Method for manufacturing rotating electrical machine, and rotating electrical machine

Abstract

A method of manufacturing a rotating electrical machine according to an embodiment includes: a step of providing, in each of a plurality of slots provided in an iron core, a segment having a first conductor portion and a first insulating portion provided on an outer surface of the first conductor portion; a step for providing, on the core, a terminal having a second conductor part and a second insulating part provided on the outer surface of the second conductor part; a step for forming a coil provided in the slot by laser welding the ends of a pair of adjacent first conductor sections; and a step for laser welding the plate-shaped bus bar at the end of the second conductor part. The bus bar has a hole penetrating in the thickness direction. In the step of laser welding the bus bar, an end portion of the second conductor portion is inserted into the hole of the bus bar.

Description

Technical Field

[0001] The embodiments of the present invention relate to a method for manufacturing a rotary electric motor and a rotary electric motor. Background Technology

[0002] For example, rotating electrical machines such as motors and generators contain coils wound around an iron core. These coils are formed by winding multiple turns of copper wire, thus lacking flexibility. Therefore, inserting a coil formed by multiple turns of copper wire into a slot in the iron core significantly degrades its workability. A technique has been proposed whereby, after inserting multiple sections into the slots, the ends of each section and the ends of adjacent sections are irradiated with a laser to weld the ends together, forming a coil wound around the iron core.

[0003] Additionally, such a coil has terminals for applying power to the coil and terminals connected to the neutral point of the coil. In this case, the terminals for applying power and the terminals connected to the neutral point are formed using the same material as the section (e.g., flat wire).

[0004] Furthermore, busbars are welded to the terminals used for applying power. These terminals are also electrically connected to control circuitry located external to the rotating motor via the busbars. Additionally, busbars are also welded to the terminals connected to the neutral point of the coil. These terminals are also electrically connected to control circuitry via the busbars.

[0005] When soldering terminals and busbars, it is necessary to position the terminals and busbars. Typically, a soldering fixture is used for positioning the terminals and busbars. However, due to the presence of components such as sections near the terminals, the shape of the soldering fixture can sometimes become complex, or the assembly and disassembly of the soldering fixture can become difficult, depending on the terminal configuration. Furthermore, if the busbar shape becomes complex, soldering the busbar to the terminal can sometimes be more difficult than soldering the ends of sections together.

[0006] Therefore, it is desirable to develop a technology that allows for easy welding of busbars and terminals.

[0007] Existing technical documents Patent documents Patent Document 1: Japanese Patent No. 6358220 Summary of the Invention

[0008] The problem that the invention aims to solve The problem to be solved by the present invention is to provide a method for manufacturing a rotary motor that enables easy welding of busbars and terminals, and the rotary motor itself.

[0009] Methods for solving problems The method for manufacturing a rotary electric motor according to the embodiment includes: a step of providing sections having a first conductor portion and a first insulating portion provided on the outer surface of the first conductor portion in a plurality of slots provided in an iron core; a step of providing terminals having a second conductor portion and a second insulating portion provided on the outer surface of the second conductor portion in the iron core; a step of laser welding the ends of an adjacent pair of first conductor portions to form a coil provided in the slots; and a step of laser welding a plate-shaped busbar at the end of the second conductor portion. The busbar has a hole extending through in the thickness direction. In the step of laser welding the busbar, the end of the second conductor portion is inserted into the hole of the busbar. Attached Figure Description

[0010] Figure 1 It is a schematic three-dimensional diagram used to illustrate the stator.

[0011] Figure 2 It is a schematic three-dimensional diagram used to illustrate the stator.

[0012] Figure 3 It is a process diagram used to illustrate the formation process of a section.

[0013] Figure 4 This is a schematic diagram used to illustrate the section.

[0014] Figure 5 It is a schematic three-dimensional drawing used to illustrate the components.

[0015] Figure 6 It is a schematic three-dimensional diagram used to illustrate the formation of components.

[0016] Figure 7 This is a schematic diagram illustrating the formation of a coil.

[0017] Figure 8 This is a process diagram illustrating the step of welding a busbar to the end of a terminal.

[0018] Figure 9 This is a process diagram illustrating the step of welding a busbar to the end of a terminal.

[0019] Figure 10 This is a process diagram illustrating the step of welding a busbar to the end of a terminal.

[0020] Figure 11 This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0021] Figure 12 This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0022] Figure 13This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0023] Figure 14 This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0024] Figure 15 This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0025] Figure 16 This is a process diagram illustrating the welding steps of a busbar in other embodiments.

[0026] Figure 17 It is a schematic three-dimensional drawing used to illustrate the components.

[0027] Figure 18 It is a schematic three-dimensional diagram used to illustrate the formation of components. Detailed Implementation

[0028] The method for manufacturing a rotary electric machine according to this embodiment can be used, for example, in the manufacture of rotary electric machines such as motors and generators. Hereinafter, as an example, the application of the method for manufacturing a rotary electric machine according to this embodiment to the manufacture of a stator will be described. However, the method for manufacturing a rotary electric machine according to this embodiment can also be used in the manufacture of other rotary electric machines.

[0029] Hereinafter, embodiments will be illustrated with reference to the accompanying drawings. Furthermore, in each drawing, the same reference numerals are used to label the same constituent elements, and detailed descriptions are omitted where appropriate.

[0030] First, the stator 1 manufactured using the rotary electric motor manufacturing method of this embodiment will be described.

[0031] Figure 1 and Figure 2 This is a schematic three-dimensional diagram used to illustrate stator 1.

[0032] like Figure 1 and Figure 2 As shown, the stator 1 is provided with an iron core 2, a coil 3, a terminal 41, a terminal 42, a busbar 51, and a busbar 52.

[0033] For example, the iron core 2 is located in the axial direction of the stator 1. Figure 1The stator 1 is formed by stacking multiple annular magnetic components in the Z direction. These magnetic components are, for example, formed from electromagnetic steel sheets (silicon steel sheets). The core 2 has a yoke 21 and multiple teeth 22. The yoke 21 is cylindrical and located on the outer periphery of the core 2. Multiple teeth 22 are evenly spaced on the inner periphery of the yoke 21. Each tooth 22 protrudes from the inner periphery of the yoke 21 toward the center of the core 2 and extends along the axial direction of the stator 1. Furthermore, slots between the teeth 22 are called slots 23. The shape, number, and size of the teeth 22 are not limited to the illustrated case and can be appropriately varied depending on the purpose, size, and specifications of the rotary motor on which the stator 1 is mounted.

[0034] The coil 3 includes multiple segments 31. Each segment 31 has a conductor portion 31a (corresponding to an example of a first conductor portion) and an insulating portion 31b (corresponding to an example of a first insulating portion) (see, for example, [reference]). Figure 4 , Figure 7 The conductor portion 31a is generally U-shaped and is formed of a material with high conductivity. The conductor portion 31a is, for example, formed of so-called pure copper or a material with copper as the main component. The conductor portion 31a is, for example, formed of a flat wire. A flat wire is a wire with a quadrilateral cross-sectional shape. An insulating portion 31b covers the outer surface of the conductor portion 31a. However, the insulating portion 31b is not provided near the ends on both sides of the conductor portion 31a, leaving the conductor portion 31a exposed. The insulating portion 31b may contain, for example, enamel.

[0035] The ends of adjacent pairs of conductor portions 31a are laser-welded to each other. Multiple segments 31 are connected via welded portions 31c, thereby forming a coil 3. In addition, an insulating portion can be provided to cover the exposed portions of the conductor portions 31a and the welded portions 31c.

[0036] Multiple coils 3 are provided. These multiple coils 3 can be arranged radially along the core 2 (a direction passing through the central axis of the core 2 and orthogonal to the Z direction). For example, as... Figure 1 As illustrated, two coils 3 can be provided. Furthermore, the appearance, number, and size of the coils 3 and the section 31 are not limited to those illustrated, and can be appropriately varied depending on the purpose, size, and specifications of the rotating electric machine on which the stator 1 is provided. For example, three coils 3 can be provided radially in the core 2, or four coils 3 can be provided.

[0037] Terminal 41 is electrically connected to one coil 3. Terminal 41 is provided, for example, to apply power to coil 3. Terminal 42 is electrically connected to the neutral point of multiple coils 3. As described later, terminals 41 and 42 can be formed, for example, using the same material as section 31. In this way, section 31, terminal 41, and terminal 42 can be manufactured through the same process, thereby achieving reduced manufacturing costs and shorter manufacturing delivery times.

[0038] Busbar 51 is plate-shaped and welded to the end of terminal 41. Terminal 41 is electrically connected to control circuits located outside the stator 1 via busbar 51.

[0039] Busbar 52 is plate-shaped and welded to the end of terminal 42. Terminal 42 is electrically connected to control circuitry located outside the stator 1 via busbar 52.

[0040] Busbars 51 and 52 are formed of a material with high conductivity. For example, they are formed of so-called pure copper or a material with copper as the main component.

[0041] Furthermore, as an example, busbars 51 and 52 with a planar shape of quadrilateral are shown, but the planar shape of busbars 51 and 52 can be appropriately changed according to the configuration of terminals 41 and 42.

[0042] exist Figure 1 and Figure 2 In the case of the stator 1 illustrated, busbars 51 and 52 extend radially outward from the core 2. However, the direction in which busbars 51 and 52 extend can be appropriately changed depending on the arrangement of section 31, terminal 41, and terminal 42. That is, busbars 51 and 52 may extend radially inward from the core 2, for example, towards at least one direction, either towards the inside or outside of the core 2.

[0043] Next, the manufacturing method of the rotary electric motor of this embodiment will be described in the manufacturing of the stator 1.

[0044] First, the iron core 2 is formed. For example, multiple plate-shaped magnetic components are formed, each having a yoke 21 and portions forming multiple teeth 22. For example, the magnetic components can be formed by punching an electromagnetic steel sheet with a thickness of approximately 0.05 mm to 1.0 mm. Then, the multiple magnetic components are stacked, for example, by welding or riveting the multiple magnetic components to form the iron core 2. Alternatively, the iron core 2 can also be formed by pressing magnetic material powder and resin binder together.

[0045] In addition, multiple segments 31 are formed that become constituent elements of coil 3.

[0046] Figure 3 This is a process diagram used to illustrate the formation process of section 31.

[0047] First, a coating containing enamel or the like is applied to the outer surface of the flat wire to form a wire 101. The formed wire 101 is then wound onto a spool 102.

[0048] like Figure 3 As shown, a spool 102 with the wire 101 wound on it is provided in the supply section 103.

[0049] Next, the wire 101 wound on the spool 102 is pulled out from the spool 102 by the wire drawing device 104, and the wire 101 is shaped into a straight line.

[0050] Next, the paint is peeled off a portion of the linear material 101 using the peeling device 105. The peeling device 105 includes, for example, a cutter 105a with a pair of parallel blades, and a cutter 105b with a pair of parallel blades. Cutters 105a and 105b peel the paint off one opposite side of the flat line included in the linear material 101, respectively. In this case, the moving direction of cutter 105b is orthogonal to the moving direction of cutter 105a. Therefore, by using cutters 105a and 105b, the paint adhering to the four sides of the flat line can be locally peeled off.

[0051] Next, the wire 101 is cut to a specified length using the cutting device 106. Near the ends of the wire 101 cut to the specified length on both sides, flat lines are exposed from the paint.

[0052] Next, the wire 101 cut to the specified length is bent to form section 31.

[0053] Figure 4 This is a schematic diagram used to illustrate section 31.

[0054] like Figure 4 As shown, segment 31 is, for example, generally U-shaped. Segment 31 has, for example, a conductor portion 31a and an insulating portion 31b. The conductor portion 31a is formed by cutting the flat wire included in the wire 101 by the cutting device 106. The insulating portion 31b is a coating applied to the flat wire. Near the end of segment 31, the portion of the conductor portion 31a exposed from the insulating portion 31b is the portion where the coating is partially peeled off by the peeling device 105.

[0055] As described above, multiple segments 31 are formed.

[0056] Additionally, terminals 41 and 42 are formed. Terminals 41 and 42 can be formed by bending the linear member 43 into a predetermined shape.

[0057] Figure 5 This is a schematic perspective view used to illustrate component 43.

[0058] like Figure 5As shown, component 43 has a conductor portion 43a (corresponding to an example of a second conductor portion) and an insulating portion 31b (corresponding to an example of a second insulating portion). Component 43 can be formed using the aforementioned wire 101. Therefore, the cross-sectional shape and cross-sectional dimensions in the direction orthogonal to the direction in which the conductor portion 43a extends can be set to be the same as the cross-sectional shape and cross-sectional dimensions in the direction orthogonal to the direction in which the conductor portion 31a extends. The ends of both sides of the conductor portion 43a protrude from the insulating portion 31b.

[0059] A stepped portion 43a1 is provided at one end of the conductor portion 43a. In a direction orthogonal to the extending direction of the conductor portion 43a, the cross-sectional dimension of the stepped portion 43a1 is smaller than the cross-sectional dimension of the conductor portion 43a. When the busbar 51 is soldered to the terminal 41 and when the busbar 52 is soldered to the terminal 42, a laser is irradiated towards the end of the stepped portion 43a1. Further details regarding the soldering of the busbar 51 and busbar 52 will be described later.

[0060] By providing cutters 105c and 105d in the aforementioned peeling device 105, the aforementioned wire 101 can be used to form component 43.

[0061] Figure 6 This is a schematic perspective view used to illustrate the formation of component 43.

[0062] like Figure 6 As shown, a pair of cutters 105c are provided. The cutter 105c has a blade 105c1 for peeling the coating off a portion of the area of ​​the wire 101 and a blade 105c2 for cutting a portion of the flat wire contained in the wire 101.

[0063] A pair of cutters 105d are provided. Each cutter 105d has a blade 105d1 for peeling paint off a portion of the area of ​​the wire 101 and a blade 105d2 for notching a portion of the flat wire contained in the wire 101. Blade 105d1 can be the same as blade 105c1. Blade 105d2 can be the same as blade 105c2.

[0064] The moving direction of cutter 105d is orthogonal to the moving direction of cutter 105c. Therefore, by using cutter 105c and cutter 105d, the paint attached to the four sides of the flat line can be partially peeled off, and a stepped portion 43a1 is formed on the flat line.

[0065] In addition, an example is shown where four sides of a flat line are cut off, but two or three sides of a flat line can also be cut off.

[0066] In addition, the coating adhering to the part of component 43 that becomes the other end (the part of welding coil 3) can be peeled off by the aforementioned cutter 105a and cutter 105b.

[0067] Cutters 105a, 105b, 105c, and 105d can be installed in the same peeling device 105 or in different peeling devices 105.

[0068] The linear material 101, which has stepped portions 43a1 and partially peeled off the paint, is cut to a predetermined length by the aforementioned cutting device 106. By cutting such linear material 101, a... Figure 5 Illustrated member 43.

[0069] Terminals 41 and 42 can be formed by bending the linear component 43 into a specified shape.

[0070] The number of terminals 41 and 42 is less than the number of segments 31. Therefore, in the same manufacturing production line, if segments 31, terminals 41 and 42 can be formed from the same material (wire 101), productivity can be increased, thereby reducing manufacturing costs and shortening manufacturing delivery time.

[0071] Next, the ends of multiple sections 31 are laser welded together to form coil 3. Figure 7 This is a schematic diagram illustrating the formation of coil 3.

[0072] First, such as Figure 7 As shown, multiple sections 31 are respectively provided in multiple slots 23 provided in the iron core 2. For example, multiple sections 31 are respectively arranged from the axial direction of the iron core 2 ( Figure 7 The section 31 (in the Z direction) is inserted into the designated slot 23. At this time, one segment 31 is inserted across multiple slots 23. For example, a so-called distributed winding coil 3 can be formed. Alternatively, a so-called wave-wound coil 3 can also be formed. In addition, insulating paper covering the section 31 can be provided for each of the multiple slots 23.

[0073] Next, the portion of section 31 protruding from the core 2 is bent toward the adjacent section 31. Then, the portion of conductor 31a exposed from insulation 31b is further bent toward the axial direction of the core 2. Figure 7 (Z-direction) bending. In addition, the portion of conductor 31a exposed from insulation 31b and the portion of adjacent conductor 31a exposed from insulation 31b are positioned to overlap in the circumferential direction of the core 2.

[0074] Then, by repeatedly performing the above steps, multiple sets of multiple sections 31 arranged in the circumferential direction of the iron core 2 will be set in the radial direction of the iron core 2.

[0075] Furthermore, an example is shown where bending is performed after multiple segments 31 are installed in slots 23, but this is not a limitation. For example, multiple segments 31 can also be bent, and the bent segments 31 can be installed in designated slots 23 respectively. In this case, the bent segments 31 can be installed from the inside to the outside of the core 2.

[0076] Here, when laser welding the ends of section 31 (conductor portion 31a) together, if there is a gap between the ends of section 31 (conductor portion 31a), the weld cross-sectional area may become smaller, or the laser may leak from the gap between the ends and damage the insulation portion 31b. Therefore, when performing laser welding, a welding fixture that brings the ends of an adjacent pair of conductor portions 31a closer to each other in the radial direction of the core 2 can be used.

[0077] Furthermore, the vicinity of the ends of adjacent pairs of conductor portions 31a can be cut off to align the end faces of the pair of conductor portions 31a. If the end faces of the pair of conductor portions 31a are aligned, it is easier to control the position of the end faces of the pair of conductor portions 31a within the focal depth range during laser welding.

[0078] Next, the ends of adjacent segments 31 (conductor portions 31a) are laser-welded to each other to form a coil 3 disposed in the slot 23. A welded portion 31c is formed at the end of the laser-welded conductor portion 31a. Multiple segments 31 (conductor portions 31a) are connected in series via the welded portion 31c to form one coil 3. In addition, multiple coils 3 are formed arranged radially along the iron core 2.

[0079] Additionally, terminals 41 and 42 are provided on the iron core 2, and the ends of terminals 41 and 42 opposite to the side where the stepped portion 43a1 is formed are welded to the coil 3. Terminal 41 is electrically connected to the end of one coil 3. Terminal 41 serves as a terminal for applying power to the coil 3. Terminal 42 is electrically connected to the neutral point of multiple coils 3. Terminal 42 serves as a terminal for electrically connecting multiple coils 3 to the neutral point of a control circuit, etc. Terminals 41 and 42 can be welded, for example, by laser welding.

[0080] Next, a busbar 51 is welded to the end of the terminal 41 on the side where the stepped portion 43a1 is formed.

[0081] Additionally, a busbar 52 is welded to the end of the terminal 42 on the side where the stepped portion 43a1 is formed.

[0082] Figures 8-10 This is a process diagram illustrating the step of welding busbar 51 (busbar 52) to the end of terminal 41 (terminal 42).

[0083] like Figure 8 As shown, the busbar 51 (busbar 52) is plate-shaped and has a hole 51a (hole 52a) extending through in the thickness direction. The shape of the hole 51a (hole 52a) can be the same as the cross-sectional shape of the conductor portion 43a of the terminal 41 (terminal 42). The size of the hole 51a (hole 52a) can be the same as or slightly larger than the cross-sectional size of the conductor portion 43a.

[0084] First, such as Figure 9 As shown, the conductor portion 43a of terminal 41 (terminal 42) is inserted into the interior of hole 51a (hole 52a). When the conductor portion 43a is inserted into the interior of hole 51a (hole 52a), the stepped portion 43a1 protrudes from busbar 51 (busbar 52).

[0085] Next, as Figure 10 As shown, a laser is irradiated onto the end of the stepped portion 43a1 protruding from the busbar 51 (busbar 52) to weld the terminal 41 (terminal 42) to the busbar 51 (busbar 52).

[0086] Here, laser welding of the busbar to the side of the conductor portion 43a of terminal 41 (terminal 42) is also considered. However, if the busbar is laser welded to the side of the conductor portion 43a, the laser is likely to enter the insulating portion 31b, thus easily damaging the insulating portion 31b. In addition, the coil 3 (segment 31) is located around terminal 41 (terminal 42), making laser irradiation difficult, or complicating the fixtures and covers used for laser welding.

[0087] In contrast, if a laser is irradiated onto the end of the terminal 41 (terminal 42) protruding from the plate-shaped busbar 51 (busbar 52), the periphery of the terminal 41 (terminal 42) is covered by the busbar 51 (busbar 52), thus suppressing damage to the insulating portion 31b of the terminal 41 (terminal 42).

[0088] Furthermore, by inserting the conductor portion 43a of terminal 41 (terminal 42) into the hole 51a of busbar 51 (hole 52a of busbar 52), alignment of busbar 51 (busbar 52) with terminal 41 (terminal 42) can be achieved.

[0089] That is, it enables the busbar 51 (busbar 52) to function as a welding cover and a welding fixture.

[0090] Furthermore, the laser irradiation direction when welding busbar 51 (busbar 52) is the same as the laser irradiation direction when welding the ends of section 31 together. Therefore, it is easier to weld busbar 51 (busbar 52) by welding the ends of section 31 together. As a result, it is possible to simplify the manufacturing process, shorten the manufacturing period, and reduce manufacturing costs.

[0091] Next, multiple coils 3, terminals 41 and 42 are fixed to the iron core 2. For example, varnish is supplied to the gap between the iron core 2 and the coils 3, terminals 41 and 42, and the varnish is cured, thereby fixing the multiple coils 3, terminals 41 and 42 to the iron core 2.

[0092] Alternatively, varnish can be supplied to the exposed portions of the conductor portion 31a and the solder portion of the coil 3, terminal 41 and terminal 42 to form an insulating portion.

[0093] When supplying varnish, if the varnish adheres to the end, outer side, or inner side of the iron core 2, for example, the adhered varnish can be removed by irradiating the varnish with a laser.

[0094] As described above, stator 1 can be manufactured.

[0095] Next, the welding of the busbar 51 (busbar 52) in other embodiments will be described.

[0096] Figures 11-13 This is a process diagram illustrating the welding steps of busbar 51 (busbar 52) in other embodiments.

[0097] like Figure 11 As shown, a conductor portion 43a and an insulating portion 31b are provided on terminal 41a (terminal 42a). Terminal 41a corresponds to the aforementioned terminal 41. Terminal 42a corresponds to the aforementioned terminal 42.

[0098] However, the stepped portion 43a1 is not provided on terminal 41a (terminal 42a). That is, the stepped portion 43a1 can be omitted from terminal 41 (terminal 42a). Such terminal 41a (terminal 42a) can be manufactured in the same manner as section 31, for example.

[0099] In addition, such as Figure 11 As shown, when welding the busbar 51 (busbar 52) to the terminal 41a (terminal 42a), a small piece of welding material 53 is used. In this case, the material of the welding material 53 is preferably the same as the material of the conductor portion 43a and the busbar 51 (busbar 52). As described above, before laser welding the ends of the segments 31 (conductor portions 31a) to each other, the vicinity of the ends of adjacent pairs of conductor portions 31a is cut off. The material of the conductor portion 31a can be set to be the same as the material of the conductor portion 43a and the busbar 51 (busbar 52). Therefore, the welding material 53 can be set as scrap material generated when the conductor portion 31a is cut off near its end. In this way, a reduction in manufacturing cost can be achieved.

[0100] First, such as Figure 12As shown, the conductor portion 43a of terminal 41a (terminal 42a) is inserted into the interior of hole 51a (hole 52a). Then, welding material 53 is placed in the opening of hole 51a (hole 52a) on the side opposite to the side where the conductor portion 43a is inserted.

[0101] Next, as Figure 13 As shown, a laser is irradiated onto the welding material 53 to weld the terminal 41a (terminal 42a) to the busbar 51 (busbar 52).

[0102] In this embodiment, the busbar 51 (busbar 52) can also function as a welding shield. Therefore, damage to the insulation portion 31b can be suppressed. Furthermore, the busbar 51 (busbar 52) can function as a welding fixture. Therefore, welding the busbar 51 (busbar 52) to the terminal 41a (terminal 42a) becomes easier. In addition, since the step portion 43a1 can be omitted, the terminal 41a (terminal 42a) can be formed using the same process as section 31. Therefore, manufacturing costs can be reduced, and manufacturing time can be shortened.

[0103] Figures 14-16 This is a process diagram illustrating the welding steps of busbar 51b (busbar 52b) in other embodiments.

[0104] Busbar 51b is equivalent to the aforementioned busbar 51. Busbar 52b is equivalent to the aforementioned busbar 52. The material of busbar 51b (busbar 52b) can, for example, be the same as the material of busbar 51 (busbar 52).

[0105] like Figure 14 As shown, the busbar 51b (busbar 52b) is plate-shaped and has a hole 51ba (hole 52ba) extending through the busbar 51b (busbar 52b) in the thickness direction. Furthermore, the hole 51ba (hole 52ba) may be further opened, for example, on one side of the busbar 51b (busbar 52b).

[0106] In addition, as an example, a busbar 51b (busbar 52b) with a planar shape of quadrilateral is shown, but the planar shape of busbar 51b (busbar 52b) can be appropriately changed according to the configuration of terminal 41b (terminal 42b), etc.

[0107] A conductor portion 43a and an insulating portion 31b are provided on terminal 41b (terminal 42b). Terminal 41b is equivalent to the aforementioned terminal 41. Terminal 42b is equivalent to the aforementioned terminal 42.

[0108] However, no stepped portion 43a1 is provided at terminal 41b (terminal 42b). Additionally, a pair of grooves 43a2 are provided near the end of conductor portion 43a. The pair of grooves 43a2 are opposite each other across the central axis of conductor portion 43a. The distance between the bottom surfaces of the pair of grooves 43a2 is the same as or slightly smaller than the width of the hole 51ba (hole 52ba) of busbar 51b (busbar 52b). The height of the grooves 43a2 is the same as or slightly larger than the thickness of busbar 51b (busbar 52b).

[0109] Therefore, as Figure 15 As shown, the portion of conductor 43a with a pair of grooves 43a2 can be disposed in the hole 51ba (hole 52ba) of busbar 51b (busbar 52b). In this case, the portion of conductor 43a with a pair of grooves 43a2 is inserted into the interior of hole 51ba (hole 52ba) from one side of busbar 51b (busbar 52b).

[0110] When the portion of conductor 43a with a pair of slots 43a2 is inserted into the interior of hole 51ba (hole 52ba), the end of conductor 43a protrudes from busbar 51b (busbar 52b).

[0111] Next, as Figure 16 As shown, a laser is irradiated onto the end of the conductor portion 43a protruding from the busbar 51b (busbar 52b) to weld the terminal 41b (terminal 42b) to the busbar 51b (busbar 52b).

[0112] In this embodiment, the portion of the conductor portion 43a with a pair of grooves 43a2 is located inside the hole 51ba (hole 52ba), thereby increasing the bonding strength between the terminal 41b (terminal 42b) and the busbar 51b (busbar 52b). Therefore, the reliability of the electrical connection between the terminal 41b (terminal 42b) and the busbar 51b (busbar 52b) can be improved.

[0113] In addition, the posture of the busbar 51b (busbar 52b) relative to the terminal 41b (terminal 42b) can be stabilized, thus making laser welding easier and improving the quality of the welded part.

[0114] Furthermore, similarly as described above, the busbar 51b (busbar 52b) can function as a welding shield. Therefore, damage to the insulation portion 31b can be suppressed. Additionally, the busbar 51b (busbar 52b) can function as a welding fixture. Therefore, welding the busbar 51b (busbar 52b) to the terminal 41b (terminal 42b) becomes easier.

[0115] Next, the manufacturing method of terminal 41b (terminal 42b) will be described.

[0116] Terminal 41b (terminal 42b) can be formed by bending the linear member 43b into a specified shape.

[0117] Figure 17 This is a schematic perspective view used to illustrate component 43b.

[0118] like Figure 17 As shown, component 43b has a conductor portion 43a and an insulating portion 31b. Component 43b can be formed using the aforementioned wire 101. Therefore, the cross-sectional shape and dimensions in the direction orthogonal to the direction in which the conductor portion 43a extends can be set to be the same as the cross-sectional shape and dimensions in the direction orthogonal to the direction in which the conductor portion 31a extends. The ends of both sides of the conductor portion 43a protrude from the insulating portion 31b.

[0119] A pair of grooves 43a2 are provided near one end of the conductor portion 43a. By providing cutters 105e and 105f in the aforementioned stripping device 105, the aforementioned wire 101 can be used to form the component 43.

[0120] Figure 18 This is a schematic perspective view used to illustrate the formation of component 43b.

[0121] like Figure 18 As shown, a pair of cutters 105e are provided. The cutter 105e has a pair of blades 105e1 for peeling the coating off a portion of the area of ​​the wire 101 and a pair of blades 105e2 for cutting a portion of the flat wire contained in the wire 101. The blades 105e2 are disposed between the blades 105e1 and the blades 105e1.

[0122] A pair of cutters 105f are provided. The cutter 105f has a pair of blades for peeling the coating off a portion of the area of ​​the wire 101.

[0123] The moving direction of cutter 105f is orthogonal to the moving direction of cutter 105e. Therefore, by using cutter 105e and cutter 105f, the paint attached to the four sides of the flat line can be partially peeled off, and a pair of grooves 43a2 are formed on the flat line.

[0124] In addition, the coating adhering to the part of component 43b that becomes the other end (the part of welding coil 3) can be peeled off by the aforementioned cutter 105a and cutter 105b.

[0125] Cutters 105a, 105b, 105e, and 105f can be installed in the same peeling device 105 or in different peeling devices 105.

[0126] A linear material 101 with a pair of grooves 43a2 and partially peeled off with paint is cut to a predetermined length by the aforementioned cutting device 106. By cutting such a linear material 101, a... Figure 17 The illustrated component 43b. By bending the linear component 43b into a predetermined shape, a terminal 41b (terminal 42b) can be formed.

[0127] The above embodiments of the present invention have been illustrated, but these embodiments are provided as examples and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other ways, and various omissions, substitutions, modifications, etc., can be made without departing from the spirit of the invention. These embodiments or variations thereof are included within the scope or spirit of the invention, and are included within the scope of the invention as described in the claims and its equivalents. Furthermore, the above-described embodiments can be combined with each other for implementation.

[0128] Explanation of reference numerals in the attached figures 1. Stator; 2. Iron core; 3. Coil; 23. Slot; 31. Section; 31a. Conductor section; 31b. Insulation part; 41~41b, terminal; 42~42b, terminal; 43. Components; 43a. Conductor section; 43a1, Stepped section; 43a2, slot; 43b. Components; 51. Busbar; 51a, Hole; 51b. Busbar; 51ba, Kong; 52. Busbar; 52a, Hole; 52b. Busbar; 52ba, Kong; 53. Welding materials; 101. Wire material; 105. Stripping device; 105a~105f, cutter.

Claims

1. A manufacturing method of a rotary electric machine, comprising: a process of disposing, in a plurality of slots provided in a core, segments each having a first conductor portion and a first insulating portion disposed on an outer surface of the first conductor portion; a process of disposing, in the core, a terminal having a second conductor portion and a second insulating portion disposed on an outer surface of the second conductor portion; a process of laser welding end portions of a pair of the first conductor portions adjacent to each other to form a coil disposed in the slot; and a process of laser welding, at the end portions of the second conductor portion, a bus bar in a plate shape, wherein the bus bar has a hole that penetrates in a thickness direction, and wherein, in the process of laser welding the bus bar, the end portions of the second conductor portion are inserted into the hole of the bus bar.

2. The manufacturing method of a rotary electric machine according to claim 1, wherein a stepped portion is provided at the end portions of the second conductor portion, and wherein, in the process of laser welding the bus bar, the stepped portion protrudes from the bus bar when the end portions of the second conductor portion are inserted into the hole of the bus bar, and laser is irradiated to the end portions of the stepped portion.

3. The manufacturing method of a rotary electric machine according to claim 1, wherein the hole of the bus bar is further opened at one edge of the bus bar, wherein a pair of grooves is provided in the vicinity of the end portions of the second conductor portion, and wherein, in the process of laser welding the bus bar, the portions of the second conductor portion provided with the pair of grooves are inserted into the inside of the hole from the one edge side of the bus bar, and laser is irradiated to the end portions of the second conductor portion that protrude from the bus bar.

4. The manufacturing method of a rotary electric machine according to claim 1, wherein, in the process of laser welding the bus bar, a piece-shaped welding material is disposed at an opening of the hole of the bus bar on a side opposite to a side into which the end portions of the second conductor portion are inserted, and laser is irradiated to the welding material.

5. A rotary electric machine, comprising: a coil disposed in a core; a terminal disposed in the core and electrically connected to the coil; and a bus bar in a plate shape having a hole that penetrates in a thickness direction, and welded to end portions of the terminal, wherein the end portions of the terminal are disposed in the hole provided in the bus bar. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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