2, the annular member 111 may be provided inside the plurality of segments 31 arranged on the innermost side of the core 2. can. The annular member 112 can be provided between the plurality of segments 31 arranged on the innermost side of the core 2 and the plurality of segments 31 arranged second from the inside of the core 2. The annular member 113 can be provided between the plurality of segments 31 arranged second from the inside of the core 2 and the plurality of segments 31 arranged third from the inside of the core 2. The annular member 114 can be provided between the plurality of segments 31 arranged third from the inside of the core 2 and the plurality of segments 31 arranged fourth from the inside of the core 2. The annular member 115 can be provided on the outside of the plurality of segments 31 arranged fourth from the inside of the core 2.

The annular member 111 may be obtained by further adding a plurality of holes 111a (corresponding to an example of the first hole) to the above-mentioned annular member 101. The hole 111a extends toward the annular member 102. The plurality of holes 111a penetrate between the outer side surface and the inner side surface of the annular member 111. The annular member 112 may be obtained by further adding a plurality of holes 112a (corresponding to an example of the second hole) to the above-mentioned annular member 102. The hole 112a faces the hole 111a. The plurality of holes 112a penetrate between the outer side surface and the inner side surface of the annular member 112. The annular member 113 may have a plurality of holes 113a added to the annular member 103 described above. The hole 113a extends toward the annular member 104. The plurality of holes 113a penetrate between the outer side surface and the inner side surface of the annular member 113. The annular member 114 may have a plurality of holes 114a added to the annular member 104 described above. The hole 114a extends toward the annular member 105. The plurality of holes 114a penetrate between the outer side surface and the inner side surface of the annular member 114. The annular member 115 may have a plurality of holes 115a added to the annular member 105 described above. The plurality of holes 115a penetrate between the outer side surface and the inner side surface of the annular member 115.

In the circumferential direction of the core 2, the holes 111a to 115a can be provided between one end of the segment 31 and the other end. Further, when viewed from a direction along the central axis of the core 2, a set of holes 111a to 115a can be arranged on a line passing through the center of the core 2. Bolts are inserted into a set of holes 111a to 115a, and by tightening the bolts with nuts, the force in the direction in which the ends of the segments 31 described above are brought close to each other can be further increased. The hole 111a or the hole 115a may be a female screw. For example, the inner wall of the hole 111a or the inner wall of the hole 115a may be threaded. By doing so, the bolt tightening work becomes easy.

If there are variations in the dimensions of the ends of the segment 31, there is a risk that gaps will occur between the end faces of the small ends. With the welding jig 110 according to the present embodiment, even if the dimensions of the end portions of the segments 31 vary, it becomes easy to bring the end faces of the segments 31 into contact with each other. Therefore, the quality of the welded portion can be further improved.

FIG. 10 is a schematic plan view for illustrating the welding jig 120 according to another embodiment.
FIG. 11 is a schematic enlarged plan view of part C in FIG.
FIG. 12 is a schematic perspective view for exemplifying the attachment of the welding jig 120.
As shown in FIGS. 10 and 11, the welding jig 120 has an annular member 101, an annular member 122, an annular member 123, an annular member 124, and an annular member 125.

The annular member 122 may have a plurality of recesses 102b1 further added to the inner side surface 102b of the annular member 102 described above. The annular member 123 may be formed by further adding a plurality of recesses 103b1 to the inner side surface 103b of the annular member 103 described above. The annular member 124 may be formed by further adding a plurality of recesses 104b1 to the inner side surface 104b of the annular member 104 described above. The annular member 125 may be formed by further adding a plurality of recesses 105b1 to the inner side surface 105b of the annular member 105 described above.

When viewed from the direction along the central axis of the core 2, a set of recesses 101a1 to 104a1 and 102b1 to 105b1 can be arranged on a line passing through the center of the core 2.

As shown in FIG. 12, when the welding jig 120 is attached to the ends of the plurality of segments 31 attached to the slots 23 of the core 2, the recesses 101a1 of the annular member 101 (in an example of the first recess). (Corresponding), one end of a plurality of segments 31 arranged on the innermost side of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted. Inside the recess 102b1 (corresponding to an example of the second recess) of the annular member 122, the other end of the plurality of segments 31 arranged on the innermost side of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is exposed. ) Is inserted.

Further, one end of a plurality of segments 31 arranged second from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted into the recess 102a1 of the annular member 122. Inside the recess 103b1 of the annular member 123, the other end of the plurality of segments 31 arranged second from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted.

Further, one end of a plurality of segments 31 arranged third from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted into the inside of the recess 103a1 of the annular member 123. Inside the recess 104b1 of the annular member 124, the other end of the plurality of segments 31 arranged third from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted.

Further, one end of a plurality of segments 31 arranged fourth from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted into the recess 104a1 of the annular member 124. Inside the recess 105b1 of the annular member 125, the other end of the plurality of segments 31 arranged fourth from the inside of the core 2 (the portion of the segment 31 where the conductor portion 31a is exposed) is inserted.

In the welding jig 120 according to the present embodiment, since the ends on both sides of the segment 31 are provided inside the recess, it is possible to further suppress the position of the end of the segment 31 from shifting. Further, since the ends on both sides of the segment 31 make line contact or surface contact with the bottom surface of the recess, the heat generated by laser welding is more easily transferred to the annular member. Therefore, the heat transferred to the insulating film 31b containing enamel and the like can be further reduced, so that it becomes easier to suppress damage to the insulating film 31b.

In the above description, an annular member having a recess only on the outer side surface or an annular member having a recess on the outer side surface and the inner side surface has been exemplified, but the annular member having a recess only on the inner side surface may be used. good.
That is, the annular member provided on the inside has a recess that can be contacted with one end of the segment 31, and the annular member provided on the outside contacts one end of the segment 31 adjacent to the segment 31. It may be at least one of having possible recesses.

FIG. 13 is a schematic perspective view for exemplifying the welding jig 220 according to another embodiment.
As shown in FIG. 13, the welding jig 220 has an annular member 101, an annular member 102, an annular member 103, an annular member 104, an annular member 105, and a cover 221. Further, the welding jig 220 may further have a nozzle 222.

As described above, the annular member 101 and the annular member 102 hold the ends of the plurality of segments 31 arranged on the innermost side of the core 2. The annular member 102 and the annular member 103 hold the ends of the plurality of segments 31 that are secondarily aligned from the inside of the core 2. The annular member 103 and the annular member 104 hold the ends of the plurality of segments 31 arranged third from the inside of the core 2. The annular member 104 and the annular member 105 hold the ends of the plurality of segments 31 that are fourth aligned from the inside of the core 2. Further, the end surface of the segment 31 is located at a position protruding from the upper surface of the annular members 101 to 105. Further, the end faces of the segments 31 adjacent to each other in the circumferential direction of the core are laser welded to each other.

Here, since laser welding is performed in the atmosphere, the quality of the welded part may deteriorate due to oxidation of the welded part or generation of blow holes. In this case, if the purge gas is supplied in the vicinity of the end portion of the segment 31, the quality of the welded portion can be maintained. However, since many ends of the segments 31 project from the upper surfaces of the annular members 101 to 105, it is difficult to evenly supply the purge gas to the ends of all the segments 31.

Therefore, the welding jig 220 is provided with a plurality of covers 221. The plurality of covers 221 have a plate shape and are provided on the annular members 101 to 105. The plurality of covers 221 extend in the radial direction of the core 2. The plurality of covers 221 are provided side by side in the circumferential direction of the core 2. When viewed from above the annular members 101 to 105, the ends of a plurality of segments 31 arranged in the radial direction of the core 2 are provided between the pair of covers 221. In this case, the end portions of the plurality of segments 31 arranged in the radial direction of the core 2 are exposed in the space between the pair of covers 221. The space between the pair of covers 221 can allow purge gas to flow. By doing so, it is possible to prevent the purge gas supplied between the pair of covers 221 from diffusing, so that it becomes easy to supply the purge gas to the ends of all the segments 31. Therefore, the quality of the welded portion can be improved.

The plurality of covers 221 can be formed from a metal such as stainless steel.
The purge gas can be, for example, nitrogen gas, an inert gas such as argon, or the like.

Further, the welding jig 220 may be further provided with a nozzle 222. For example, the nozzle 222 can be a tubular member extending in the circumferential direction of the core 2. The nozzle 222 may be provided with a supply port 222b for supplying purge gas to the internal space of the nozzle 222. A plurality of nozzle holes 222a communicating with the internal space of the nozzle 222 can be provided on the outer side surface of the nozzle 222. The nozzle hole 222a is provided at a position facing the space between the pair of covers 221. Therefore, the purge gas supplied from the supply port 222b to the internal space of the nozzle 222 can be supplied to the space between the pair of covers 221 via the nozzle holes 222a.

The nozzle 222 can be provided inside the annular member 101 or outside the annular member 105. In this case, as shown in FIG. 13, if the nozzle 222 is provided inside the annular member 101, it is possible to form a flow of purge gas from the inside to the outside of the core 2. Therefore, it becomes easy to discharge the gas and dust generated during welding to the outside of the core 2, so that the quality of the welded portion can be further improved.

FIG. 14 is a schematic perspective view for exemplifying the welding jig 320 according to another embodiment.
As shown in FIG. 14, the welding jig 320 has an annular member 101, an annular member 102, an annular member 103, an annular member 104, an annular member 105, a cover 221 and a lid 321. Further, the welding jig 320 may further have the above-mentioned nozzle 222.

The lid 321 can have a plate shape. The planar shape of the lid 321 can be annular (for example, substantially annular). The lid 321 is provided on a plurality of covers 221 provided side by side in the circumferential direction of the core 2. The lid 321 is provided with a plurality of holes 321a (corresponding to an example of the third hole) penetrating in the thickness direction. The hole 321a can be located above the end of the segment 31. That is, when viewed from above the annular members 101 to 105, the end face of one end of the segment 31 and the end face of one end of the segment 31 adjacent to the segment 31 are inside the hole 321a. It is provided. Therefore, the laser beam can be applied to the end face of the segment 31 through the hole 321a.

The space partitioned by the pair of covers 221 and the lid 321 serves as a flow path for the purge gas. By doing so, it is possible to prevent the purge gas supplied between the pair of covers 221 from diffusing above the covers 221. Therefore, the purge gas can be effectively used, and the consumption of the purge gas can be reduced. Further, since the purge with the purge gas can be performed more reliably, the quality of the welded portion can be further improved.
The lid 321 can be made of, for example, a metal such as stainless steel.

FIG. 15 is a schematic perspective view for exemplifying the welding jig 420 according to another embodiment.
As shown in FIG. 15, the welding jig 420 has an annular member 401, an annular member 402, an annular member 403, an annular member 404, and an annular member 405. The annular member 401, the annular member 402, the annular member 403, the annular member 404, and the annular member 405 can be formed of, for example, a metal such as stainless steel.

The annular member 401 has an annular portion 401a and a plurality of convex portions 401b. The annular portion 401a can be the same as the annular member 101 described above. That is, the annular member 401 may be the above-mentioned annular member 101 further provided with a plurality of convex portions 401b.

The plurality of convex portions 401b can be provided on the upper surface of the annular portion 401a. The plurality of convex portions 401b are provided side by side in the circumferential direction of the core 2. Between the pair of convex portions 401b, the ends of the plurality of segments 31 arranged on the innermost side of the core 2 are exposed. The convex portion 401b is provided with a hole 401b1 that penetrates the core 2 in the radial direction.

The annular member 402 has an annular portion 402a and a plurality of convex portions 402b. The annular portion 402a can be the same as the annular member 102 described above. That is, the annular member 402 may be provided with a plurality of convex portions 402b on the annular member 102 described above.

The plurality of convex portions 402b can be provided on the upper surface of the annular portion 402a. The plurality of convex portions 402b are provided side by side in the circumferential direction of the core 2. Between the pair of convex portions 402b, the ends of the plurality of segments 31 arranged second from the inside of the core 2 are exposed. The convex portion 402b is provided with a hole 402b1 that penetrates the core 2 in the radial direction.

The annular member 403 has an annular portion 403a and a plurality of convex portions 403b. The annular portion 403a can be the same as the annular member 103 described above. That is, the annular member 403 can be made by further providing a plurality of convex portions 403b on the annular member 103 described above.

The plurality of convex portions 403b can be provided on the upper surface of the annular portion 403a. The plurality of convex portions 403b are provided side by side in the circumferential direction of the core 2. Between the pair of convex portions 403b, the ends of the plurality of segments 31 arranged third from the inside of the core 2 are exposed. The convex portion 403b is provided with a hole 403b1 that penetrates the core 2 in the radial direction.

The annular member 404 has an annular portion 404a and a plurality of convex portions 404b. The annular portion 404a can be the same as the annular member 104 described above. That is, the annular member 404 may be provided with a plurality of convex portions 404b on the annular member 104 described above.

The plurality of convex portions 404b can be provided on the upper surface of the annular portion 404a. The plurality of convex portions 404b are provided side by side in the circumferential direction of the core 2. Between the pair of convex portions 404b, the ends of the plurality of segments 31 arranged fourth from the inside of the core 2 are exposed. The convex portion 404b is provided with a hole 404b1 that penetrates in the radial direction of the core 2.

The annular member 405 has an annular portion 405a and a plurality of convex portions 405b. The annular portion 405a can be the same as the annular member 105 described above. That is, the annular member 405 may be formed by further providing a plurality of convex portions 405b on the annular member 105 described above.

The plurality of convex portions 405b can be provided on the upper surface of the annular portion 405a. The plurality of convex portions 405b are provided side by side in the circumferential direction of the core 2. Between the pair of convex portions 405b, the ends of the plurality of segments 31 arranged fifth from the inside of the core 2 are exposed. The convex portion 405b is provided with a hole 405b1 that penetrates the core 2 in the radial direction.

When viewed from the direction along the central axis of the core 2, a set of holes 401b1 to 405b1 can be arranged on a line passing through the center of the core 2. Bolts are inserted inside a set of holes 401b1 to 405b1, and by tightening the bolts with nuts, the force in the direction in which the ends of the segments 31 described above are brought close to each other can be further increased. The inner wall of the hole 401b1 or the hole 405b1 may be threaded. By doing so, the bolt tightening work becomes easy.

Note that at least if the convex portion 401b and the convex portion 405b are provided, tightening with a bolt can be performed. Therefore, the

convex portions

402b, 403b, and 404b can be omitted. That is, the annular member 401, the annular member 102, the annular member 103, the annular member 104, and the annular member 405 may be provided.

However, if the convex portions 401b to 405b are provided, the set of convex portions 401b to 405b arranged in the radial direction of the core 2 can be provided with the function of the cover 221 described above. That is, the space between the set of convex portions 401b to 405b and the adjacent set of convex portions 401b to 405b can be used as a flow path for the purge gas. Therefore, it is possible to suppress the diffusion of the supplied purge gas, so that the quality of the welded portion can be improved.

Further, as shown in FIG. 15, inside the recess 401a1 of the annular portion 401a, the ends of two segments 31 overlapping in the circumferential direction of the core 2 are provided. Inside the recess 402a1 of the annular portion 402a, the ends of two segments 31 that overlap in the circumferential direction of the core 2 are provided. Inside the recess 403a1 of the annular portion 403a, the ends of two segments 31 that overlap in the circumferential direction of the core 2 are provided. Inside the recess 404a1 of the annular portion 404a, the ends of two segments 31 that overlap in the circumferential direction of the core 2 are provided. By doing so, the segment 31 and the segment 31 adjacent to the segment 31 can be positioned by one recess. Therefore, it is possible to more effectively suppress the displacement of the end portion of the segment 31.

Further, as shown in FIG. 15, the upper surface of the annular portions 401a to 405a and the end surface of the segment 31 can be made to be substantially in the same plane. By doing so, the flow of the purge gas flowing between the set of convex portions 401b to 405b and the adjacent set of convex portions 401b to 405b is suppressed from being disturbed by the end portion of the segment 31. can do.

Here, as described with reference to FIG. 8, when the end surface of the segment 31 and the upper surface of the annular portions 401a to 405a are in substantially the same plane, the end surface of the segment 31 and the upper surface of the annular portions 401a to 405a are joined. May be done.

Therefore, in the case where the upper surface of the annular portions 401a to 405a and the end surface of the segment 31 are substantially in the same plane, a curved surface or a slope is provided on the edge of the upper surface of the annular portions 401a to 405a.

FIG. 16A is a schematic cross-sectional view for illustrating a curved surface.
FIG. 16B is a schematic cross-sectional view for illustrating a slope.
In FIG. 16A, the curved surface provided on the

annular portions

401a and 402a will be described, and in FIG. 16B, the slope provided on the

annular portions

401a and 402a will be described, but the other annular portions 403a to The same can be applied to 405a.

As shown in FIG. 16A, the edge of the portion of the upper surface of the annular portion 401a provided with the recess 401a1 can be a curved surface 401a2. The edge of the portion of the upper surface of the annular portion 402a facing the recess 401a1 can be a curved surface 402a2. The radius of the curved surfaces 401a2 and 402a2 can be, for example, 2 mm or more.

As shown in FIG. 16B, the edge of the portion of the upper surface of the annular portion 401a provided with the recess 401a1 can be a slope 401a3. The edge of the portion of the upper surface of the annular portion 402a facing the recess 401a1 can be a slope 402a3. The length of the slope 401a3 in the direction parallel to the upper surface of the annular portion 401a and the length in the direction perpendicular to the upper surface of the annular portion 401a can be 2 mm or more. The length of the slope 402a3 in the direction parallel to the upper surface of the annular portion 402a and the length in the direction perpendicular to the upper surface of the annular portion 402a can be 2 mm or more.

If the curved surface 401a2 or the slope 401a3 is provided, the distance between the end surface of the segment 31 and the upper surface of the

annular portions

401a and 402a can be separated. Therefore, at the time of laser welding, the end surface of the segment 31 and the annular portion 401a can be separated. , 402a can be prevented from being joined to the upper surface.

(Manufacturing method of rotary electric machine)
Next, a method for manufacturing the stator will be described as a method for manufacturing the rotary electric machine according to the present embodiment.
17 (a) to 21 are schematic perspective views for illustrating a step of welding the ends of a plurality of segments 31.

First, form core 2. For example, a plurality of plate-shaped magnetic members having a yoke 21 and a plurality of portions to be teeth 22 are formed. For example, the magnetic material member can be formed by processing an electromagnetic steel sheet having a thickness of about 0.05 mm to 1.0 mm by punching. Then, a plurality of magnetic material members are laminated, and for example, the plurality of magnetic material members are welded or caulked to form the core 2. The core 2 can also be formed by pressure molding a magnetic material powder and a resin binder.

Next, a plurality of segments 31 that are components of the coil 3 are formed.
First, the conductor portion 31a is formed by bending a flat wire having a predetermined length into a substantially U shape. Subsequently, a paint containing enamel or the like is applied to the outer surface of the conductor portion 31a to form the insulating film 31b. A paint containing enamel or the like may be applied to the surface of the flat wire, cut to a predetermined length, and bent into a substantially U shape.
Next, as shown in FIG. 2 described above, the insulating film 31b near the ends on both sides of the conductor portion 31a is peeled off to expose the conductor portion 31a.
The plurality of segments 31 can also be formed by the following procedure.
First, a paint containing enamel or the like as the insulating film 31b is applied to the flat copper wire serving as the conductor portion 31a. You may purchase a flat copper wire coated with enamel or the like.
Next, a flat copper wire coated with enamel or the like is cut to a predetermined length to form a wire rod to be a segment 31.
Next, the enamel and the like in the vicinity of both ends of the cut flat copper wire are peeled off.
Next, the flat copper wire from which the enamel and the like have been peeled off is bent into a substantially U shape.
As described above, a plurality of segments 31 can be formed.

Next, as shown in FIG. 3 described above, each of the plurality of segments 31 is mounted in a predetermined slot 23 of the core 2. For example, each of the plurality of segments 31 is inserted into a predetermined slot 23 from the axial direction of the core 2 (Z direction in FIG. 1). At this time, one segment 31 is inserted across the plurality of slots 23. The coil 3 according to the present embodiment can be a so-called distributed winding coil. Further, the coil 3 according to the present embodiment can be a so-called wave-wound coil.

Subsequently, as shown in FIG. 3, the portion of the segment 31 protruding from the core 2 is bent in a direction approaching the adjacent segment 31. Further, the vicinity of the portion where the conductor portion 31a is exposed is bent in the axial direction of the core 2 (Z direction in FIG. 3). In the circumferential direction of the core 2, the portion of the segment 31 where the conductor portion 31a is exposed overlaps with the portion of the adjacent segment 31 where the conductor portion 31a is exposed.

Then, by repeating the above procedure, a plurality of sets of a plurality of segments 31 arranged in the circumferential direction of the core 2 are formed in the radial direction of the core 2.

Although the case where the bending process is performed after mounting a plurality of segments 31 in the slot 23 is illustrated, the present invention is not limited to this. For example, a plurality of segments 31 may be bent, and each of the plurality of bent segments 31 may be installed in a predetermined slot 23. In this case, the bent segment 31 can be mounted from the inside to the outside of the core 2. Further, as shown in FIG. 17A, a cylindrical insulating cover 2a can be provided inside the core 2 to close the opening of the slot 23.

Next, the end faces of the adjacent segments 31 are welded to each other to form a plurality of coils 3 mounted in the slots 23.
Here, as an example, as shown in FIG. 17A, a case where four sets of a plurality of segments 31 arranged in the circumferential direction of the core 2 are provided in the radial direction of the core 2 will be described.

In the welding process according to the present embodiment, the above-mentioned welding jig 100 is used.
First, as shown in FIG. 17B, the annular member 101 is provided inside the plurality of segments 31 arranged on the innermost side of the core 2.
Subsequently, as shown in FIG. 18A, an annular member 102 is provided between the plurality of segments 31 arranged on the innermost side of the core 2 and the plurality of segments 31 arranged second from the inside of the core 2.

Subsequently, as shown in FIG. 18A, the annular member 103 is placed between the plurality of segments 31 arranged second from the inside of the core 2 and the plurality of segments 31 arranged third from the inside of the core 2. prepare.
Further, an annular member 104 is provided between the plurality of segments 31 arranged third from the inside of the core 2 and the plurality of segments 31 arranged fourth from the inside of the core 2.
Further, the annular member 105 is provided on the outside of the plurality of segments 31 arranged fourth from the inside of the core 2.

When the annular members 101 to 105 are attached, the annular members arranged inside the plurality of segments 31 arranged in the circumferential direction of the core 2 move one end of each of the plurality of segments 31 to the outside of the core 2. Press toward. An annular member arranged outside the plurality of segments 31 arranged in the circumferential direction of the core 2 presses the other end of each of the plurality of segments 31 toward the inside of the core 2. Therefore, the end faces of the segments 31 can be brought into close contact with each other.

Further, when the holes 111a to 115a illustrated in FIG. 9 and the holes 401b1 to 405b1 illustrated in FIG. 15 are provided, bolts are inserted into these holes and the bolts are inserted so that the annular members are close to each other. Can be tightened.

Further, when the plurality of covers 221 illustrated in FIG. 13 are provided, as shown in FIG. 19A, the plurality of covers 221 can be provided side by side in the circumferential direction of the core 2. At this time, the ends of the plurality of segments 31 arranged in the radial direction of the core 2 are exposed between the pair of covers 221. Further, as illustrated in FIG. 13, a nozzle 222 for supplying purge gas may be provided in the space between the pair of covers 221.

Further, when the lid 321 illustrated in FIG. 14 is provided, the lid 321 can be provided on the plurality of covers 221 as shown in FIG. 19 (a).

Subsequently, the end faces of the segments 31 are irradiated with the laser beam 500 to weld the end faces of the adjacent segments 31 to each other. At this time, the purge gas can be supplied in the vicinity of the ends of the plurality of segments 31. For example, the purge gas can be supplied to the space between the nozzle 222 and the pair of covers 221. When the lid 321 is provided, the laser beam 500 can irradiate the end face of the segment 31 through the hole 321a as shown in FIG. 20 (a).

The laser light 500 can have, for example, a wavelength in the infrared region. If the laser beam 500 has a wavelength in the infrared region, it becomes easy to irradiate the laser beam with a relatively high output. For example, the wavelength of the laser beam 500 can be about 1040 nm to 1070 nm. For example, the output of the laser beam 500 can be about 4 kW.

In this case, the laser welding machine can be, for example, a fiber laser, a disk laser, or the like. Further, the laser welder is preferably a CW laser (Continuous wave laser) capable of continuously emitting a laser. Further, it is preferable that the laser welder is provided with a laser-scannable one, for example, a galvano mirror or the like.

By welding the end faces of adjacent segments 31, the welded portion 31c illustrated in FIG. 3 is formed. Further, by connecting a plurality of segments 31 in series, one coil 3 is formed. Further, four coils 3 arranged in the radial direction of the core 2 are formed.

Then, the welding jig is removed.
If the lid 321 and the plurality of covers 221 and the nozzle 222 are provided, they are removed as shown in FIG. 20 (b).

Subsequently, as shown in FIG. 21, the annular members 101 to 105 are sequentially removed.
As described above, the four coils 3 mounted in the slot 23 can be formed.

Next, a resin or the like is applied to the portion of the coil 3 where the conductor portion 31a is exposed to insulate the coil 3.
Next, the four coils 3 can be fixed to the core 2. For example, the coil 3 can be fixed to the core 2 by dropping the varnish into the gap between the slot 23 and the coil 3 and curing the varnish.
The stator 1 can be manufactured as described above.

As described above, the method for manufacturing a rotary electric machine according to the present embodiment includes a step of providing a coil 3 in a plurality of slots 23. The coil 3 includes a plurality of segments 31. In the step of providing the coil 3, the ends of the plurality of segments 31 are held by the welding jig described above. The end faces of the ends of the plurality of segments 31 held by the welding jig are irradiated with the laser beam.

Although some embodiments of the present invention have been exemplified above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other embodiments, and various omissions, replacements, changes, and the like can be made without departing from the gist of the invention. These embodiments and variations thereof are included in the scope and gist of the invention, and are also included in the scope of the invention described in the claims and the equivalent scope thereof. In addition, each of the above-described embodiments can be implemented in combination with each other.

Claims

A welding jig that holds one end of the first segment and one end of the second segment adjacent to the first segment in an overlapped state.
A first annular member that exhibits an annular shape and is accessible to one end of the first segment.
A second annular shape that exhibits an annular shape, is provided outside the first annular member with the first segment and the second segment interposed therebetween, and can come into contact with one end of the second segment. Members and
Have,
The first annular member has a first recess that is accessible to one end of the first segment, and
The second annular member is at least one of a welding jig having a second recess that can contact one end of the second segment.
The welding jig according to claim 1, wherein the first recess is capable of line contact or surface contact with one end of the first segment.
The welding jig according to claim 1, wherein the second recess is capable of line contact or surface contact with one end of the second segment.
The first annular member is provided with a first hole extending toward the second annular member.
The welding jig according to any one of claims 1 to 3, wherein the second annular member is provided with a second hole facing the first hole.
The welding jig according to claim 4, wherein the first hole or the second hole is a female screw.
It is plate-shaped and further comprises a pair of covers provided on the first annular member and the second annular member.
When viewed from above the first annular member and the second annular member, one end of the first segment and one end of the second segment are between the pair of covers. The welding jig according to any one of claims 1 to 5, which is provided with an end portion.
The welding jig according to claim 6, wherein purge gas can flow in the space between the pair of covers.
It is plate-shaped and is further provided with a lid provided on the pair of covers and having a third hole penetrating in the thickness direction.
When viewed from above the first annular member and the second annular member, the inside of the third hole contains an end face of one end of the first segment and the second segment. The welding jig according to claim 6 or 7, wherein the end face of one end is provided.
The first annular member is provided at a position separated from the end face of one end of the first segment.
The welding jig according to any one of claims 1 to 8, wherein the second annular member is provided at a position separated from the end surface of one end of the second segment.
One surface of the first annular member is provided in substantially the same plane as the end surface of one end of the first segment.
The welding jig according to any one of claims 1 to 8, wherein a curved surface or an inclined surface is provided on the edge of the first recess.
One surface of the second annular member is provided in substantially the same plane as the end surface of one end of the second segment.
The welding jig according to any one of claims 1 to 8, wherein a curved surface or an inclined surface is provided on the edge of the second recess.
It is a manufacturing method of a rotary electric machine including a process of providing coils in a plurality of slots.
The coil contains a plurality of segments and contains a plurality of segments.
In the step of providing the coil, the ends of the plurality of segments are held by the welding jig according to any one of claims 1 to 11.
A method for manufacturing a rotary electric machine that irradiates an end face of an end portion of the plurality of segments held by the welding jig with a laser beam.