Method of joining a neutral line

Abstract

The present application provides a neutral wire joining method that can suppress damage or deformation of a neutral busbar even when the neutral busbar is gripped by multiple gripping devices. The present application provides a neutral wire joining method that joins a first U-phase neutral wire, a first V-phase neutral wire, and a first W-phase neutral wire to a neutral busbar by welding in a state where the first U-phase neutral wire and the neutral busbar are gripped by a first gripping device, the first V-phase neutral wire and the neutral busbar are gripped by a second gripping device, and the first W-phase neutral wire and the neutral busbar are gripped by a third gripping device, the neutral wire joining method including a step of providing a predetermined gap between a reference jig branch portion and a support jig and a neutral busbar to position the neutral busbar.

Description

Technical Field

[0001] This invention relates to a method for joining neutral lines. Background Technology

[0002] Patent Document 1 discloses a method for manufacturing a stator, which includes multiple clamping devices that clamp the front ends of two legs of a segmented coil to each other.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2020-89108 Summary of the Invention

[0004] When the neutral busbar is clamped by multiple clamping devices, the internal stress of the neutral busbar increases, which may cause damage or deformation to the neutral busbar.

[0005] The present invention aims to solve this problem by providing a neutral wire splicing method that can suppress damage or deformation of the neutral busbar even when the neutral busbar is clamped by multiple clamping devices.

[0006] This invention provides a method for joining a neutral line, comprising: a neutral line busbar for joining the U-phase neutral line, V-phase neutral line, and W-phase neutral line of a stator coil; a clamp for positioning the neutral line busbar when joining the U-phase neutral line, V-phase neutral line, and W-phase neutral line of the stator coil to the neutral line busbar; and a first clamping device, a second clamping device, and a third clamping device, wherein the first clamping device clamps the U-phase neutral line of the stator coil to the neutral line busbar, the second clamping device clamps the V-phase neutral line of the stator coil to the neutral line busbar, and the third clamping device clamps the W-phase neutral line of the stator coil. The stator coil's U-phase neutral wire and the neutral busbar are joined together by welding while the first clamping device holds the stator coil's U-phase neutral wire and the neutral busbar, the second clamping device holds the stator coil's V-phase neutral wire and the neutral busbar, and the third clamping device holds the stator coil's W-phase neutral wire and the neutral busbar. The joining method includes the following steps: the clamps are positioned with a predetermined gap between themselves and the neutral busbar to locate the neutral busbar. This structure suppresses damage or deformation to the neutral busbar.

[0007] The neutral wire connection method includes the following steps: clamping the U-phase neutral wire of the stator coil to the neutral busbar using the first clamping device; then clamping the V-phase neutral wire of the stator coil to the neutral busbar using the second clamping device; and finally clamping the W-phase neutral wire of the stator coil to the neutral busbar using the third clamping device. This structure suppresses damage or deformation to the neutral busbar.

[0008] The neutral busbar has: a U-phase connection portion, which engages with the U-phase neutral line of the stator coil; a V-phase connection portion, which engages with the V-phase neutral line of the stator coil; and a W-phase connection portion, which engages with the W-phase neutral line of the stator coil. The U-phase, V-phase, and W-phase connection portions of the neutral busbar are arranged along the length of the neutral busbar in the order of the V-phase connection portion, the U-phase connection portion, and the W-phase connection portion. This structure suppresses damage or deformation of the neutral busbar.

[0009] The stator coil's U-phase neutral line has a first U-phase neutral line and a second U-phase neutral line; the stator coil's V-phase neutral line has a first V-phase neutral line and a second V-phase neutral line; and the stator coil's W-phase neutral line has a first W-phase neutral line and a second W-phase neutral line. The neutral line joining method includes the following steps: joining the first U-phase, first V-phase, and first W-phase neutral lines of the stator coil to the neutral line busbar by welding; removing the clamp from the neutral line busbar; and joining the second U-phase, second V-phase, and second W-phase neutral lines of the stator coil to the neutral line busbar by welding. This structure increases the ratio of processing time to production time.

[0010] Invention Effects

[0011] This invention provides a neutral wire joining method that can suppress damage or deformation of the neutral busbar even when it is held by multiple clamping devices. Attached Figure Description

[0012] Figure 1 This is a schematic top view of the stator showing the state of the neutral busbar being positioned using a clamp.

[0013] Figure 2 This diagram shows the state of the first U-phase neutral line, the first V-phase neutral line, and the first W-phase neutral line of the stator coil being held together with the neutral line busbar by a clamping device.

[0014] Figure 3 This is a schematic diagram of the stator coil.

[0015] Figure 4 From Figure 1 A schematic structural diagram of the positioning reference unit and its surroundings when viewed from the direction shown in IV.

[0016] Figure 5 This is a partial, approximate top view of the area near the notch of the reference fixture branch.

[0017] Figure 6 From Figure 5 A rough structural diagram showing the view near the notch of the reference fixture branch in the direction shown in VI.

[0018] Figure 7 This is a partial, approximate top view of the area near the notch of the support fixture.

[0019] Figure 8 From Figure 7 A rough structural diagram showing the area near the notch of the support clamp when viewed from the direction indicated by VIII.

[0020] Figure 9 This diagram shows the state of the second U-phase neutral line, the second V-phase neutral line, and the second W-phase neutral line of the stator coil being held together with the neutral line busbar by a clamping device. Detailed Implementation

[0021] The following uses Figures 1-9 The embodiments of the present invention will be described. Figure 1 This is a schematic top view of the stator showing the state of the neutral busbar being positioned using a clamp. Figure 2 This diagram shows the state of the first U-phase neutral line, the first V-phase neutral line, and the first W-phase neutral line of the stator coil being held together with the neutral line busbar by a clamping device. Figure 3 This is a schematic diagram of the stator coil. Figure 4 From Figure 1 A schematic structural diagram of the positioning reference unit and its surroundings when viewed from the direction shown in IV. Figure 5 This is a partial, approximate top view of the area near the notch of the reference fixture branch. Figure 6 From Figure 5 A rough structural diagram showing the view near the notch of the reference fixture branch in the direction shown in VI. Figure 7 This is a partial, approximate top view of the area near the notch of the support fixture. Figure 8 From Figure 7 A rough structural diagram showing the area near the notch of the support clamp when viewed from the direction indicated by VIII. Figure 9 This diagram illustrates the state in which the neutral wires of phases 2U, 2V, and 2W of the stator coils are clamped to the neutral busbar using a clamping device. In the following description, the axial, radial, and circumferential directions of the stator 10 are respectively designated as the Z direction, R direction, and C direction (refer to...). Figure 2 ).

[0022] First, use Figures 1-3 The stator 10, which joins the neutral line in the neutral line joining method according to the present invention, will be described. The stator 10, combined with a rotor (not shown), constitutes a rotary electric machine. A rotary electric machine is, for example, a rotating electrical machine that functions as a motor installed in vehicles such as electric vehicles, hybrid vehicles, and fuel cell vehicles, and as a generator; it is a so-called electric generator.

[0023] like Figure 1 , Figure 2 As shown, the stator 10 has a stator core 11, stator coils 20, and a neutral busbar 30. The stator core 11 is formed in a generally cylindrical shape, consisting of a core 11 with a core 11 in the axial direction. Figure 1 The stator core 11 is formed by stacking multiple roughly circular electromagnetic steel plates on the paper (in the depth direction). Each electromagnetic steel plate constituting the stator core 11 has a roughly identical shape and is formed separately through stamping or other processes. The stator core 11 has: a circular magnetic yoke 12, along the circumferential direction (…). Figure 1 Extending in the C direction; multiple teeth 13, extending radially from the inner circumference of the yoke 12 (in the C direction); Figure 1 The inner side protrudes in the R direction; and multiple grooves 14 are formed between the teeth.

[0024] A stator coil 20 is wound on the stator core 11. The stator coil 20 is formed by electrically connecting multiple segmented coils 21 inserted into slots 14. Furthermore, the stator coil 20 extends radially from the stator core 11. Figure 1 The R direction) is configured in the slot 14 as a whole, but in Figure 1 Only a portion of the stator coil 20 is shown in the image.

[0025] The segmented coil 21 is, for example, a conductor formed by bending a flat wire with an insulating film made of enameled resin or the like into a roughly U-shape. The segmented coil 21 has two (a pair) legs, at the front end of each leg, where the insulating film is removed, exposing the conductor. The front end of one leg of the segmented coil 21 is electrically connected to the front end of the leg of the other segmented coil 21 by welding. Thus, the stator coil 20 is wound around the stator core 11.

[0026] like Figure 3 As shown, the stator coil 20 includes a U-phase stator coil 20U, a V-phase stator coil 20V, and a W-phase stator coil 20W. The U-phase stator coil 20U, the V-phase stator coil 20V, and the W-phase stator coil 20W are connected by a double star connection (2Y connection). Alternatively, the stator coil 20 can also be connected by a single star connection.

[0027] The U-phase stator coil 20U is composed of a first coil 20U1 and a second coil 20U2 connected in parallel. The first coil 20U1 and the second coil 20U2 each have a first U-phase lead 23U1 and a second U-phase lead 23U2 formed by a leg of a segmented coil 21, and first U-phase neutral lines 22U1 and 22U2, respectively. The first U-phase lead 23U1 and the second U-phase lead 23U2 are formed at one end of the first coil 20U1 and the second coil 20U2, respectively, and are connected to an input terminal 25U. The input terminal 25U is connected to a power line supplied with power from an external source. The first U-phase neutral lines 22U1 and 22U2 are formed at the other end of the first coil 20U1 and the second coil 20U2, respectively, and are connected to a neutral busbar 30.

[0028] The V-phase stator coil 20V is composed of a first coil 20V1 and a second coil 20V2 connected in parallel. The first coil 20V1 and the second coil 20V2 each have a first V-phase lead 23V1 and a second V-phase lead 23V2 formed by a leg of a segmented coil 21, and a first V-phase neutral line 22V1 and a second V-phase neutral line 22V2, respectively. The first V-phase lead 23V1 and the second V-phase lead 23V2 are formed at one end of the first coil 20V1 and the second coil 20V2, respectively, and are connected to the input terminal 25V. The input terminal 25V is connected to a power line supplied with power from an external source. The first V-phase neutral line 22V1 and the second V-phase neutral line 22V2 are formed at the other end of the first coil 20V1 and the second coil 20V2, respectively, and are connected to the neutral busbar 30.

[0029] The W-phase stator coil 20W is composed of a first coil 20W1 and a second coil 20W2 connected in parallel. The first coil 20W1 and the second coil 20W2 each have a first W-phase lead 23W1 and a second W-phase lead 23W2 formed by a leg of a segmented coil 21, and a first W-phase neutral line 22W1 and a second W-phase neutral line 22W2, respectively. The first W-phase lead 23W1 and the second W-phase lead 23W2 are formed at one end of the first coil 20W1 and the second coil 20W2, and are connected to the input terminal 25W. The input terminal 25W is connected to a power line supplied with power from an external source. The first W-phase neutral line 22W1 and the second W-phase neutral line 22W2 are formed at the other end of the first coil 20W1 and the second coil 20W2, and are connected to the neutral busbar 30.

[0030] like Figure 1 , Figure 2 As shown, the neutral line 22U1 of phase 1U, the neutral line 22U2 of phase 2U, the neutral line 22V1 of phase 1V, the neutral line 22V2 of phase 2V, the neutral line 22W1 of phase 1W, and the neutral line 22W2 of phase 2W extend outward from the axial end face of the stator core 11. Figure 1 The paper and the front side, Figure 2 (On the upper side of the Z-axis). The neutral line 22U1 of the first U phase, the neutral line 22U2 of the second U phase, the neutral line 22V1 of the first V phase, the neutral line 22V2 of the second V phase, the neutral line 22W1 of the first W phase, and the neutral line 22W2 of the second W phase are arranged at predetermined intervals along the circumference of the stator core 11, from one side of the circumference of the stator core 11 towards the other side (from... Figure 1 (The upper side faces the lower side) are arranged in the following order: the neutral line of the 2nd phase V, 22V2; the neutral line of the 1st phase V, 22V1; the neutral line of the 2nd phase U, 22U2; the neutral line of the 1st phase U, 22U1; the neutral line of the 2nd phase W, 22W2; and the neutral line of the 1st phase W, 22W1.

[0031] like Figure 1 , Figure 2 As shown, the neutral busbar 30 is formed of a flat metal component and is roughly arc-shaped. The neutral busbar 30 is configured along the circumference of the stator core 11. Figure 1 (Extending in the C direction). The neutral busbar 30 has a busbar main body 31 and a first U phase connection part 32U1, a second U phase connection part 32U2, a first V phase connection part 32V1, a second V phase connection part 32V2, a first W phase connection part 32W1, and a second W phase connection part 32W2.

[0032] The main body 31 of the busbar is connected to the neutral busbar 30 through the neutral lines of the U-phase stator coil 20U, the V-phase stator coil 20V and the W-phase stator coil 20W, and serves as the neutral point of the stator coil 20.

[0033] The first U-phase connection 32U1, the second U-phase connection 32U2, the first V-phase connection 32V1, the second V-phase connection 32V2, the first W-phase connection 32W1, and the second W-phase connection 32W2 are arranged at predetermined intervals along the length of the neutral busbar 30 on the main body 31 of the busbar, facing from one side of the stator core 11 circumferentially towards the other side (from... Figure 1 (The upper side facing the lower side) is arranged in the following order: 2V phase connection 32V2, 1V phase connection 32V1, 2U phase connection 32U2, 1U phase connection 32U1, 2W phase connection 32W2, 1W phase connection 32W1. The 1U phase connection 32U1, 2U phase connection 32U2, 1V phase connection 32V1, 2V phase connection 32V2, 1W phase connection 32W1, and 2W phase connection 32W2 are arranged radially from the busbar main body 31 towards the stator core 11. Figure 2 After extending inside the R direction, it bends at approximately a right angle along the axial direction of the stator core 11. Figure 2 (in the Z direction) and extends in a direction away from the stator core 11.

[0034] The first U-phase connection part 32U1 and the second U-phase connection part 32U2 are respectively connected to the first U-phase neutral line 22U1 and the second U-phase neutral line 22U2 of the U-phase stator coil 20U in the radial direction of the stator core 11. Figure 1 The first V-phase connection part 32V1 and the second V-phase connection part 32V2 are respectively connected to the first V-phase neutral line 22V1 and the second V-phase neutral line 22V2 of the V-phase stator coil 20V in the radial direction of the stator core 11. Figure 1 The first W-phase connection part 32W1 and the second W-phase connection part 32W2 are respectively connected to the first W-phase neutral line 22W1 and the second W-phase neutral line 22W2 of the W-phase stator coil 20W in the radial direction of the stator core 11. Figure 1 (R direction) connects to the outside.

[0035] like Figure 1 As shown, a radial ( ) is provided between the first U-phase connection portion 32U1 and the second W-phase connection portion 32W2 of the neutral busbar 30, pointing towards the stator core 11. Figure 1 A recessed portion 33 is provided on the outer side of the neutral busbar 30 in the R direction. Furthermore, a first end portion 34, which is L-shaped when viewed from above, is provided at the end of the neutral busbar 30 on the side of the first W phase connection portion 32W1. A second end portion 35, which is L-shaped when viewed from above, is provided at the end of the neutral busbar 30 on the side of the second V phase connection portion 32V2. The recessed portion 33, the first end portion 34, and the second end portion 35 are used for positioning the neutral busbar 30, as will be described in detail later.

[0036] A thermistor unit 40 is installed on the neutral busbar 30 to determine the temperature of the neutral busbar 30 and the temperature of the stator coil 20.

[0037] Next, the connection method of the neutral line to the neutral line busbar 30 of each of the U-phase stator coil 20U, V-phase stator coil 20V and W-phase stator coil 20W will be explained.

[0038] The joining method is carried out through the following steps (1) to (6).

[0039] (1) Use clamp 50 to position the neutral busbar 30.

[0040] (2) The first U-phase neutral line 22U1, the first V-phase neutral line 22V1 and the first W-phase neutral line 22W1 of the stator coil 20 and the neutral line busbar 30 are clamped by the first clamping device 60, the second clamping device 70 and the third clamping device 80.

[0041] (3) The first U phase neutral line 22U1, the first V phase neutral line 22V1 and the first W phase neutral line 22W1 are connected to the neutral line busbar 30 by welding.

[0042] (4) Remove clamp 50 from neutral busbar 30.

[0043] (5) The first clamping device 60, the second clamping device 70 and the third clamping device 80 clamp the second U phase neutral line 22U2, the second V phase neutral line 22V2 and the second W phase neutral line 22W2 of the stator coil 20 and the neutral line busbar 30.

[0044] (6) The neutral line 22U2 of the second phase, the neutral line 22V2 of the second phase and the neutral line 22W2 of the second phase are connected to the neutral line busbar 30 by welding.

[0045] First, use Figure 1 , Figures 4-8 The process of positioning the neutral busbar 30 using clamp 50 is explained below. Figure 1 As shown, the clamp 50 for positioning the neutral busbar 30 has a reference clamp 51 and a support clamp 55. The reference clamp 51 has a reference clamp main body 52 and a reference clamp branch 53.

[0046] The main body 52 of the reference fixture is a roughly rectangular parallelepiped with a rectangular cross-section, and extends radially along the stator core 11. Figure 1 The reference fixture branch 53 extends along the R direction. The cross-section of the reference fixture branch 53 is rectangular, and it is formed in an L-shape when viewed from above the stator core 11. The reference fixture branch 53 extends from the center of the reference fixture body 52 along the circumference of the stator core 11 (in the R direction). Figure 1 After extending in the C direction, it bends at approximately a right angle and extends in the direction close to the stator core 11.

[0047] On the radial inner side of the stator core 11 of the reference fixture body 52 ( Figure 1 The front end of the left side is provided with a notch 52a. The notch 52a is located on the outer side of the stator core 11 of the reference fixture body 52 along the axis. Figure 1 (the paper surface and the front side) and from the radial inner side of the stator core 11 ( Figure 1 The end on the left side is radially outward from the stator core 11. Figure 1 (On the right side) only the portion of the specified length was removed.

[0048] On the radial inner side of the stator core 11 of the reference fixture body 52 ( Figure 1 The left side has a side portion 52b and a bottom portion 52c. The side portion 52b is radially inward toward the stator core 11. Figure 1 The left side of the stator core 11, which forms the notch 52a, is radially outward ( Figure 1 The right side. The bottom part 52c faces outward along the axis of the stator core 11. Figure 1The surface of the paper and the front side) forms the axial inner side of the stator core 11 with the notch 52a. Figure 1 (The deeper side of the paper).

[0049] A positioning reference portion 52d is provided on the main body 52 of the reference fixture. The positioning reference portion 52d extends axially outward from the bottom part 52c toward the stator core 11. Figure 1 A roughly prismatic protrusion is formed on the front side of the paper. That is, the positioning reference portion 52d is formed in a portion of the space created by the notch portion 52a. The positioning reference portion 52d is located radially inside the stator core 11 of the reference fixture body portion 52. Figure 1 Left side) end and circumferential direction of stator core 11 ( Figure 1 (C direction) Central part.

[0050] The portion surrounding the recess 33 into the notch 52a contains the neutral busbar 30, and the positioning reference portion 52d fits into the recessed portion of the recess 33. For example... Figure 4 As shown, between the recess 33 and the positioning reference portion 52d, in the circumferential direction of the stator core 11 ( Figure 4 A predetermined gap G12 is provided in the C direction. Furthermore, although not shown, a radial gap G12 is provided between the recess 33 and the positioning reference portion 52d in the stator core 11 (in the C direction). Figure 4 A predetermined gap G11 is provided on the paper (in the depth direction). These gaps G11 and G12 are formed to allow the positioning reference part 52d to fit into the recessed portion of the recess 33. The neutral busbar 30 and the bottom part 52c are in the axial direction of the stator core 11 (in the depth direction). Figure 4 Contact in the Z direction.

[0051] like Figure 1 As shown, on the radial inner side of the stator core 11 of the reference fixture branch 53 ( Figure 1 The front end of the left side is provided with a notch 53a. The notch 53a is located on the outer side of the stator core 11 of the reference clamp branch 53 along the axial direction. Figure 1 (Paper surface and front side) and radially outward from the end of the reference fixture branch 53 in the length direction towards the stator core 11 ( Figure 1 (Lower right side) and from the reference fixture main body 52 side of the reference fixture branch 53 ( Figure 1 The end of the stator core 11 is on the side opposite to the main body of the reference clamp 52 in the circumferential direction (upper side). Figure 1 (Lower left side) Only the specified length was removed.

[0052] On the radial inner side of the stator core 11 of the reference fixture branch 53 ( Figure 1 The left side has a first side portion 53b, a second side portion 53c, and a bottom portion 53d. The first side portion 53b is radially inward toward the stator core 11. Figure 1 The surface on the upper left side, forming the notch 53a, the stator core 11 radially outward ( Figure 1 The lower right side). The second side 53c is the side of the reference clamp body 52 facing the stator core 11 circumferentially. Figure 1 The upper right side, which forms the notch 53a, is the side of the stator core 11 circumferentially opposite to the reference fixture body 52. Figure 1 The bottom surface 53d faces the stator core 11 axially outward (lower left side). Figure 1 The surface of the paper and the front side) forms the axial inner side of the stator core 11 with notch 53a. Figure 1 (The deeper side of the paper).

[0053] The first end 34 of the neutral busbar 30 is inserted into the notch 53a. For example... Figure 5 As shown, between the first end portion 34 and the first side portion 53b, in the radial direction of the stator core 11 ( Figure 5 A specified clearance G21 is provided on the R direction. For example... Figure 5 , Figure 6 As shown, between the first end portion 34 and the second side portion 53c, in the circumferential direction of the stator core 11 ( Figure 5 A specified gap G22 is provided on the C direction. For example... Figure 6 As shown, between the first end 34 and the bottom portion 53d, in the axial direction of the stator core 11 ( Figure 6 A specified gap G23 is provided on the Z direction.

[0054] like Figure 1 As shown, the support clamp 55 is a roughly rectangular parallelepiped with a rectangular cross-section, and extends radially relative to the stator core 11. Figure 1 (R direction) circumferential direction ( Figure 1 Extending in the direction of inclination (C direction). For example... Figure 1 As shown, on the side of the neutral busbar 30 of the support clamp 55 ( Figure 1 The front end of the lower side is provided with a notch 55a.

[0055] Notch 55a is located on the outer side of the stator core 11 supporting the clamp 55 ( ) Figure 1 (paper surface and front side) and radially inward from the stator core 11 of the support clamp 55 ( Figure 1 The end of the lower left side is radially outward from the stator core 11. Figure 1 (upper right side) and from the reference clamp body 52 side of the stator core 11 circumferentially of the support clamp 55 ( Figure 1 The end of the stator core 11 (lower right side) is on the side opposite to the reference fixture body 52 in the circumferential direction. Figure 1 (Top left side) Only the portion of the specified length was removed.

[0056] On the side of the neutral busbar 30 of the support clamp 55 ( Figure 1 The lower end has a first side portion 55b, a second side portion 55c, and a bottom portion 55d. The first side portion 55b is radially inward toward the stator core 11. Figure 1 The lower left side) of the stator core 11, which forms the notch 55a, is radially outer ( Figure 1 The upper right side). The second side 55c is the reference fixture body 52 side facing the stator core 11 circumferentially. Figure 1 The lower right side, which forms the notch 55a, is the side of the stator core 11 circumferentially opposite to the reference fixture body 52. Figure 1 The top left side. The bottom surface 55d faces the stator core 11 axially outward ( Figure 1 The surface of the paper and the front side) forms the axial inner side of the stator core of the notch 55a ( Figure 1 (The deeper side of the paper).

[0057] The second end 35 of the neutral busbar 30 is inserted into the notch 55a. For example... Figure 7 As shown, between the second end portion 35 and the first side portion 55b, in the radial direction of the stator core 11 ( Figure 7 A specified clearance G31 is provided on the R direction. For example... Figure 7 , Figure 8 As shown, between the second end portion 35 and the second side portion 55c, in the circumferential direction of the stator core 11 ( Figure 7 A specified gap G32 is provided on the C direction. For example... Figure 8 As shown, between the second end 35 and the bottom portion 55d, in the axial direction of the stator core 11 ( Figure 8 A specified clearance G33 is provided on the Z direction.

[0058] Next, use Figure 2 The process of clamping the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 of the stator coil 20 with the neutral busbar 30 using the first clamping device 60, the second clamping device 70, and the third clamping device 80 will be explained. First, the clamping of the first U-phase neutral line 22U1 of the U-phase stator coil 20U with the first U-phase connection portion 32U1 of the neutral busbar 30 based on the first clamping device 60 will be explained.

[0059] The first clamping device 60 has a movable part 61 and a fixed part 62. The movable part 61 is radially along the stator core 11 ( Figure 2 Extending in the R direction, in the axial direction of the stator core 11 formed on the radially inner side of the stator core 11 ( Figure 2A fixing part 62 is disposed in a through hole (in the Z direction). A through part 63 formed by the through hole in the axial direction of the stator core 11 is provided between the radially inner end of the fixing part 62 and the radially inner end of the stator core of the movable part 61. The first U-phase neutral line 22U1 of the U-phase stator coil 20U and the first U-phase connection part 32U1 of the neutral line busbar 30 are inserted into the through part 63. With the first U-phase neutral line 22U1 and the first U-phase connection part 32U1 inserted into the through part 63, the movable part 61 is pulled radially outward by an actuator (not shown), and the first U-phase neutral line 22U1 and the first U-phase connection part 32U1 are clamped.

[0060] Next, use Figure 2 The clamping of the first V-phase neutral line 22V1 of the V-phase stator coil 20V and the first V-phase connection portion 32V1 of the neutral busbar 30 based on the second clamping device 70 will be described. The second clamping device 70 has a movable part 71, a fixed part 72, and a through part 73. The structure or function of these movable parts 71, fixed parts 72, and through parts 73 are the same as those of the movable parts 61, fixed parts 62, and through parts 63 of the first clamping device 60, so the description is omitted. The first V-phase neutral line 22V1 and the first V-phase connection portion 32V1 are clamped by the second clamping device 70.

[0061] Next, use Figure 2 The clamping of the first W-phase neutral line 22W1 of the W-phase stator coil 20W and the first W-phase connection portion 32W1 of the neutral busbar 30 based on the third clamping device 80 will be described. The third clamping device 80 has a movable part 81, a fixed part 82, and a through part 83. The structure or function of these movable parts 81, fixed parts 82, and through parts 83 are the same as those of the movable parts 61, fixed parts 62, and through parts 63 of the first clamping device 60, so the description is omitted. The first W-phase neutral line 22W1 and the first W-phase connection portion 32W1 are clamped by the third clamping device 80.

[0062] The clamping of the first clamping device 60, the second clamping device 70, and the third clamping device 80 is not performed simultaneously, but in a predetermined order. Specifically, firstly, the first clamping device 60 clamps the first U-phase neutral line 22U1 and the first U-phase connection portion 32U1. Next, the second clamping device 70 clamps the first V-phase neutral line 22V1 and the first V-phase connection portion 32V1. Finally, the third clamping device 80 clamps the first W-phase neutral line 22W1 and the first W-phase connection portion 32W1.

[0063] Next, use Figure 2The process of joining the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 to the neutral busbar 30 by welding (3) will be explained. First, the joining of the first U-phase neutral line 22U1 of the U-phase stator coil 20U to the first U-phase connection 32U1 of the neutral busbar 30 by welding will be explained.

[0064] The first clamping device 60 is connected to the positive side of a welding power source (not shown) and functions as an electrode. A welding torch electrode (not shown) connected to the negative side of the welding power source is positioned above the first clamping device 60. When the welding torch electrode is brought close to the through-hole 63 of the first clamping device 60, a high-temperature arc is generated from the welding torch electrode, thereby melting and joining the first U-phase neutral line 22U1 and the first U-phase connection portion 32U1 together.

[0065] Next, use Figure 2 The welding-based joining of the first V-phase neutral line 22V1 of the V-phase stator coil 20V and the first V-phase connection portion 32V1 of the neutral busbar 30 will be described. The second clamping device 70 is connected to the positive side of a welding power source (not shown) and functions as an electrode. A welding torch electrode (not shown) connected to the negative side of the welding power source is positioned above the second clamping device 70. When the welding torch electrode is brought close to the through-hole 73 of the second clamping device 70, a high-temperature arc is generated from the welding torch electrode, thereby melting and joining the first V-phase neutral line 22V1 and the first V-phase connection portion 32V1 together.

[0066] Next, use Figure 2 The welding-based joining of the first W-phase neutral line 22W1 of the W-phase stator coil 20W and the first W-phase connection portion 32W1 of the neutral busbar 30 will be described. The third clamping device 80 is connected to the positive side of a welding power source (not shown) and functions as an electrode. A welding torch electrode (not shown) connected to the negative side of the welding power source is positioned above the third clamping device 80. When the welding torch electrode is brought close to the through portion 83 of the third clamping device 80, a high-temperature arc is generated from the welding torch electrode, thereby melting and joining the first W-phase neutral line 22W1 and the first W-phase connection portion 32W1 together.

[0067] Next, (4) the clamp 50 is removed from the neutral busbar 30. And the clamping based on the first clamping device 60, the second clamping device 70 and the third clamping device 80 is released.

[0068] Next, use Figure 9 The process of clamping the second U-phase neutral line 22U2, the second V-phase neutral line 22V2 and the second W-phase neutral line 22W2 of the stator coil 20 with the neutral line busbar 30 using the first clamping device 60, the second clamping device 70 and the third clamping device 80 is described.

[0069] First, such as Figure 9 As shown, the second U-phase neutral line 22U2 of the U-phase stator coil 20U and the second U-phase connection portion 32U2 of the neutral busbar 30 are clamped by the first clamping device 60. This clamping is the same as the clamping of the first U-phase neutral line 22U1 and the first U-phase connection portion 32U1 based on the first clamping device 60, so the description is omitted.

[0070] Next, as Figure 9 As shown, the second clamping device 70 clamps the second V-phase neutral line 22V2 of the V-phase stator coil 20V to the second V-phase connection portion 32V2 of the neutral busbar 30. This clamping is the same as the clamping of the first V-phase neutral line 22V1 and the first V-phase connection portion 32V1 based on the second clamping device 70, so the description is omitted.

[0071] Next, as Figure 9 As shown, the second W-phase neutral line 22W2 of the W-phase stator coil 20W and the second W-phase connection portion 32W2 of the neutral busbar 30 are clamped by the third clamping device 80. This clamping is the same as the clamping of the first W-phase neutral line 22W1 and the first W-phase connection portion 32W1 based on the third clamping device 80, so the description is omitted.

[0072] Next, the process of connecting the neutral line 22U2, the neutral line 22V2 and the neutral line 22W2 of the second phase to the neutral line busbar 30 by welding (6) will be explained.

[0073] First, the second U-phase neutral line 22U2 of the U-phase stator coil 20U is joined to the second U-phase connection portion 32U2 of the neutral line busbar 30 by welding. The joint based on this welding is the same as the joint based on welding between the first U-phase neutral line 22U1 and the first U-phase connection portion 32U1, so the description is omitted.

[0074] Next, the second V-phase neutral line 22V2 of the V-phase stator coil 20V is joined to the second V-phase connection portion 32V2 of the neutral line busbar 30 by welding. The joint based on this welding is the same as the joint based on welding between the first V-phase neutral line 22V1 and the first V-phase connection portion 32V1, so the description is omitted.

[0075] Next, the second W-phase neutral line 22W2 of the W-phase stator coil 20W is joined to the second W-phase connection portion 32W2 of the neutral line busbar 30 by welding. The joint based on this welding is the same as the joint based on welding between the first W-phase neutral line 22W1 and the first W-phase connection portion 32W1, so the description is omitted.

[0076] In this invention, a clamp 50 is provided for positioning the neutral busbar 30 when the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 of the stator coil 20 are joined to the neutral busbar 30. Furthermore, while the first U-phase neutral line 22U1 and the neutral busbar 30 are clamped by the first clamping device 60, the first V-phase neutral line 22V1 and the neutral busbar 30 are clamped by the second clamping device 70, and the first W-phase neutral line 22W1 and the neutral busbar 30 are clamped by the third clamping device 80, the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 are joined to the neutral busbar 30 by welding. Then, the clamp 50 sets a predetermined gap between itself and the neutral busbar 30 to position the neutral busbar 30.

[0077] When the neutral wire and neutral busbar of the stator coil are clamped by multiple clamping devices, the internal stress of the neutral busbar increases, which may cause damage or deformation to the neutral busbar. Specifically, when clamped by the second clamping device 70, a radial force is applied to the movable part 71 towards the stator core 11. Figure 2 A pulling force is applied outward in the R direction. As a result, a force is applied near the second end 35 of the neutral busbar 30, which is intended to twist or move horizontally. Figure 2 A force is applied to rotate the stator core 11 in the R or C direction. Furthermore, when clamped by the third clamping device 80, a force is applied to the movable part 81 to pull it radially outward from the stator core 11. As a result, a force is applied near the first end 34 of the neutral busbar 30 to twist or move it horizontally. Figure 2 The force that rotates in the R or C direction.

[0078] In contrast, in this invention, a predetermined gap is provided between the clamp 50 and the neutral busbar 30. Specifically, as... Figure 5 , Figure 6 As shown, between the first end 34 of the neutral busbar 30 and the reference clamp branch 53, predetermined gaps G21, G22, and G23 are respectively provided in the radial, circumferential, and axial directions of the stator core 11. Furthermore, as... Figure 7 , Figure 8 As shown, between the second end 35 of the neutral busbar 30 and the support clamp 55, specified gaps G31, G32, and G33 are respectively provided in the radial, circumferential, and axial directions of the stator core 11.

[0079] By setting this gap, the force acting on the neutral busbar 30 can be released, thus preventing the internal stress of the neutral busbar 30 from increasing and suppressing damage or deformation of the neutral busbar 30. Furthermore, the number or position of the gaps provided between the clamp 50 and the neutral busbar 30 can be appropriately changed.

[0080] Furthermore, in this invention, firstly, the first clamping device 60 clamps the first U-phase neutral line 22U1 and the first U-phase connection portion 32U1. Next, the second clamping device 70 clamps the first V-phase neutral line 22V1 and the first V-phase connection portion 32V1. Finally, the third clamping device 80 clamps the first W-phase neutral line 22W1 and the first W-phase connection portion 32W1.

[0081] Even if clamping based on the first clamping device 60, the second clamping device 70, and the third clamping device 80 is attempted simultaneously, the clamping times between the devices will be staggered due to manufacturing errors in the neutral busbar 30. This staggering is not constant between products, therefore, the clamping order varies between products, ultimately making it impossible to obtain reproducibility of the shape of the joined neutral busbar 30. Therefore, in this invention, clamping based on the first clamping device 60, the second clamping device 70, and the third clamping device 80 is performed in a predetermined order. Specifically, clamping is first performed using the first clamping device 60, then using the second clamping device 70, and finally using the third clamping device 80.

[0082] First, by clamping the first U-phase connection portion 32U1 located at the center of the neutral busbar 30 along its length, displacement of the ends of the neutral busbar 30 along its length can be suppressed. Furthermore, the first U-phase connection portion 32U1 and the first W-phase connection portion 32W1 are supported at two points: the main body of the reference clamp 52 and the branch of the reference clamp 53. In contrast, the first U-phase connection portion 32U1 and the first V-phase connection portion 32V1 are essentially supported at only one point by the support clamp 55. Therefore, by using the first V-phase connection portion 32V1, which has fewer support points, as the second clamp, displacement of the first V-phase connection portion 32V1 can be suppressed. Thus, by clamping in a predetermined sequence, the amount of displacement of the neutral busbar 30 can be suppressed, and the reproducibility of the shape of the neutral busbar 30 after connection can be obtained.

[0083] In this invention, a clamp 50 is used to position the neutral busbar 30, and the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 of the stator coil 20 are joined to the neutral busbar 30 by welding. Then, after removing the clamp 50 from the neutral busbar 30, the second U-phase neutral line 22U2, the second V-phase neutral line 22V2, and the second W-phase neutral line 22W2 of the stator coil 20 are joined to the neutral busbar 30 by welding.

[0084] After the first U-phase neutral line 22U1, the first V-phase neutral line 22V1, and the first W-phase neutral line 22W1 are joined to the neutral busbar 30 by welding, the position of the neutral busbar 30 is determined. Therefore, the fixture 50 can be removed from the neutral busbar 30, and the second U-phase neutral line 22U2, the second V-phase neutral line 22V2, and the second W-phase neutral line 22W2 can be joined to the neutral busbar 30 by welding. As a result, the ratio of processing time to production time (net processing time ratio) can be increased.

[0085] Furthermore, the present invention is not limited to the above-described embodiments, and appropriate modifications can be made without departing from the spirit of the invention.

[0086] Symbol Explanation

[0087] 20 - Stator coil, 22U1 - Neutral line of phase 1U, 22U2 - Neutral line of phase 2U, 22V1 - Neutral line of phase 1V, 22V2 - Neutral line of phase 2V, 22W1 - Neutral line of phase 1W, 22W2 - Neutral line of phase 2W, 30 - Neutral busbar, 52 - Main body of reference fixture, 53 - Branch of reference fixture, 55 - Support fixture, 60 - First clamping device, 70 - Second clamping device, 80 - Third clamping device.

Claims

1. A method for joining neutral lines, characterized in that, have: The neutral busbar connects to the U-phase neutral line, V-phase neutral line, and W-phase neutral line of the stator coil. A clamp, which positions the neutral busbar when engaging the U-phase neutral line, V-phase neutral line, and W-phase neutral line of the stator coil with the neutral busbar; and The system comprises a first clamping device, a second clamping device, and a third clamping device. The first clamping device clamps the U-phase neutral wire of the stator coil to the neutral busbar; the second clamping device clamps the V-phase neutral wire of the stator coil to the neutral busbar; and the third clamping device clamps the W-phase neutral wire of the stator coil to the neutral busbar. With the U-phase neutral wire of the stator coil clamped to the neutral busbar by the first clamping device, the V-phase neutral wire of the stator coil clamped to the neutral busbar by the second clamping device, and the W-phase neutral wire of the stator coil clamped to the neutral busbar by the third clamping device, the U-phase neutral wire, V-phase neutral wire, and W-phase neutral wire of the stator coil are joined to the neutral busbar by welding. The joining method of the neutral wires includes the following steps: The clamp has a predetermined gap between itself and the neutral busbar to position the neutral busbar.

2. The method for joining neutral lines according to claim 1, characterized in that, The process includes the following steps: The first clamping device clamps the U-phase neutral line of the stator coil to the neutral busbar. Then, the second clamping device clamps the V-phase neutral line of the stator coil to the neutral busbar. Then, the third clamping device clamps the W-phase neutral line of the stator coil to the neutral busbar.

3. The method for joining neutral lines according to claim 1 or 2, characterized in that, The neutral busbar has: a U-phase connection portion, which engages with the U-phase neutral line of the stator coil; a V-phase connection portion, which engages with the V-phase neutral line of the stator coil; and a W-phase connection portion, which engages with the W-phase neutral line of the stator coil. The U-phase connection, V-phase connection, and W-phase connection of the neutral busbar are arranged along the length of the neutral busbar in the order of V-phase connection, U-phase connection, and W-phase connection.

4. The neutral line joining method according to claim 1, characterized in that, The U-phase neutral line of the stator coil has a first U-phase neutral line and a second U-phase neutral line. The V-phase neutral line of the stator coil has a first V-phase neutral line and a second V-phase neutral line. The W-phase neutral line of the stator coil has a first W-phase neutral line and a second W-phase neutral line. The method for joining the neutral line includes the following steps: The first U-phase neutral line, the first V-phase neutral line, and the first W-phase neutral line of the stator coil are joined to the neutral line busbar by welding. Remove the clamp from the neutral busbar; and The neutral lines of the second U phase, the second V phase, and the second W phase of the stator coil are joined to the neutral busbar by welding.

Images