Power line welding method
The described method enhances stator coil processing speed by using a welding apparatus with support and grip release mechanisms to facilitate simultaneous welding of power lines, addressing the delay issue in existing clamp jig-based methods.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2024-11-26
- Publication Date
- 2026-06-05
AI Technical Summary
Existing methods for welding power lines in stator coils require the use of a clamp jig that necessitates continuous holding, delaying the processing speed of the stator coil.
A method involving a welding apparatus with positioning, gripping, and electrode components that supports and welds power lines at multiple points, allowing for the release of support and grip after initial welding, enabling overlapping processes and reducing cycle time.
This method increases the processing speed of stator coils by allowing simultaneous welding of multiple power lines, thereby shortening the cycle time of the welding apparatus.
Smart Images
Figure 2026092409000001_ABST
Abstract
Description
Technical Field
[0001] The present disclosure relates to a method for welding power lines.
Background Art
[0002] Patent Document 1 discloses a clamp jig that enables an operator to hold the positions of a plurality of terminal wires at once so that the terminal wires do not fall off even when the operator releases the terminal wires when welding the lead wire of the stator coil and the tip of the terminal wire.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, when welding the lead wire and the terminal wire at a plurality of welding portions using the clamp jig disclosed in Patent Document 1, it is necessary to hold the position of the terminal wire using the clamp jig until welding is completed at all the welding portions. Therefore, the clamp jig cannot be removed during welding, and the processing speed of the stator coil has been delayed.
[0005] The present disclosure has been made in view of the above circumstances, and provides a method for welding a power line capable of increasing the processing speed of a stator coil.
Means for Solving the Problems
[0006] A method for welding a power line according to an aspect of the present disclosure is a method for welding a power line in which a lead wire drawn from a stator coil and a power line are welded through a plurality of welding points, wherein the power line is supported by a positioning portion that determines the position of the power line, and a gripping portion and an electrode that grip the power line. The power line is welded by the electrode, A first welding step involves welding a first leader wire and the power wire at a first welding point, After the first welding step, a clamping step is performed at the second welding point to clamp the second lead wire and the power wire, The clamping step is followed by a second welding step in which the second lead wire and the power wire are welded at the second welding point. In the clamping step, the power line is not supported by the positioning portion, but is supported by the gripping portion and the electrode. In the second welding step, the power line is not supported by the positioning portion and the gripping portion, but is supported and welded by the electrode. [Effects of the Invention]
[0007] According to this disclosure, a welding method for power lines that can increase the processing speed of stator coils can be provided. [Brief explanation of the drawing]
[0008] [Figure 1] (a) A schematic perspective view of the first welding step in a power wire welding method according to an embodiment of the present disclosure. (b) A schematic perspective view of the power wire after the support and gripping have been released following the first welding step in a power wire welding method according to an embodiment of the present disclosure. (c) A schematic perspective view of the clamping step in a power wire welding method according to an embodiment of the present disclosure. (d) A schematic perspective view of the second welding step in a power wire welding method according to an embodiment of the present disclosure. [Figure 2] This is a flowchart of a welding method for power lines according to an embodiment of the present disclosure. [Modes for carrying out the invention]
[0009] The following describes specific embodiments of this disclosure in detail with reference to the drawings. However, this disclosure is not limited to the following embodiments. Also, for clarity, the following descriptions and drawings have been simplified as appropriate. Furthermore, in terms of the notation of reference numerals, for example, "power lines 21-23" refers to "power lines 21, 22, and 23".
[0010] <Configuration of stator coil, power lines, and welding equipment> The stator coil according to the embodiments of this disclosure is, for example, a coil provided in a stator used in an electric motor. The embodiments of this disclosure disclose a method for welding a power line, which includes a lead wire drawn out from the stator coil provided in the stator and a power line having a power line terminal to which the lead wire is welded, via a plurality of welding points.
[0011] Figure 1(a) is a schematic perspective view of the first welding step according to an embodiment of the present disclosure. The welding method for power lines according to the embodiment of this disclosure is performed by welding power lines 21, 22, and 23 to the stator coil 1 using a welding apparatus 5.
[0012] A stator coil 1 is a coil provided in a cylindrical stator core C, which generates the force to rotate the rotor in the rotating part of an electric motor, for example. The stator coil 1 is arranged spirally within the slots of the stator core C, and its ends are curved in the circumferential direction of the stator core C. The stator core C is the core of a stator used in a three-phase motor configured with a double star connection, for example, and multiple stator coils 1 constitute the U-phase coil, V-phase coil, and W-phase coil, respectively. The stator coil 1 is constructed by insulating and coating a metal wire, such as copper or aluminum, with a resin such as polyurethane or fluoroacrylic resin.
[0013] The stator coil 1 has lead wires 11 to 16 for welding to power lines 21 to 23. Lead wires 11 and 12 are welded to power line 21, lead wires 13 and 14 are welded to power line 22, and lead wires 15 and 16 are welded to power line 23.
[0014] Power lines 21-23 function as terminal wires for the stator by being welded to lead lines 11-16. The ends of power lines 21-23 that are welded to lead lines 11-16 have so-called 2Y terminals, where the ends are split into a Y shape as tip sections 31-36. As a result, for example, lead line 11 is welded to tip section 31 of power line 21, and lead line 12 is welded to tip section 32 of power line 21. In other words, each of the power lines 21-23 is welded to the stator coil 1 via two welding points.
[0015] The power lines 21-23 have terminal sections 41-43 for functioning as terminal lines for the stator. Each of the terminal sections 41-43 is provided with a through hole for functioning as a terminal hole.
[0016] The welding apparatus 5 comprises positioning members 61-63, guide members 71-73, gripping members 81-83, and electrodes 91-93. Here, the positioning members 61-63 and guide members 71-73 are positioning parts, and the gripping members 81-83 are gripping parts. The welding apparatus 5 supports the power lines 21-23 and welds the power lines 21-23 to the stator coil 1.
[0017] In addition to the components shown in this disclosure, the welding apparatus 5 also has a power unit that moves the positioning members 61-63, guide members 71-73, gripping members 81-83, and electrodes 91-93 in the vertical or horizontal direction. As a result, the welding apparatus 5 supports the power lines 21-23 and functions as a device capable of welding the lead lines 11-16 and the power lines 21-23.
[0018] Further, the welding device 5 may be configured to be able to weld members other than the power lines 21 to 23 to the stator coil 1. For example, it may be configured to be able to weld a neutral line having six welding points to be welded to the lead-out lines 11 to 16. At this time, the positioning members 61 to 63, the guide members 71 to 73, and the gripping members 81 to 83 have a shape capable of gripping the neutral line, and the electrodes 91 to 93 have a shape capable of welding the stator coil 1 and the neutral line. In this case, 1 to 5 of the six welding points are the first welding points, and the welding points other than the first welding points are the second welding points.
[0019] The positioning members 61 to 63 are members having convex portions, and the convex portions penetrate through the through holes provided in the terminal portions 41 to 43. Since the positioning members 61 to 63 fix the terminal portions 41 to 43 so as not to move in the horizontal direction, the positions of the power lines 21 to 23 in the horizontal direction are defined. Further, the positioning members 61 to 63 may have a function of defining the positions of the power lines 21 to 23 in the vertical direction by supporting the terminal portions 41 to 43 from below. Further, as shown in Fig. 1(a), the positioning members 61 to 63 may be integrally formed as one member. The material of the positioning members 61 to 63 is, for example, an iron-based metal such as iron or carbon steel, or an alloy steel such as stainless steel.
[0020] The guide members 71 to 73 are U-shaped members in side view. The guide members 71 to 73 limit the horizontal movement of the power lines 21 to 23 by arranging the power lines 21 to 23 inside the U shape. The material of the guide members 71 to 73 is, for example, an iron-based metal such as iron or carbon steel, or an alloy steel such as stainless steel.
[0021] The gripping members 81 to 83 fix the positions of the power lines 21 to 23 by sandwiching and gripping the terminal portions 41 to 43 from above and below. In Fig. 1(a), when gripping the terminal portions 41 to 43, the gripping members 81 to 83 have a U shape so that the positioning members 61 to 63 and the gripping members 81 to 83 do not interfere with each other. The material of the gripping members 81 to 83 is, for example, an iron-based metal such as iron or carbon steel, or an alloy steel such as stainless steel.
[0022] Electrodes 91-93 grip the lead wires 11-16 and the tip portions 31-36 by clamping them horizontally. Furthermore, electrodes 91-93 weld the lead wires 11-16 and the tip portions 31-36 together by applying current to the gripped areas. The material of electrodes 91-93 is an alloy containing tungsten, molybdenum, copper, chromium, zirconium, etc.
[0023] <Welding method for power lines> Next, a welding method for power lines according to an embodiment of the present disclosure will be described with reference to Figures 1 and 2. Figures 1(a) to 1(d) are schematic perspective views of each step of the welding method for power lines according to an embodiment of the present disclosure. Figure 2 is a flowchart of the welding method for power lines according to an embodiment of the present disclosure.
[0024] First, at the first welding points on the power lines 21-23, the lead wires 11-16 and the tips 31-36 of the power lines 21-23 are welded (step S1). Here, the first welding points refer to the points where lead wire 11 and tip 31 are welded, where lead wire 13 and tip 33 are welded, and where lead wire 15 and tip 35 are welded. In step S1, the power lines 21-23 are supported by positioning members 61-63, guide members 71-73, gripping members 81-83, and electrodes 91-93.
[0025] In step S1, after welding at the first welding point is completed, the support and gripping of the power lines 21-23 by the positioning members 61-63, guide members 71-73, and electrodes 91-93 are released (step S2), as shown in Figure 1(b). That is, in step S2, the power lines 21-23 are supported by the gripping members 81-83 and the first welding point where welding was performed in step S1.
[0026] In step S2 and subsequent steps, the positioning members 61-63 and guide members 71-73 do not support the power lines 21-23. Therefore, the positioning members 61-63 and guide members 71-73 can be used to support the power lines during welding of other stator coils to power lines. This makes it possible to overlap the welding processes of multiple power lines, improving the ratio of processing time. As the ratio of processing time improves, the cycle time of the welding apparatus 5 is shortened, and as a result, the processing speed of the stator coil 1 can be increased.
[0027] On the other hand, in step S2, the gripping members 81 to 83 continue to grip the power lines 21 to 23. This prevents the position of the terminals 41 to 43 from descending when the positioning members 61 to 63 release their support for the power lines 21 to 23.
[0028] Next, as shown in Figure 1(c), at the second welding point, electrodes 91-93 grip the power lines 21-23 (step S3). Here, the second welding point refers to the point where the leader line 12 and the tip 32 are welded, the point where the leader line 14 and the tip 34 are welded, and the point where the leader line 16 and the tip 36 are welded. In step S3, the power lines 21-23 are supported by gripping members 81-83, electrodes 91-93, and the first welding point.
[0029] Unlike the positioning members 61-63 and guide members 71-73, the gripping of the power lines 21-23 by the gripping members 81-83 continues even in step S3. Therefore, when gripping the power lines 21-23 with the electrodes 91-93, it is possible to suppress misalignment of the terminal portions 41-43 and grip the power lines 21-23.
[0030] Next, the gripping members 81-83 release their grip on the power lines 21-23 (step S4). Because electrodes 91-93 gripped the power lines 21-23 in step S3, even when the gripping members 81-83 release their grip on the power lines 21-23, the lead wires 11-16 and power lines 21-23 can be welded together without shifting the position of the power lines 21-23. For this reason, the gripping members 81-83 can be used to grip power lines in welding other stator coils to power lines. This makes it possible to overlap the welding processes of multiple power lines, improving the processing time ratio. Because the processing time ratio is improved, the cycle time of the welding apparatus 5 is shortened, and as a result, the processing speed of the stator coil 1 can be increased.
[0031] Finally, as shown in Figure 1(d), at the second welding points on the power lines 21-23, the lead wires 11-16 and the ends 31-36 of the power lines 21-23 are welded together (step S5). As a result, power line 21 is welded to lead wires 11 and 12, power line 22 is welded to lead wires 13 and 14, and power line 23 is welded to lead wires 15 and 16.
[0032] As described above, the power line welding method according to the embodiment of this disclosure releases the support and gripping of the power line by the positioning member, guide member and gripping member after welding at the first welding point and before welding at the second welding point. This improves the ratio of processing time in the power line welding process and shortens the cycle time of the welding apparatus, thereby providing a power line welding method that can increase the processing speed of the stator coil. [Explanation of Symbols]
[0033] 1 Stator coil 11, 12, 13, 14, 15, 16 Leader wires 21, 22, 23 power line 31, 32, 33, 34, 35, 36 Tip 41, 42, 43 terminal section 5. Welding equipment 61, 62, 63 Positioning members 71, 72, 73 Guide members 81, 82, 83 Gripping members 91, 92, 93 electrodes C Stator Core
Claims
[Claim 1] A method for welding power lines, comprising welding a lead wire drawn from a stator coil and a power line via multiple welding points, The power line is supported by a positioning unit that determines the position of the power line, a gripping unit that grips the power line, and an electrode. The power line is welded by the electrode, A first welding step involves welding a first leader wire and the power wire at a first welding point, After the first welding step, a clamping step is performed at the second welding point to clamp the second lead wire and the power wire, The process includes a second welding step, after the clamping step, in which the second lead wire and the power wire are welded at the second welding point. In the clamping step, the power line is not supported by the positioning portion, but is supported by the gripping portion and the electrode. In the second welding step, the power line is not supported by the positioning part and the gripping part, but is supported and welded by the electrode. A welding method for power lines.