Method for producing rotary electrical machine and rotary electrical machine

Abstract

A method for producing a rotary electrical machine in accordance with an embodiment comprises: a step for providing, to each of a plurality of slots provided to a core, a segment which has a first conductor part and a first insulation part that is provided to the outer surface of the first conductor part; a step for providing, to the core, a terminal which has a second conductor part and a second insulation part that is provided to the outer surface of the second conductor part; a step for performing laser welding of end portions of a pair of adjacent first conductor parts so as to form a coil which is provided to each of the slots; and a step for performing laser welding of a plate-like bus bar to an end portion of the second conductor part. The bus bar has a hole which passes therethrough in the thickness direction. In the step for performing the laser welding of the bus bar, the end portion of the second conductor part is inserted into the hole in the bus bar.

Description

Method for manufacturing a rotating electric machine, and a rotating electric machine

[0001] An embodiment of the present invention relates to a method for manufacturing a rotating electric machine, and a rotating electric machine.

[0002] For example, rotating electrical machines such as motors and generators are provided with coils wound around cores. The coils are formed by winding copper wire multiple times, which results in poor flexibility. Therefore, inserting a coil formed by winding copper wire multiple times into a slot in a core significantly reduces workability. To address this issue, a technology has been proposed in which multiple segments are inserted into the slots, and then an end of one segment is irradiated with a laser beam to weld the ends together, thereby forming a coil wound around a core.

[0003] Furthermore, such a coil is electrically connected to a terminal for applying power to the coil and a terminal connected to the neutral point of the coil. In this case, the terminal for applying power and the terminal connected to the neutral point are formed using the same material as the segments (e.g., rectangular wire).

[0004] In addition, a bus bar is welded to the terminal for applying electric power. The terminal for applying electric power is then electrically connected via the bus bar to a control circuit or the like provided outside the rotating electric machine. In addition, a bus bar is welded to the terminal connected to the neutral point of the coil. The terminal connected to the neutral point is then electrically connected via the bus bar to the control circuit or the like.

[0005] When welding the terminal and the busbar, the terminal and the busbar must be positioned. Generally, a welding jig is used to position the terminal and the busbar. However, because components such as segments are present near the terminal, the shape of the welding jig may become complex or it may be difficult to attach and detach the welding jig depending on the arrangement of the terminal. Furthermore, the shape of the busbar may become complex, making it more difficult to weld the busbar and the terminal compared to welding the ends of the segments together.

[0006] Therefore, there has been a demand for the development of a technology that allows for easy welding of bus bars and terminals.

[0007] Patent No. 6358220

[0008] An object of the present invention is to provide a method for manufacturing a rotating electric machine that allows welding of bus bars and terminals to be easily performed, and a rotating electric machine.

[0009] A method for manufacturing a rotating electric machine according to an embodiment includes the steps of: providing a segment, each of which has a first conductor and a first insulating portion provided on an outer surface of the first conductor, in a plurality of slots provided in a core; providing a terminal, each of which has a second conductor and a second insulating portion provided on the outer surface of the second conductor, in the core; laser welding ends of a pair of adjacent first conductors to form coils provided in the slots; and laser welding a plate-shaped bus bar to the ends of the second conductors. The bus bar has a hole penetrating through its thickness. In the step of laser welding the bus bar, the ends of the second conductors are inserted into the holes of the bus bar.

[0010] 1 is a schematic perspective view illustrating a stator; FIG. 2 is a schematic perspective view illustrating a stator; FIG. 3 is a process diagram illustrating a segment forming process; FIG. 4 is a schematic perspective view illustrating a segment; FIG. 5 is a schematic perspective view illustrating a member; FIG. 6 is a schematic perspective view illustrating the formation of a member; FIG. 7 is a schematic perspective view illustrating the formation of a coil; FIG. 8 is a process diagram illustrating the procedure for welding a busbar to an end of a terminal; FIG. 9 is a process diagram illustrating the procedure for welding a busbar to an end of a terminal; FIG. 10 is a process diagram illustrating the procedure for welding a busbar to an end of a terminal; FIG. 11 is a process diagram illustrating the procedure for welding a busbar to an end of a terminal; FIG. 12 is a process diagram illustrating the procedure for welding a busbar according to another embodiment; FIG. 13 is a process diagram illustrating the procedure for welding a busbar according to another embodiment; FIG. 14 is a process diagram illustrating the procedure for welding a busbar according to another embodiment; FIG. 15 is a schematic perspective view illustrating the formation of a member;

[0011] The method for manufacturing a rotating electric machine according to this embodiment can be used, for example, when manufacturing a rotating electric machine such as a motor or a generator. In the following, as an example, a case will be described in which the method for manufacturing a rotating electric machine according to this embodiment is used to manufacture a stator. However, the method for manufacturing a rotating electric machine according to this embodiment can also be used to manufacture other rotating electric machines.

[0012] Hereinafter, embodiments will be illustrated with reference to the drawings. In the drawings, like components are designated by like reference numerals and detailed descriptions thereof will be omitted where appropriate.

[0013] First, a description will be given of a stator 1 manufactured using a manufacturing method for a rotating electric machine according to this embodiment. Figures 1 and 2 are schematic perspective views illustrating the stator 1. As shown in Figures 1 and 2, the stator 1 is provided with a core 2, coils 3, terminals 41 and 42, bus bars 51 and 52.

[0014] The core 2 is, for example, formed by laminating multiple annular magnetic members in the axial direction of the stator 1 (Z direction in FIG. 1 ). The magnetic members are formed, for example, from electromagnetic steel sheets (silicon steel sheets). The core 2 includes a yoke 21 and multiple teeth 22. The yoke 21 is cylindrical and located on the outer periphery of the core 2. The multiple teeth 22 are provided at equal intervals on the inner circumferential surface of the yoke 21. Each of the multiple teeth 22 protrudes from the inner circumferential surface of the yoke 21 toward the center of the core 2 and extends in the axial direction of the stator 1. Grooves provided between the teeth 22 form slots 23. The shape, number, and size of the teeth 22 are not limited to those illustrated and can be changed as appropriate depending on the application, size, specifications, etc. of the rotating electric machine in which the stator 1 is installed.

[0015] 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, Figures 4 and 7). The conductor portion 31a is generally U-shaped and formed from a highly conductive material. The conductor portion 31a is formed, for example, from so-called pure copper or a material primarily composed of copper. The conductor portion 31a is formed, for example, from a rectangular wire. The rectangular wire is a wire material with a rectangular cross-section. The insulating portion 31b covers the outer surface of the conductor portion 31a. However, the insulating portion 31b is not provided near both ends of the conductor portion 31a, leaving the conductor portion 31a exposed. The insulating portion 31b includes, for example, enamel.

[0016] The ends of a pair of adjacent conductor portions 31a are laser welded together. A plurality of segments 31 are connected via welds 31c to form a single coil 3. An insulating portion may also be provided to cover the exposed portions of the conductor portions 31a and the welds 31c.

[0017] A plurality of coils 3 are provided. The plurality of coils 3 can be arranged side by side in the radial direction of the core 2 (a direction passing through the central axis of the core 2 and perpendicular to the Z direction). For example, as illustrated in FIG. 1 , two coils 3 can be provided. Note that the external shape, number, size, etc. of the coils 3 and the segments 31 are not limited to those illustrated, and can be changed as appropriate depending on the application, size, specifications, etc. of the rotating electric machine in which the stator 1 is installed. For example, three or four coils 3 can be provided in the radial direction of the core 2.

[0018] 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 points of multiple coils 3. As will be described later, terminals 41 and 42 can be formed, for example, using the same material as segments 31. In this way, segments 31, terminals 41, and terminals 42 can be manufactured in the same process, thereby reducing manufacturing costs and shortening manufacturing lead times.

[0019] Busbar 51 is plate-shaped and welded to the end of terminal 41. Terminal 41 is electrically connected to a control circuit and the like provided outside stator 1 via busbar 51. Busbar 52 is plate-shaped and welded to the end of terminal 42. Terminal 42 is electrically connected to a control circuit and the like provided outside stator 1 via busbar 52.

[0020] The bus bars 51 and 52 are made of a material with high electrical conductivity, such as pure copper or a material containing copper as a main component.

[0021] As an example, busbars 51 and 52 having a rectangular planar shape are shown, but the planar shapes of busbars 51 and 52 can be changed as appropriate depending on the arrangement of terminals 41 and 42, etc.

[0022] 1 and 2 , the bus bars 51 and 52 extend radially outward from the core 2. However, the direction in which the bus bars 51 and 52 extend can be changed as appropriate depending on the arrangement of the segments 31, terminals 41 and 42, etc. That is, it is sufficient for the bus bars 51 and 52 to extend radially outward from the core 2, for example, in at least one of the directions toward the inside and the outside of the core 2.

[0023] Next, a case where the manufacturing method of the rotating electric machine according to this embodiment is used to manufacture the stator 1 will be described. First, the core 2 is formed. For example, a plurality of plate-shaped magnetic members each having a yoke 21 and portions that will become the plurality of teeth 22 are formed. For example, the magnetic members can be formed by punching electromagnetic steel sheets with a thickness of approximately 0.05 mm to 1.0 mm. Then, the plurality of magnetic members are stacked, and the core 2 is formed by, for example, welding or crimping the plurality of magnetic members. The core 2 can also be formed by pressure-molding a magnetic material powder and a resin binder.

[0024] Furthermore, a plurality of segments 31 are formed as components of the coil 3. FIG. 3 is a process diagram illustrating the process of forming the segments 31. First, a paint containing enamel or the like is applied to the outer surface of a rectangular wire to form a wire material 101. The formed wire material 101 is wound around a reel 102. As shown in FIG. 3, the reel 102 around which the wire material 101 is wound is set in a supply unit 103.

[0025] Next, the wire material 101 wound around the reel 102 is drawn out from the reel 102 by the wire drawing device 104, and the wire material 101 is formed into a straight shape.

[0026] Next, the paint on a portion of the wire 101 is removed by the stripping device 105. The stripping device 105 has, for example, a cutter 105a with a pair of parallel blades and a cutter 105b with a pair of parallel blades. The cutter 105a and the cutter 105b each strip the paint along a pair of surfaces of the rectangular wire included in the wire 101. In this case, the movement direction of the cutter 105b is perpendicular to the movement direction of the cutter 105a. Therefore, the cutter 105a and the cutter 105b can partially strip the paint adhering to the four sides of the rectangular wire.

[0027] Next, the wire material 101 is cut to a predetermined length by a cutting device 106. Near the ends on both sides of the wire material 101 cut to a predetermined length, the rectangular wire is exposed from the paint.

[0028] Next, the wire material 101 cut to a predetermined length is bent to form a segment 31. FIG. 4 is a schematic diagram illustrating the segment 31. As shown in FIG. 4, the segment 31 is, for example, approximately U-shaped. The segment 31 has, for example, a conductor portion 31a and an insulating portion 31b. The conductor portion 31a is formed by cutting the rectangular wire included in the wire material 101 using a cutting device 106. The insulating portion 31b is paint that was applied to the rectangular wire. The portion of the conductor portion 31a exposed from the insulating portion 31b near the end of the segment 31 is where the paint has been partially removed using a stripping device 105. Multiple segments 31 are formed in this manner.

[0029] Furthermore, terminals 41 and 42 are formed. Terminals 41 and 42 can be formed by bending a linear member 43 into a predetermined shape. FIG. 5 is a schematic perspective view illustrating member 43. As shown in FIG. 5, member 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). Member 43 can be formed using the linear material 101 described above. Therefore, the cross-sectional shape and cross-sectional dimensions in a direction perpendicular to the extension direction of conductor portion 43a can be the same as the cross-sectional shape and cross-sectional dimensions in a direction perpendicular to the extension direction of conductor portion 31a. The vicinities of both end portions of conductor portion 43a are exposed from insulating portion 31b.

[0030] A stepped portion 43a1 is provided at one end of the conductor portion 43a. The cross-sectional dimension of the stepped portion 43a1 in a direction perpendicular to the extension direction of the conductor portion 43a is smaller than the cross-sectional dimension of the conductor portion 43a. When welding the bus bar 51 to the terminal 41 and when welding the bus bar 52 to the terminal 42, a laser beam is irradiated onto the end of the stepped portion 43a1. The welding of the bus bar 51 and the bus bar 52 will be described in detail below.

[0031] The member 43 can be formed from the wire material 101 by providing the cutter 105c and the cutter 105d to the peeling device 105.

[0032] 6 is a schematic perspective view illustrating the formation of the member 43. As shown in FIG. 6, a pair of cutters 105c are provided. The cutter 105c has a blade 105c1 that removes the paint from a portion of the linear material 101, and a blade 105c2 that cuts out a portion of the rectangular wire included in the linear material 101.

[0033] A pair of cutters 105d are provided. The cutter 105d has a blade 105d1 that removes paint from a portion of the wire 101, and a blade 105d2 that cuts out a portion of the rectangular wire included in the wire 101. The blade 105d1 may be the same as the blade 105c1. The blade 105d2 may be the same as the blade 105c2.

[0034] The movement direction of cutter 105d is perpendicular to the movement direction of cutter 105c. Therefore, cutter 105c and cutter 105d can partially remove the paint adhering to the four sides of the rectangular wire and form a stepped portion 43a1 in the rectangular wire. Although the example shows the case where four sides of the rectangular wire are cut out, two sides or three sides of the rectangular wire may be cut out.

[0035] The paint adhering to the other end of the member 43 (the portion to which the coil 3 is welded) can be removed by the cutter 105a and the cutter 105b described above.

[0036] The cutter 105 a and the cutter 105 b , and the cutter 105 c and the cutter 105 d can be provided in the same peeling device 105 or in different peeling devices 105 .

[0037] The linear material 101, with the stepped portion 43a1 formed and the paint partially peeled off, is cut to a predetermined length by the cutting device 106. By cutting such linear material 101, the member 43 illustrated in Fig. 5 is formed. By bending the linear material 43 into a predetermined shape, the terminals 41 and 42 can be formed.

[0038] The number of terminals 41 and 42 is smaller than the number of segments 31. Therefore, if segments 31, terminals 41, and terminals 42 can be formed from the same material (wire material 101) on the same production line, productivity can be improved, and ultimately, production costs can be reduced and production delivery times can be shortened.

[0039] Next, the ends of the multiple segments 31 are laser welded together to form the coil 3. FIG. 7 is a schematic diagram illustrating the formation of the coil 3. First, as shown in FIG. 7, multiple segments 31 are provided in each of multiple slots 23 provided in the core 2. For example, each of the multiple segments 31 is inserted into a predetermined slot 23 from the axial direction of the core 2 (Z direction in FIG. 7). 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 winding coil 3 can be formed. Furthermore, insulating paper covering the segment 31 can be provided for each of the multiple slots 23.

[0040] Next, the portion of each segment 31 protruding from the core 2 is bent toward the adjacent segment 31. Furthermore, the portion of each conductor 31a near the portion exposed from the insulating portion 31b is bent in the axial direction of the core 2 (the Z direction in FIG. 7 ). The portion of each conductor 31a exposed from the insulating portion 31b and the portion of each adjacent conductor 31a exposed from the insulating portion 31b are positioned so that they overlap in the circumferential direction of the core 2. By repeating the above procedure, multiple sets of segments 31 lined up in the circumferential direction of the core 2 are provided in the radial direction of the core 2.

[0041] Although the above example illustrates a case where the bending process is performed after the multiple segments 31 are fitted into the slots 23, the present invention is not limited to this. For example, the multiple segments 31 may be bent, and each of the multiple bent segments 31 may be fitted into a predetermined slot 23. In this case, the bent segments 31 may be fitted from the inside to the outside of the core 2.

[0042] Here, when laser welding the ends of the segments 31 (conductor portions 31 a), if there is a gap between the ends of the segments 31 (conductor portions 31 a), the cross-sectional area of ​​the weld may become small, or laser light may leak through the gap between the ends, damaging the insulating portion 31 b. Therefore, when performing laser welding, a welding jig may be used that brings the ends of a pair of adjacent conductor portions 31 a closer to each other in the radial direction of the core 2.

[0043] Furthermore, by cutting the vicinity of the ends of a pair of adjacent conductors 31 a, the positions of the end faces of the pair of conductors 31 a can be aligned. If the positions of the end faces of the pair of conductors 31 a are aligned, it becomes easy to place the positions of the end faces of the pair of conductors 31 a within the range of the focal depth when performing laser welding.

[0044] Next, the ends of adjacent segments 31 (conductor portions 31 a) are laser welded together to form the coil 3 provided in the slot 23. Welded portions 31 c are formed at the ends of the laser-welded conductor portions 31 a. A single coil 3 is formed by connecting multiple segments 31 (conductor portions 31 a) in series via the welded portions 31 c. A plurality of coils 3 are also formed aligned radially around the core 2.

[0045] Terminals 41 and 42 are also provided on the core 2, and the ends of the terminals 41 and 42 opposite to the side where the stepped portion 43a1 is formed are welded to the coil 3. The terminal 41 is electrically connected to an end of one coil 3. The terminal 41 serves as a terminal for applying power to the coil 3. The terminal 42 is electrically connected to the neutral points of the multiple coils 3. The terminal 42 serves as a terminal for electrically connecting the multiple coils 3 to the neutral points of a control circuit or the like. The terminals 41 and 42 can be welded by, for example, laser welding.

[0046] Next, bus bar 51 is welded to the end of terminal 41 on the side where stepped portion 43a1 is formed, and bus bar 52 is welded to the end of terminal 42 on the side where stepped portion 43a1 is formed.

[0047] 8 to 10 are process diagrams illustrating a procedure for welding a bus bar 51 (bus bar 52) to an end of a terminal 41 (terminal 42). As shown in FIG. 8, the bus bar 51 (bus bar 52) is plate-shaped and has a hole 51a (hole 52a) penetrating through 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 dimensions of the hole 51a (hole 52a) can be the same as the cross-sectional dimensions of the conductor portion 43a or slightly larger than the cross-sectional dimensions of the conductor portion 43a.

[0048] 9, the conductor portion 43a of the terminal 41 (terminal 42) is inserted into the hole 51a (hole 52a). When the conductor portion 43a is inserted into the hole 51a (hole 52a), the stepped portion 43a1 protrudes from the bus bar 51 (bus bar 52).

[0049] Next, as shown in FIG. 10, a laser beam is applied to the end of the stepped portion 43a1 protruding from the bus bar 51 (bus bar 52), thereby welding the terminal 41 (terminal 42) and the bus bar 51 (bus bar 52).

[0050] Here, it is also conceivable to laser-weld a bus bar to the side surface of the conductor portion 43 a of the terminal 41 (terminal 42). However, when the bus bar is laser-welded to the side surface of the conductor portion 43 a, the laser light is more likely to be incident on the insulating portion 31 b, which is more likely to cause damage to the insulating portion 31 b. Furthermore, the coil 3 (segments 31) is present around the terminal 41 (terminal 42), which makes it difficult to irradiate the laser light and makes the jig and cover used for laser welding more complicated.

[0051] In contrast, if laser light is irradiated onto the end of the terminal 41 (terminal 42) protruding from the plate-shaped bus bar 51 (bus bar 52), the periphery of the terminal 41 (terminal 42) is covered by the bus bar 51 (bus bar 52), thereby preventing damage to the insulating portion 31b of the terminal 41 (terminal 42).

[0052] Furthermore, the busbar 51 (busbar 52) and the terminal 41 (terminal 42) can be aligned by inserting the conductor portion 43a of the terminal 41 (terminal 42) into the hole 51a of the busbar 51 (hole 52a of the busbar 52). That is, the busbar 51 (busbar 52) can serve as a welding cover and a welding jig.

[0053] Furthermore, the direction of laser light irradiation when welding the bus bar 51 (bus bar 52) is the same as the direction of laser light irradiation when welding the ends of the segments 31. This makes it easy to weld the bus bar 51 (bus bar 52) after welding the ends of the segments 31. This makes it possible to simplify the manufacturing process, shorten the manufacturing period, and reduce manufacturing costs.

[0054] Next, the plurality of coils 3, terminals 41, and terminals 42 are fixed to the core 2. For example, varnish is supplied into the gaps between the core 2 and the coils 3, terminals 41, and terminals 42, and the varnish is hardened, thereby fixing the plurality of coils 3, terminals 41, and terminals 42 to the core 2.

[0055] Furthermore, it is also possible to form insulating portions by supplying, for example, varnish to the portions of the coil 3, the terminals 41, and the terminals 42 where the conductor portions 31a are exposed and to the welded portions.

[0056] If the varnish adheres to the ends, outer portion, or inner portion of the core 2 when the varnish is supplied, the varnish can be removed, for example, by irradiating the adhered varnish with a laser beam. In this manner, the stator 1 can be manufactured.

[0057] Next, welding of the bus bar 51 (bus bar 52) according to another embodiment will be described. Figures 11 to 13 are process diagrams illustrating the welding procedure of the bus bar 51 (bus bar 52) according to another embodiment.

[0058] 11, the terminal 41a (terminal 42a) is provided with a conductor portion 43a and an insulating portion 31b. The terminal 41a corresponds to the above-mentioned terminal 41. The terminal 42a corresponds to the above-mentioned terminal 42.

[0059] However, the terminal 41a (terminal 42a) does not have the stepped portion 43a1. That is, the terminal 41a (terminal 42a) can be the terminal 41 (terminal 42) without the stepped portion 43a1. Such a terminal 41a (terminal 42a) can be manufactured in the same manner as the segment 31, for example.

[0060] As shown in FIG. 11 , a piece-shaped welding material 53 is used to weld the bus bar 51 (bus bar 52) and the terminal 41a (terminal 42a). In this case, the material of the welding material 53 is preferably the same as the material of the conductor portion 43a and the bus bar 51 (bus bar 52). As described above, before laser welding the ends of the segments 31 (conductor portions 31a), the vicinity of the ends of a pair of adjacent conductor portions 31a are cut. The material of the conductor portions 31a can be the same as the material of the conductor portion 43a and the bus bar 51 (bus bar 52). Therefore, the welding material 53 can be scrap metal generated when the vicinity of the end of the conductor portion 31a is cut. This can reduce manufacturing costs.

[0061] First, as shown in Fig. 12, the conductor portion 43a of the terminal 41a (terminal 42a) is inserted into the hole 51a (hole 52a). Then, the welding material 53 is placed on the opening of the hole 51a (hole 52a) on the side opposite to the side where the conductor portion 43a is inserted.

[0062] Subsequently, as shown in FIG. 13, the welding material 53 is irradiated with a laser beam to weld the terminal 41a (terminal 42a) and the bus bar 51 (bus bar 52).

[0063] In this embodiment, too, the bus bar 51 (bus bar 52) can function as a welding cover. This can prevent damage to the insulating portion 31b. The bus bar 51 (bus bar 52) can also function as a welding jig. This facilitates welding the bus bar 51 (bus bar 52) to the terminal 41a (terminal 42a). Furthermore, since the stepped portion 43a1 can be omitted, the terminal 41a (terminal 42a) can be formed in the same process as the segment 31. This can reduce manufacturing costs and shorten manufacturing time.

[0064] 14 to 16 are process diagrams illustrating a welding procedure for a bus bar 51b (bus bar 52b) according to another embodiment.

[0065] Bus bar 51b corresponds to the above-described bus bar 51. Bus bar 52b corresponds to the above-described bus bar 52. The material of bus bar 51b (bus bar 52b) may be the same as the material of bus bar 51 (bus bar 52), for example.

[0066] 14, the bus bar 51b (bus bar 52b) has a plate-like shape and has a hole 51ba (hole 52ba) penetrating through the bus bar 51b (bus bar 52b) in the thickness direction. The hole 51ba (hole 52ba) penetrates the bus bar 51b (bus bar 52b) in the thickness direction. The hole 51ba (hole 52ba) also opens, for example, on one side of the bus bar 51b (bus bar 52b).

[0067] As an example, the busbar 51b (busbar 52b) having a rectangular planar shape has been illustrated, but the planar shape of the busbar 51b (busbar 52b) can be changed as appropriate depending on the arrangement of the terminals 41b (terminals 42b), etc.

[0068] The terminal 41b (terminal 42b) is provided with a conductor portion 43a and an insulating portion 31b. The terminal 41b corresponds to the above-mentioned terminal 41. The terminal 42b corresponds to the above-mentioned terminal 42.

[0069] However, terminal 41b (terminal 42b) does not have a stepped portion 43a1. In addition, a pair of grooves 43a2 is provided near the end of conductor portion 43a. The pair of grooves 43a2 face 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 dimension of hole 51ba (hole 52ba) of busbar 51b (busbar 52b). The height dimension of groove 43a2 is the same as or slightly larger than the thickness of busbar 51b (busbar 52b).

[0070] 15, the portion of the conductor portion 43a where the pair of grooves 43a2 are provided can be provided in the hole 51ba (hole 52ba) of the bus bar 51b (bus bar 52b). In this case, the portion of the conductor portion 43a where the pair of grooves 43a2 are provided is inserted into the hole 51ba (hole 52ba) from one side of the bus bar 51b (bus bar 52b).

[0071] When the portion of the conductor portion 43a where the pair of grooves 43a2 is provided is inserted into the hole 51ba (hole 52ba), the end of the conductor portion 43a protrudes from the bus bar 51b (bus bar 52b).

[0072] Next, as shown in FIG. 16, the end of the conductor portion 43a protruding from the bus bar 51b (bus bar 52b) is irradiated with laser light to weld the terminal 41b (terminal 42b) and the bus bar 51b (bus bar 52b).

[0073] In this embodiment, the portion of the conductor portion 43a where the pair of grooves 43a2 are provided is located inside the hole 51ba (hole 52ba), which increases the bonding strength between the terminal 41b (terminal 42b) and the bus bar 51b (bus bar 52b), thereby improving the reliability of the electrical connection between the terminal 41b (terminal 42b) and the bus bar 51b (bus bar 52b).

[0074] Furthermore, since the posture of the bus bar 51b (bus bar 52b) relative to the terminal 41b (terminal 42b) can be stabilized, laser welding becomes easier and the quality of the welded portion can be improved.

[0075] As described above, the bus bar 51b (bus bar 52b) can also function as a welding cover, which can prevent damage to the insulating portion 31b. The bus bar 51b (bus bar 52b) can also function as a welding jig, which can facilitate welding the bus bar 51b (bus bar 52b) to the terminal 41b (terminal 42b).

[0076] Next, a method for manufacturing the terminal 41b (terminal 42b) will be described. The terminal 41b (terminal 42b) can be formed by bending a linear member 43b into a predetermined shape.

[0077] Fig. 17 is a schematic perspective view illustrating the member 43b. As shown in Fig. 17, the member 43b has a conductor portion 43a and an insulating portion 31b. The member 43b can be formed using the above-described wire material 101. Therefore, the cross-sectional shape and cross-sectional dimensions in a direction perpendicular to the extension direction of the conductor portion 43a can be the same as the cross-sectional shape and cross-sectional dimensions in a direction perpendicular to the extension direction of the conductor portion 31a. Both end portions of the conductor portion 43a are exposed from the insulating portion 31b.

[0078] A pair of grooves 43a2 are provided near one end of the conductor portion 43a. The member 43 can be formed from the wire material 101 by providing the peeling device 105 with the cutters 105e and 105f.

[0079] Fig. 18 is a schematic perspective view illustrating the formation of member 43b. As shown in Fig. 18, a pair of cutters 105e are provided. The cutter 105e has a pair of blades 105e1 that remove paint from a portion of the linear material 101, and a blade 105e2 that cuts out a portion of the rectangular wire included in the linear material 101. The blade 105e2 is provided between the blades 105e1 and 105e1.

[0080] The cutter 105f is provided in pair. The cutter 105f has a pair of blades that remove the paint from a partial area of ​​the wire 101.

[0081] The movement direction of cutter 105f is perpendicular to the movement direction of cutter 105e, so cutter 105e and cutter 105f can partially peel off the paint adhering to the four sides of the rectangular wire and form a pair of grooves 43a2 in the rectangular wire.

[0082] The paint adhering to the other end of the member 43b (the portion to which the coil 3 is welded) can be removed by the cutter 105a and the cutter 105b described above.

[0083] The cutter 105 a and the cutter 105 b , and the cutter 105 e and the cutter 105 f can be provided in the same peeling device 105 or in different peeling devices 105 .

[0084] The linear material 101, in which the pair of grooves 43a2 are formed and the paint has been partially peeled off, is cut to a predetermined length by the above-mentioned cutting device 106. By cutting such linear material 101, the member 43b illustrated in Fig. 17 is formed. By bending the linear member 43b into a predetermined shape, the terminal 41b (terminal 42b) can be formed.

[0085] Although several embodiments of the present invention have been described above, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other.

[0086] REFERENCE SIGNS LIST 1 stator 2 core 3 coil 23 slot 31 segment 31a conductor portion 31b insulating portion 41 to 41b terminals 42 to 42b terminals 43 member 43a conductor portion 43a1 stepped portion 43a2 groove 43b member 51 bus bar 51a hole 51b bus bar 51ba hole 52 bus bar 52a hole 52b bus bar 52ba hole 53 welding material 101 wire material 105 peeling device 105a to 105f cutter

Claims

1. A method for manufacturing a rotating electric machine comprising the steps of: providing a segment in each of a plurality of slots provided in a core, the segment having a first conductor portion and a first insulating portion provided on the outer surface of the first conductor portion; providing a terminal on the core, the terminal having a second conductor portion and a second insulating portion provided on the outer surface of the second conductor portion; laser welding ends of a pair of adjacent first conductor portions to form a coil provided in the slot; and laser welding a plate-shaped bus bar to the end of the second conductor portion, wherein the bus bar has a hole penetrating in the thickness direction, and in the step of laser welding the bus bar, the end of the second conductor portion is inserted into the hole of the bus bar.

2. A method for manufacturing a rotating electric machine as described in claim 1, wherein a stepped portion is provided at an end of the second conductor portion, and in the process of laser welding the bus bar, when the end of the second conductor portion is inserted into the hole of the bus bar, the stepped portion protrudes from the bus bar and laser light is irradiated onto the end of the stepped portion.

3. A method for manufacturing a rotating electric machine as described in claim 1, wherein the hole of the busbar further opens to one side of the busbar, and a pair of grooves are provided near the end of the second conductor portion, and in the process of laser welding the busbar, the portion of the second conductor portion having the pair of grooves is inserted into the hole from the side of the one side of the busbar, and laser light is irradiated to the end of the second conductor portion protruding from the busbar.

4. A method for manufacturing a rotating electric machine as described in claim 1, wherein in the process of laser welding the busbar, a piece-shaped welding material is provided in the opening of the hole of the busbar on the side opposite to the side into which the end of the second conductor portion is inserted, and laser light is irradiated onto the welding material.

5. A rotating electric machine comprising: a coil provided in a core; a terminal provided on the core and electrically connected to the coil; and a plate-shaped bus bar having a hole penetrating in the thickness direction and welded to an end of the terminal, wherein the end of the terminal is provided in the hole provided in the bus bar.

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