Conductive wire, welding method, and manufacturing method of rotating electric machine

Abstract

This invention provides a conductive wire capable of rapidly generating the melting of a metal conductor during arc welding, a welding method, and a method for manufacturing a rotary motor. The first conductive wire (31) and the linear body (30) integrally have a pointed, mountain-shaped protrusion (301) that generates an arc (A) between the welding torch electrode (52) and the arc welding electrode. When the first conductive wire (31) is welded to the winding (121) of the U-phase, an arc (A) is generated between the mountain-shaped protrusion (301) and the welding torch electrode (52), causing the mountain-shaped protrusion (301) to melt.

Description

Technical Field

[0001] This invention relates to conductive wires, welding methods, and methods for manufacturing rotating electric machines. Background Technology

[0002] Previously, the component described in Patent Document 1 was known as a connecting component that connects the stator winding of a rotating electric machine, which is mounted on, for example, an electric vehicle, a so-called hybrid vehicle and used as a driving source and generator, to a terminal block.

[0003] The connecting component described in Patent Document 1 has multiple linear conductors, one end of which is connected to the winding and the other end of which is connected to the terminal block. These multiple linear conductors are interconnected by a resin molding part. One end of the linear conductor is connected to the winding of the stator by welding.

[0004] Existing technical documents

[0005] Patent documents

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2017-79528 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] As a welding method for one end of the linear conductor to the stator winding, arc welding, which connects the metal conductors to each other by discharging in gas, is considered. However, if the winding becomes thicker due to the increased capacity of the rotating motor, and the linear conductor also becomes thicker, the heat generated by the discharge will diffuse due to thermal conduction in the winding or linear conductor and will not remain at the discharge site, requiring a long time before the metal conductor begins to melt. In addition, if the discharge time is prolonged, the insulating layer such as the enamel covering the metal conductor of the winding or linear conductor may melt due to the heat.

[0009] Therefore, the object of the present invention is to provide a conductive wire capable of rapidly producing the melting of a metal conductor during arc welding, a welding method, and a method for manufacturing a rotary motor.

[0010] Methods for solving problems

[0011] To address the aforementioned issues, this invention provides a conductive wire that integrally comprises a thin, mountain-shaped protrusion with a linear body, which generates an electric arc between electrodes used in arc welding.

[0012] In addition, in order to solve the above-mentioned problems, the present invention provides a welding method for welding a pair of conductive components by arc welding, wherein at least one of the conductive components has a pointed, mountain-shaped protrusion, and an arc is generated between the mountain-shaped protrusion and an electrode to melt the mountain-shaped protrusion and weld the pair of conductive components together.

[0013] In addition, in order to solve the above-mentioned problems, the present invention provides a method for manufacturing a rotary electric motor, the rotary electric motor comprising: a rotor and a stator; a winding wound around the stator; and a conductive wire welded to the end of the winding. The method for manufacturing the rotary electric motor is characterized in that a pointed, mountain-shaped protrusion is integrally formed on the conductive wire and the linear body, and an electric arc is generated between the mountain-shaped protrusion and an electrode when the body is in contact with the end of the winding, thereby melting the mountain-shaped protrusion and welding the winding to the conductive wire.

[0014] The effects of the invention

[0015] According to the conductive wire, welding method, and manufacturing method of the rotary motor of the present invention, the melting of the metal conductor can be rapidly generated during arc welding. Attached Figure Description

[0016] Figure 1 This is a perspective view showing the rotary motor and terminal block of the first embodiment of the present invention together.

[0017] Figures 2(a) and 2(b) are structural diagrams of the rotary motor and terminal block viewed from the direction of the rotation axis and from the side.

[0018] Figure 3 This is a circuit diagram illustrating an example of the circuit structure in a three-phase motor formed by winding.

[0019] Figure 4(a) is a perspective view showing the connecting parts. Figure 4(b) is a perspective view showing the first to sixth conductive lines, omitting the first to third molded resin parts.

[0020] Figures 5(a) and 5(b) are perspective views showing one end of the winding of the U phase and one end of the first conductive wire before and after welding.

[0021] Figures 6(a) to 6(c) Figure 6(d) is an axial end face view, a front view, and a side view of one end of the first conductive wire. Figure 6(d) is a cross-sectional view along line AA of Figure 6(b).

[0022] Figure 7 This is an explanatory diagram showing the welding process of welding the first conductive wire to one end of the winding of the U phase.

[0023] Figure 8This is a perspective view showing one end of the first conductive wire with the mountain-shaped protrusion of the second embodiment and the winding of the U phase.

[0024] Figures 9(a) to 9(c) This is an axial end face view, a front view, and a side view of one end of the first conductive line in the second configuration.

[0025] Figure 10 This is a perspective view showing one end of the first conductive wire with the mountain-shaped protrusion of the third embodiment and the winding of the U phase.

[0026] Figures 11(a) to 11(c) This is an axial end face view, a front view, and a side view of one end of the first conductive line in the third method.

[0027] Figure 12 This is a perspective view showing one end of the first conductive wire with the mountain-shaped protrusion of the fourth embodiment and the winding of the U phase.

[0028] Figures 13(a) to 13(c) This is an axial end face view, a front view, and a side view of one end of the first conductive line in the fourth configuration.

[0029] Figures 14(a) and 14(b) are perspective views showing one end of the winding of the U phase and one end of the first conductive wire before and after welding.

[0030] In the diagram: 1…rotary motor; 12…stator; 121M…conductor section (conductive component); 122-123…winding wire; 13…rotor; 30…body; 31-36…first to sixth conductive wires; 301-304…mountain-shaped protrusions; 301a, 302a, 303a, 304a…front end; 3M…conductor section (conductive component); 52…welding torch electrode (electrode); A…electric arc. Detailed Implementation

[0031] [First Implementation Method]

[0032] Figure 1 This is a perspective view showing the rotary motor 1 and terminal block 100 according to the first embodiment of the present invention. Figures 2(a) and 2(b) are structural diagrams of the rotary motor 1 and terminal block 100 viewed from the direction of the rotation axis and from the side. In Figure 2(b), a portion of the rotary motor 1 is broken off to illustrate its internal structure.

[0033] The rotary motor 1 is mounted on the vehicle as a drive source and generator for driving, and is connected to an inverter (not shown) via a terminal block 100. The rotary motor (1) has a three-phase motor (10) and a connecting member (2). The windings (121-123) of the three-phase motor (10), described later, are electrically connected to the first to third washers (101-103) of the terminal block (100) via the connecting member (2).

[0034] The three-phase motor 10 has: a bottomed cylindrical motor housing 11; a stator 12 housed in the motor housing 11; a rotor 13 disposed inside the stator 12; a shaft 14 passing through the center of the rotor 13 and supported so as to be able to rotate integrally with the rotor 13; and a cover member 15 made of molding resin covering the opening of the motor housing 11.

[0035] The stator 12 has U-phase, V-phase, and W-phase windings 121-123 wound on a ring-shaped stator core 120 surrounding the rotor 13. More specifically, any one of the U-phase, V-phase, and W-phase windings 121-123 is wound on a plurality of teeth provided on the stator core 120. The stator core 120 is made of a magnetic material such as steel. The windings 121-123 are flat insulated wires with an insulating coating of enamel formed on the outer circumferential surface of a conductor made of copper. A portion of the windings 121-123 protrudes from the cover member 15 to the outside of the motor housing 11 and is molded by the cover member 15.

[0036] The rotor 13 includes a cylindrical rotor core 13a with a through hole for inserting a shaft 14, and a magnet 132 disposed on the outer periphery of the rotor core 13a. The magnet 132 has multiple magnetic poles arranged with alternating S and N poles. The shaft 14 is rotatably supported on the motor housing 11 by bearings (not shown) and rotates about the rotation axis O. Hereinafter, the direction parallel to the rotation axis O will be referred to as the axial direction.

[0037] Figure 3 This is a circuit diagram illustrating an example of the circuit structure in a three-phase motor 10 formed by windings 121 to 123. The U-phase winding 121, the V-phase winding 122, and the W-phase winding 123 are located at multiple points (in... Figure 3 In the example shown, coils are formed by winding the coils (6 in total) around the stator core 120 and connecting them to the neutral point 12n at their respective centers. U-phase current is supplied to one end 121a and the other end 121b of the U-phase winding 121. V-phase current is supplied to one end 122a and the other end 122b of the V-phase winding 122. W-phase current is supplied to one end 123a and the other end 123b of the W-phase winding 123. One end 121a, 122a, 123a of each phase winding 121-123 and the other end 121b, 122b, 123b protrude axially from the cover member 15.

[0038] Figure 4(a) is a perspective view showing the connecting member 2. The connecting member 2 includes first to third connecting terminals 21 to 23 that connect to the terminal block 100, first to sixth conductive wires 31 to 36, and first to third molded resin portions 41 to 44 formed of a resin molding body. Figure 4(b) is a perspective view showing the first to sixth conductive wires 31 to 36, omitting the illustration of the first to third molded resin portions 41 to 44.

[0039] One end of the first conductive wire 31 is connected to one end 121a of the U-phase winding 121, and the other end is connected to the first connecting terminal 21. One end of the second conductive wire 32 is connected to the other end 121b of the U-phase winding 12, and the other end is connected to the first connecting terminal 21. One end of the third conductive wire 33 is connected to one end 122a of the V-phase winding 122, and the other end is connected to the second connecting terminal 22. One end of the fourth conductive wire 34 is connected to the other end 122b of the V-phase winding 122, and the other end is connected to the second connecting terminal 22. One end of the fifth conductive wire 35 is connected to one end 123a of the W-phase winding 123, and the other end is connected to the third connecting terminal 23. One end of the sixth conductive wire 36 is connected to the other end 123b of the W-phase winding 123, and the other end is connected to the third connecting terminal 23.

[0040] The connections of one end of the first and second conductive wires 31 and 32 to one and the other ends 121a and 121b of the U-phase winding 121, the connections of one end of the third and fourth conductive wires 33 and 34 to one and the other ends 122a and 122b of the V-phase winding 122, and the connections of one end of the fifth and sixth conductive wires 35 and 36 to one and the other ends 123a and 123b of the W-phase winding 123 are performed by arc welding based on gas discharge. Details of this welding method will be described later.

[0041] The connections between the other ends of the first and second conductive wires 31 and 32 and the first connecting terminal 21, the other ends of the third and fourth conductive wires 33 and 34 and the second connecting terminal 22, and the other ends of the fifth and sixth conductive wires 35 and 36 and the third connecting terminal 23 are made by riveting. The first connecting terminal 21 is connected to the first washer 101 of the terminal block 100, the second connecting terminal 22 is connected to the second washer 102 of the terminal block 100 by bolt 110, and the third connecting terminal 23 is connected to the third washer 103 of the terminal block 100 by bolt 110. The first to third washers 101 to 103 are connected to the inverter by wiring (not shown in the figure).

[0042] Figures 5(a) and 5(b) are perspective views showing one end 121a of the winding 121 of the U phase and one end of the first conductive line 31 before and after welding. Figures 6(a) to 6(c) Figure 6(d) shows the axial end face view, front view, and side view of one end of the first conductive wire 31. Figure 6(d) is a cross-sectional view along line AA of Figure 6(b). In addition, although detailed illustrations are omitted, one end of the second to sixth conductive wires 32 to 36 is also constructed in the same way as one end of the first conductive wire 31, and is respectively welded to one end 122a, 123a of the windings 121 to 123 and the other end 121b, 122b, 123b.

[0043] The U-phase winding 121 has a conductor portion 121M made of a highly conductive metal such as copper, which is covered by an insulating layer 121I made of an insulator such as enamel. At one end 121a, the insulating layer 121I is removed to expose the conductor portion 121M. The first conductive wire 31 has a conductor portion 3M integrally formed between its linear body 30 and the arc welding electrode (described later), which has a pointed, mountain-shaped protrusion 301 that generates an arc. Except for its two ends, it is covered by the insulating layer 3I. The conductor portion 3M is made of a highly conductive metal such as copper, and the insulating layer 3I is made of an insulator such as enamel.

[0044] In the state before welding shown in Figure 5(a), the end 30a of the main body 30 connected to the winding 121 of the U phase extends axially parallel to one end 121a of the winding 121 of the U phase, and the cross-sectional shape of the section perpendicular to this extension direction is rectangular, as shown in Figure 6(d). The end 30a of the main body 30 protrudes from the insulating layer 3I and contacts the conductor portion 121M of the winding 121 of the U phase.

[0045] A mountain-shaped protrusion 301 protrudes from the end portion 30a of the main body 30 along its extending direction. In this embodiment, the mountain-shaped protrusion 301 is trapezoidal, and the width W1 of the long side direction in the cross-section of the end portion 30a of the main body 30 (see Figure 6(b)) becomes narrower closer to the front end portion 301a. The width of the base end portion 301b of the mountain-shaped protrusion 301 in the same direction is narrower than the width of the end portion 30a of the main body 30 in the long side direction, and the mountain-shaped protrusion 301 protrudes perpendicularly from the axial end face 30a1 of the end portion 30a. In addition, the front end portion 301a of the mountain-shaped protrusion 301 protrudes axially from the end face 121a of one end portion 121a of the U-phase winding 121. This end face 121a1 is a plane perpendicular to the axial direction.

[0046] In addition, in this embodiment, the width W2 of the mountain-shaped protrusion 301 in the short side direction of the end 30a of the main body 30 (see Figure 6(c)) is constant from the base end 301b to the front end 301a.

[0047] Figure 7This is an explanatory diagram showing the welding process of welding the first conductive wire 31 to one end 121a of the winding 121 of the U phase. This welding process is performed by arc welding, and more specifically, by TIG (Tungsten Inert Gas) welding using an electrode made of tungsten and an inert gas. Figure 7 The image shows a portion of the welding head 5.

[0048] TIG welding is performed with a welding head 5 positioned vertically above the mountain-shaped protrusion 301 of the first conductive wire 31. The welding head 5 is movable in the vertical direction by an actuator (not shown), and has a welding torch nozzle 51 that supplies inert gas G to the welding area and a welding torch electrode 52 that protrudes downward from the opening 510 of the welding torch nozzle 51.

[0049] In this embodiment, a touch-start method is adopted where, after the welding torch electrode 52 is brought into contact with the front end 301a of the mountain-shaped protrusion 301 to initiate energization, the welding head 5 is moved upward, generating an arc discharge between the welding torch electrode 52 and the mountain-shaped protrusion 301. The first conductive wire 31 is electrically grounded to become the cathode, and the welding torch electrode 52 becomes the anode. Figure 7 In the diagram, the electric arc A generated between the welding torch electrode 52 and the mountain-shaped protrusion 301 is represented by a dashed line. The mountain-shaped protrusion 301 melts and flows down due to the heat of the electric arc A.

[0050] Through this arc discharge, the mountain-shaped protrusion 301 becomes the starting point for the melting of the conductor portion 3M, as shown in Figure 5(b). The end 30a of the main body 30 of the first conductive wire 31 is welded to one end 121a of the winding 121 of the U phase. The welded area is coated with an insulating coating after cooling. In addition, the second to sixth conductive wires 32 to 36 can be TIG welded simultaneously with the first conductive wire 31, or they can be TIG welded sequentially through a single welding head 5.

[0051] (Function and effects of the first embodiment)

[0052] According to the first embodiment described above, since the electric arc A is generated concentrated at the mountain-shaped protrusion 301, the mountain-shaped protrusion 301 melts rapidly. Furthermore, starting from the mountain-shaped protrusion 301, a portion of the end 30a of the main body 30 also melts, and welding to one end 121a of the winding 121 of the U-phase proceeds rapidly. Therefore, it is also possible to suppress the melting of the insulating layers 3I and 121I due to heat conduction.

[0053] In addition, in this embodiment, since the front end 301a of the mountain-shaped protrusion 301 generates an electric arc A when it is closer to the welding torch electrode 52 than the end face 121a1 of the winding 121 of the U phase, the electric arc A is concentrated at the front end 301a of the mountain-shaped protrusion 301, and the mountain-shaped protrusion 301 melts more rapidly.

[0054] Furthermore, in this embodiment, the case where a mountain-shaped protrusion 301 is provided on the first conductive wire 31 has been described, but the same mountain-shaped protrusion can also be provided on the winding 121 of the U phase. In this case, the mountain-shaped protrusion protrudes axially from the end face 121a1 of one end 121a of the winding 121 of the U phase. Alternatively, if a mountain-shaped protrusion is provided on the winding 121 of the U phase, the mountain-shaped protrusion 301 of the first conductive wire 31 can be omitted. That is, in the welding method of this embodiment, it is sufficient to provide a mountain-shaped protrusion on at least one of the conductive components of the pair of conductive components to be welded. In the above example, the conductor portion 3M of the first conductive wire 31 and the conductor portion 121M of the winding 121 of the U phase correspond to this pair of conductive components.

[0055] [Second Implementation]

[0056] Next, refer to Figure 8 The second embodiment of the present invention is illustrated in Figure 9. Figure 8 This is a perspective view showing one end 121a of the first conductive line 31 having the mountain-shaped protrusion 302 of the second embodiment and the winding 121 of the U phase. Figures 9(a) to 9(c) These are the axial end face view, front view, and side view of one end of the first conductive line 31 in this embodiment.

[0057] This embodiment is identical to the first embodiment except that the shape of the mountain-shaped protrusion 302 differs from that of the mountain-shaped protrusion 301 in the first embodiment. Therefore, the focus is on describing the different parts, while other parts are marked with the same symbols as those used in the first embodiment, and repeated descriptions are omitted. The same applies to the third to fifth embodiments described later.

[0058] In the second embodiment, the mountain-shaped protrusion 302 is triangular in shape, and the width W1 of the long side of the cross-section of the end 30a of the main body 30 gradually narrows from the base end 302b to the front end 302a. The width W1 of the base end 302b of the mountain-shaped protrusion 302 is equal to the entire width of the end 30a of the main body 30 in the long side direction. The width W2 of the mountain-shaped protrusion 302 in the short side direction of the end 30a of the main body 30 is constant from the base end 302b to the front end 302a. The front end 302a of the mountain-shaped protrusion 302 protrudes axially from the end face 121a1 of one end 121a of the U-phase winding 121. The first conductive wire 31 and the U-phase winding 121 are connected by TIG welding, as in the first embodiment.

[0059] According to this second embodiment, the same function and effect as the first embodiment can also be obtained.

[0060] [Third Implementation Method]

[0061] Next, refer to Figure 10 The third embodiment of the present invention will be described with reference to Figure 11. Figure 10 This is a perspective view showing one end 121a of the first conductive line 31 and the winding 121 of the U phase having the mountain-shaped protrusion 303 of the third embodiment. Figures 11(a) to 11(c) These are axial end face views, front views, and side views of one end of the first conductive wire 31 in this embodiment. Additionally, in Figure 10 And in Figure 11(c), the central axis C of the end 30a of the main body 30 is represented by a single-dotted line.

[0062] In the third embodiment, the mountain-shaped protrusion 303 is a triangular shape in which the width W2 of the short side of the end 30a of the main body 30 gradually narrows from the base end 303b toward the front end 303a. The front end 303a of the mountain-shaped protrusion 303 is offset on the side of the winding 121 of the U phase closer to the central axis C. The width W1 of the mountain-shaped protrusion 303 in the length direction of the end 30a of the main body 30 is constant. The front end 303a of the mountain-shaped protrusion 303 protrudes axially beyond the end face 121a1 of the winding 121 of the U phase. The first conductive wire 31 and the winding 121 of the U phase are connected by TIG welding, as in the first embodiment.

[0063] According to this third embodiment, the same function and effect as the first embodiment can also be obtained. In addition, the front end portion 303a of the mountain-shaped protrusion 303 is biased towards the winding 121 side of the U phase compared with the central axis C, so the molten mountain-shaped protrusion 303 easily flows towards the end face 121a1 side of the winding 121 of the U phase.

[0064] [Fourth Implementation Method]

[0065] Next, refer to Figure 12 Figure 13 illustrates the fourth embodiment of the present invention. Figure 12 This is a perspective view showing one end 121a of the first conductive line 31 with the mountain-shaped protrusion 304 of the fourth embodiment and the winding 121 of the U phase. Figures 13(a) to 13(c) These are the axial end face view, front view, and side view of one end of the first conductive wire 31 in this embodiment. Figure 12 And in Figure 13(c), the central axis C of the end 30a of the main body 30 is represented by a single-dotted line.

[0066] In the fourth embodiment, the mountain-shaped protrusion 304 is a pyramidal shape in which the width W2 in the short side direction and the width W1 in the long side direction of the end portion 30a of the main body 30 gradually narrow from the base end portion 304b toward the front end portion 304a. The front end portion 304a of the mountain-shaped protrusion 304 is offset to the side in the short side direction closer to the winding 121 of the U phase than the central axis C. The end face 121a1 of the front end portion 304a of the mountain-shaped protrusion 304 protrudes axially from the end portion 121a of the winding 121a of the U phase. The first conductive wire 31 and the winding 121 of the U phase are connected by TIG welding, as in the first embodiment.

[0067] According to this fourth embodiment, the same function and effect as the first embodiment can be obtained. Furthermore, the front end portion 304a of the mountain-shaped protrusion 304 is biased towards the winding 121 side of the U-phase compared to the central axis C, thus the molten mountain-shaped protrusion 304 easily flows towards the end face 121a1 side of the winding 121 of the U-phase. In addition, since the front end portion 304a of the mountain-shaped protrusion 304 is sharp and needle-like, the TIG welding arc is more easily concentrated at the front end portion 304a.

[0068] [Fifth Implementation Method]

[0069] Next, the fifth embodiment of the present invention will be described with reference to FIG14. FIG14(a) and FIG14(b) are perspective views showing one end 121a of the winding 121 of the U phase before and after welding and one end of the first conductive wire 31 of this embodiment.

[0070] In this embodiment, the mountain-shaped protrusion 301 protrudes in a direction intersecting the extending direction of the main body 30. The end 30a of the main body 30, which is connected to the winding 121 of the U phase, is bent along the circumferential direction of the stator 12, and the mountain-shaped protrusion 301 is integrally provided with this end 30a. The mountain-shaped protrusion 301 protrudes along the axial direction of the stator 12 in a direction intersecting the extending direction of the end 30a (the circumferential direction of the stator 12).

[0071] The cross-sectional shape of the end portion 30a perpendicular to its extension direction is rectangular, and the mountain-shaped protrusion 301 protrudes from the end portion of the long side of this cross-section. The front end portion 301a of the mountain-shaped protrusion 301 protrudes axially from the end face 121a1 of one end portion 121a of the winding 121 of phase U.

[0072] The mountain-shaped protrusion 301 becomes the starting point for the melting of the conductor portion 3M caused by the arc discharge, as shown in Figure 14(b). The end 30a of the main body 30 of the first conductive wire 31 is welded to one end 121a of the winding 121 of the U phase.

[0073] According to this fifth embodiment, the same function and effect as the first embodiment can also be obtained. In addition, in FIG14(a), it is shown that the mountain-shaped protrusion 301 is formed in the same shape as the mountain-shaped protrusion 301 in the first embodiment, but it can also be formed in the same shape as the mountain-shaped protrusions 302 to 304 in the second to fourth embodiments.

[0074] (Summary of Implementation Methods)

[0075] Next, the technical ideas learned from the embodiments described above will be described by reference to symbols and the like. However, the symbols used in the following description are not limited to specifically representing the components of the embodiments as described in the claims.

[0076] [1] The conductive wires 31 to 36 are integrally formed with the linear body 30 and have pointed, mountain-shaped protrusions 301 to 304 that generate an electric arc A between the electrode 52 and the arc welding electrode.

[0077] [2] According to the conductive wires 31 to 36 described in [1] above, the mountain-shaped protrusions 301 to 304 protrude from the end 30a of the main body 30 along the extension direction of the end 30a.

[0078] [3] According to the conductive wires 31 to 36 described in [2] above, the cross-sectional shape of the end 30a in the cross-section of the main body 30 perpendicular to the extension direction is rectangular, and the width W1 of the long side in the cross-section of the mountain protrusions 301 and 302 is narrower as it gets closer to the front end 301a and 302a.

[0079] [4] According to the conductive wires 31 to 36 described in [2] or [3] above, the cross-sectional shape of the end 30a in the cross-section of the main body 30 perpendicular to the extension direction is rectangular, and the width W2 of the short side in the cross-section of the mountain protrusions 303 and 304 is narrower as it gets closer to the front end 302a and 304a.

[0080] [5] According to the conductive wires 31 to 36 described in [4] above, the front ends 302a and 304a of the mountain-shaped protrusions 303 and 304 are biased toward the side of the short side than the central axis C of the ends.

[0081] [6] According to the conductive lines 31 to 36 described in [1] above, the mountain-shaped protrusion 301 protrudes in a direction that intersects with the extension direction of the main body 30.

[0082] [7] According to the conductive wires 31 to 36 described in [6] above, the mountain-shaped protrusion 301 is integrally provided with the end 30a of the main body 30, the cross-sectional shape of the end 30a perpendicular to the extension direction is rectangular, and the mountain-shaped protrusion 301 protrudes from the end of the long side direction of the cross-section.

[0083] [8] A welding method for welding a pair of conductive components 3M and 121M by arc welding, wherein at least one of the conductive components 3M and 121M has a pointed mountain-shaped protrusion 301-304, and an arc A is generated between the mountain-shaped protrusion 301-304 and the electrode 52 of the welding torch, so that the mountain-shaped protrusion 301-304 melts to weld the pair of conductive components 3M and 121M.

[0084] [9] According to the welding method described above [8], wherein the mountain-shaped protrusions 301 to 304 are disposed on one of the conductive components 3M of the pair of conductive components 3M and 121M, and during the welding, the electric arc A is generated when the front ends 301a, 302a, 303a, and 304a of the mountain-shaped protrusions 301 to 304 are closer to the electrode 52 than the end 121a of the other conductive component 121M.

[0085]

[10] A method for manufacturing a rotary electric motor 1, the rotary electric motor 1 comprising: a rotor 13 and a stator 12; windings 121-123 wound around the stator 12; and conductive wires 31-36 welded to the ends 121a, 121b, 122a, 122b, 123a, 123b of the windings 121-123, the method for manufacturing the rotary electric motor 1 characterized in that the conductive wires 31-36 are connected to the linear body 3 The main body 30 is integrally formed with pointed, mountain-shaped protrusions 301-304. When the main body 30 is in contact with the ends 121a, 121b, 122a, 122b, 123a, and 123b of the windings 121-123, an electric arc A is generated between the mountain-shaped protrusions 301-304 and the electrode 52, causing the mountain-shaped protrusions 301-304 to melt and weld the windings 121-123 to the conductive wires 31-36.

[0086] The embodiments of the present invention have been described above, but the embodiments described above do not limit the invention as defined in the claims. Furthermore, it should be noted that not all combinations of the features described in the embodiments are necessarily necessary means to solve the problems of the invention.

[0087] Furthermore, the present invention can be implemented with appropriate modifications without departing from its spirit. For example, in the above embodiments, the case of combining the first to sixth conductive wires 31 to 36 with the three-phase motor 10 has been described, but it is not limited thereto, and the present invention can be applied to conductive wires used in various applications. In addition, the welding method of the present invention is not limited to welding conductive wires and windings, but can also be applied to various objects for arc welding of a pair of conductive components.

Claims

1. A welding method for welding a pair of conductive components by electric arc welding, characterized in that, A pointed, mountain-shaped protrusion is integrally formed on one of the pair of conductive components with the linear body. A welding torch electrode with a welding head is positioned above the vertical direction of the mountain-shaped protrusion. An electric arc is generated between the mountain-shaped protrusion and the welding torch electrode when the body is in contact with the end of the other conductive component of the pair of conductive components and the front end of the mountain-shaped protrusion is closer to the welding torch electrode than the end face of the other conductive component. The mountain-shaped protrusion melts due to the electric arc, and starting from the mountain-shaped protrusion, a portion of the main body also melts, welding the pair of conductive components together.

2. The welding method according to claim 1, characterized in that, The mountain-shaped protrusion extends from the end of the body along the direction of extension of that end.

3. The welding method according to claim 2, characterized in that, The cross-sectional shape of the end portion of the main body in a section perpendicular to the extending direction is rectangular. The width of the cross-section of the mountain-shaped protrusion in the long side direction becomes narrower towards the front end.

4. The welding method according to claim 2 or 3, characterized in that, The cross-sectional shape of the end portion of the main body in a section perpendicular to the extending direction is rectangular. The width of the short side of the cross-section of the mountain-shaped protrusion becomes narrower towards the front end.

5. The welding method according to claim 4, characterized in that, The front end of the mountain-shaped protrusion is offset to one side of the shorter side than the central axis of the end.

6. The welding method according to claim 1, characterized in that, The mountain-shaped protrusion extends in a direction that intersects with the extension direction of the main body.

7. The welding method according to claim 6, characterized in that, The mountain-shaped protrusion is integrally set at the end of the main body. The cross-sectional shape of the end of the main body perpendicular to its extending direction is rectangular. The mountain-shaped protrusion extends from the end of the long side of the cross section.

8. A method for manufacturing a rotary electric motor, the rotary electric motor comprising: a rotor and a stator; a winding wound around the stator; and conductive wires welded to the ends of the winding. The method for manufacturing the rotary electric motor is characterized in that, A pointed, mountain-shaped protrusion is integrally formed on the conductive wire and the linear body. A welding torch electrode with a welding head is positioned above the vertical direction of the mountain-shaped protrusion of the conductive wire. With the main body of the conductive wire in contact with the end of the winding and the front end of the mountain-shaped protrusion closer to the welding torch electrode than the end face of the winding, an electric arc is generated between the mountain-shaped protrusion and the welding torch electrode. The mountain-shaped protrusion melts due to the electric arc, and starting from the mountain-shaped protrusion, a portion of the main body also melts, welding the winding and the conductive wire together.

Images