Method for manufacturing rotary machine

Abstract

An embodiment of the present invention provides a method which is for manufacturing a rotary machine and which makes it possible to improve work safety when a conductive member is welded to a metal wire. In a method for manufacturing a rotary machine according to an embodiment, a first jig which can be rotated in the circumferential direction is disposed with respect to a stator including a plurality of first metal wires arranged in the circumferential direction and having the shape of a cylinder which extends in a first direction. Furthermore, in the manufacturing method, a first conductive member which has a plurality of recesses that are arranged in the circumferential direction is disposed on the first jig. Moreover, in the manufacturing method, at least one of the first conductive member and the plurality of first metal wires is pressed against the other in a state where ends of the plurality of first metal wires in the first direction are respectively engaged with the plurality of recesses.

Description

Manufacturing method of a rotating machine

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

[0002] A rotating machine includes a coil. The coil includes a plurality of metal wires. A conductive member is welded to the end of each metal wire, and the metal wires are electrically connected to each other by the conductive member. When welding the conductive member to the metal wires, a technique is needed that can improve the stability of the welding process.

[0003] JP 2013-17273 A

[0004] An object of the present invention is to provide a method for manufacturing a rotating machine that can improve the stability of the work when welding a conductive member to a metal wire.

[0005] In a method for manufacturing a rotating machine according to an embodiment, a first jig rotatable in the circumferential direction is placed on a stator having a cylindrical shape extending in a first direction and including a plurality of first metal wires arranged in the circumferential direction. The manufacturing method further includes placing a first conductive member having a plurality of recesses arranged in the circumferential direction on the first jig. The manufacturing method further includes pressing at least one of the plurality of first metal wires and the first conductive member toward the other in a state in which end portions of the plurality of first metal wires in the first direction are fitted into the plurality of recesses.

[0006] FIG. 1 is a perspective view showing an example of a stator. FIG. 2 is a schematic view illustrating a segment before being attached to a core. FIG. 3 is a schematic view illustrating a coil attached to a core. FIG. 4 is an enlarged perspective view of a portion of FIG. 1. FIG. 5 is a perspective view showing a welding process. FIG. 6 is a schematic plan view showing a stator. FIG. 7 is a perspective view showing a pole. FIGS. 8(a) and 8(b) are plan views showing an example of a jig. FIGS. 9(a) and 9(b) are plan views showing an example of a jig. FIGS. 10(a) and 10(b) are plan views showing a state in which the jigs are attached. FIG. 11 is a plan view showing a state in which the jigs are attached. FIG. 12 is an enlarged plan view of a portion of FIG. 11. FIG. 13 is a plan view showing a state in which the jigs are attached. FIG. 14 is a plan view showing another example of a jig. FIGS. 15(a) to 15(c) are plan views showing another example of a jig. 16(a) and 16(b) are plan views showing a state in which the jig is attached. FIGS. 17(a) and 17(b) are plan views showing a state in which the jig is attached. FIGS. 18(a) and 18(b) are plan views showing a state in which the jig is attached. FIG. 19 is a cross-sectional view illustrating a rotating machine manufactured by the manufacturing method according to the embodiment.

[0007] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Furthermore, even when the same part is shown, the dimensions and ratios may be different depending on the drawing. In this specification and each drawing, elements similar to those already described are designated by the same reference numerals, and detailed description will be omitted as appropriate.

[0008] An embodiment of the present invention relates to a method for manufacturing a rotating machine. The rotating machine is a motor, a generator, or the like. The rotating machine includes a core and a coil attached to the core. For example, after segments are inserted into slots in the core, ends of adjacent segments are welded together to form a coil. Furthermore, a conductive member is joined to each coil to electrically connect the coils to each other. Here, as an example, an example will be described in which the embodiment is applied to a manufacturing method of a stator in a motor.

[0009] Fig. 1 is a perspective view showing an example of a stator. As shown in Fig. 1, the stator 10 has a cylindrical shape and includes a core 20 and a coil 30. Here, the direction in which the stator 10 extends (the central axis direction of the stator 10) is referred to as the Z direction (first direction). The direction around the Z direction is referred to as the circumferential direction. The direction passing through the central axis of the stator 10 and perpendicular to the Z direction is referred to as the radial direction.

[0010] The core 20 is formed by stacking a plurality of annular magnetic members in the Z direction. The magnetic members are made of, for example, electromagnetic steel plates (silicon steel plates). The core 20 includes a yoke 21 and a plurality of teeth 22.

[0011] The yoke 21 is an annular part and is located on the outer periphery of the core 20. A plurality of teeth 22 are provided at equal intervals on the inner circumferential surface of the yoke 21. Each of the plurality of teeth 22 protrudes from the inner circumferential surface of the yoke 21 toward the center of the core 20 and extends in the Z direction. Grooves (slots 23) are formed between the teeth 22. A portion of the coil 30 is inserted into and fixed in the slot 23.

[0012] 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 machine in which the stator 10 is installed.

[0013] 2 is a schematic diagram illustrating a segment before being attached to a core. The coil 30 is composed of a plurality of segments 31. The external shape of the segment 31 before being attached to the core 20 is, for example, a substantially U-shape, as shown in FIG. 2. The segment 31 includes a metal wire 31a and an insulating film 31b.

[0014] The metal wire 31a is made of a material with high conductivity. For example, a rectangular wire is used as the metal wire 31a. The rectangular wire is a linear member with a square cross section. The cross-sectional dimension of the rectangular wire is, for example, about 1 mm to 4 mm. The metal wire 31a can be made of so-called pure copper or a material containing copper as a main component.

[0015] The insulating film 31b covers the outer surface of the metal wire 31a. However, the insulating film 31b is not provided near both ends of the metal wire 31a, so that the metal wire 31a is exposed. The insulating film 31b is made of an insulating material such as enamel.

[0016] 3 is a schematic diagram illustrating a coil attached to a core. As shown in FIG. 3, a segment 31 is provided inside the slot 23. Both ends of the segment 31 protrude from one end of the core 20. The protruding portion of the segment 31 is bent toward the adjacent segment 31.

[0017] Furthermore, the portions of the metal wires 31a that are exposed from the insulating film 31b extend in the Z direction. In the circumferential direction, the exposed portions of the metal wires 31a overlap with the exposed portions of adjacent metal wires 31a and are electrically connected to each other. The ends of adjacent metal wires 31a are laser welded to each other. A single coil 30 is formed by connecting multiple segments 31 via welds 31c.

[0018] 1, the coils 30 are arranged in a radial direction. For example, three coils 30 are provided, one for a U phase, one for a V phase, and one for a W phase. The external shapes, number, size, etc. of the coils 30 and the segments 31 are not limited to those shown in the example, and can be changed as appropriate depending on the application, size, specifications, etc. of the rotating machine in which the stator 10 is installed.

[0019] Fig. 4 is an enlarged perspective view of a portion of Fig. 1. As shown in Figs. 1 and 4, the coil 30 includes a neutral point 40. The neutral point 40 is a part of the coil 30 and is located at the end in the Z direction. The neutral point 40 protrudes further upward than other parts of the coil 30 (such as the welded portion 31c). At the neutral point 40, the metal wire 31a is not covered with the insulating film 31b and is exposed to the outside.

[0020] The stator 10 includes a plurality of neutral points 40 arranged in the circumferential direction. A conductive member 50 is joined to the plurality of neutral points 40. Specifically, the conductive member 50 has a plurality of recesses 50a arranged in the circumferential direction. The neutral points 40 are fitted into the recesses 50a, respectively, and the conductive member 50 is joined to each neutral point 40. The conductive member 50 is made of a metal such as copper or aluminum. For example, a flat plate is used as the conductive member 50.

[0021] As shown in FIG. 1 , terminals 60 for supplying current from an external circuit to the coil 30 are connected to the conductive member 50. Alternatively, the conductive member 50 and the terminals 60 may be formed integrally. In the example shown in FIG. 1 , two conductive members 50 (conductive member 51, conductive member 52) and three terminals 60 (terminals 61, 62, and 63) are provided. The conductive member 51 is joined to a plurality of neutral points 40. The conductive member 52 is joined to another plurality of neutral points 40. The three terminals 61 to 63 are electrically connected to the conductive members 51 and 52, respectively.

[0022] An example of a manufacturing method for the stator 10 will now be described. First, a plurality of plate-shaped magnetic members are fabricated. Each magnetic member includes a portion corresponding to the yoke 21 and a portion corresponding to the plurality of teeth 22. For example, the magnetic members are formed by punching electromagnetic steel plates with a thickness of approximately 0.05 mm to 1.0 mm. The core 20 is formed by stacking the plurality of magnetic members and fixing them to each other by welding or crimping. Alternatively, the core 20 may be formed by pressure molding a magnetic material powder and a resin binder.

[0023] A plurality of segments 31 are prepared. At both end portions of each segment 31, metal wire 31a is exposed from insulating film 31b. As shown in FIG. 2, the segments 31 are bent into a substantially U-shape, and as shown in FIG. 3, each segment 31 is inserted into a slot 23 of the core 20. At this time, one segment 31 is inserted across multiple slots 23. The coil 30 may be a so-called distributed winding coil or a so-called wave winding coil.

[0024] As shown in Figure 3, the vicinity of the end of each segment 31 is bent, and the ends of adjacent segments 31 are welded together. This forms a plurality of coils 30 fitted in the slots 23. Laser welding can be used for the welding. Laser welding can use laser light in the infrared range or shorter wavelengths in the blue to green range.

[0025] Resin or the like is applied to the coil 30 at the portion where the metal wire 31a is exposed, forming an insulating film 31b. However, the insulating film 31b is not formed at the neutral point 40, leaving the metal wire 31a exposed. Varnish is dripped into the gap between the slot 23 and the coil 30, and the varnish is allowed to harden, thereby fixing the coil 30 to the core 20.

[0026] After the coil 30 is fixed, the conductive member 50 is brought into contact with the neutral point 40, and the neutral point 40 and the conductive member 50 are welded together. Then, the terminal 60 is appropriately joined to the conductive member 50. Through the above steps, the stator 10 is fabricated. Then, a rotor is provided inside the stator 10, thereby fabricating a rotating machine.

[0027] 5 is a perspective view showing the welding process. For example, as shown in FIG. 5, the neutral point 40 and the conductive member 50 are welded by irradiating them with a laser L. At this time, it is preferable that the neutral point 40 is in close contact with at least a portion of the conductive member 50. The close contact between the neutral point 40 and the conductive member 50 and the small gap between them stabilizes the welding process and improves the strength of the welded portion.

[0028] In this embodiment, a jig is used to accurately bring the conductive member 50 into close contact with the plurality of neutral points 40. The jig used in the manufacturing process and how to use it will be described in detail below.

[0029] FIG. 6 is a schematic plan view showing a stator. For example, as shown in FIG. 6, the stator 10 includes a plurality of neutral points 41 and a plurality of neutral points 42. The plurality of neutral points 41 are ends of a plurality of metal wires 31a (first metal wires) in the Z direction. The plurality of neutral points 41 are located on the inner periphery and lined up along the circumferential direction. The conductive member 51 (first conductive member) shown in FIG. 1 is joined to the plurality of neutral points 41. The plurality of neutral points 42 are ends of another plurality of metal wires 31a (second metal wires) in the Z direction. The plurality of neutral points 42 are located on the outer periphery and lined up along the circumferential direction. The conductive member 52 shown in FIG. 1 is joined to the plurality of neutral points 42.

[0030] FIG. 7 is a perspective view of a pole. The pole 100 shown in FIG. 7 is used to support a jig. The pole 100 includes a base 110, a cylindrical portion 120, and a protrusion 130. The base 110 is the portion that comes into contact with the floor surface. The base 110 extends along the floor surface to allow the pole 100 to stand stably. The cylindrical portion 120 is located on the base 110 and extends vertically. The protrusion 130 is located at the top of the cylindrical portion 120 and protrudes radially from the cylindrical portion 120. The protrusion 130 is provided to hook the jig.

[0031] 8(a), 8(b), 9(a), and 9(b) are plan views showing examples of jigs. Fig. 8(a) shows a jig 200a (an example of a first jig). A conductive member 51 can be placed on the jig 200a. The jig 200a includes an annular portion 210, a support portion 220, and a base 230.

[0032] A hole is provided in the center of the annular portion 210. The jig 200a is attached to the pole 100 by passing the cylindrical portion 120 of the pole 100 through this hole. The annular portion 210 is rotatable in the circumferential direction relative to the cylindrical portion 120. Furthermore, the annular portion 210 is hooked onto the protrusion 130, thereby fixing the vertical position of the jig 200a. The support portion 220 is a rod-shaped portion extending radially and connected to the annular portion 210.

[0033] The base 230 is a plate-like portion extending in the circumferential direction. The base 230 has an arc shape in a plan view and is connected to the tip of the support portion 220. The base 230 has a protrusion 231 that protrudes upward. The conductive member 51 is fitted into an area defined by the protrusion 231. The protrusion 231 comes into contact with the side surface of the placed conductive member 51 and prevents the conductive member 51 from shifting out of position. Instead of the protrusion 231, a recess may be provided on the top surface of the base 230. When the conductive member 51 is placed, the conductive member 51 is fitted into the recess, thereby preventing the conductive member 51 from shifting out of position.

[0034] With the annular portion 210 hooked onto the protrusion 130, the annular portion 210 rotates circumferentially around the cylindrical portion 120, thereby changing the circumferential position of the base 230. This also changes the circumferential position of the conductive member 51 arranged on the base 230.

[0035] The annular portion 210 includes a locking mechanism 211. The locking mechanism 211 can be switched between a locked state and an unlocked state. In the locked state, rotation of the annular portion 210 in the circumferential direction is restricted. In the unlocked state, the annular portion 210 is rotatable in the circumferential direction. After the jig 200a is rotated in the circumferential direction and the position of the conductive member 51 is determined, the position of the jig 200a in the circumferential direction is fixed by the locking mechanism 211.

[0036] For example, the locking mechanism 211 includes a bolt provided along the radial direction. By turning the bolt, the locking mechanism 211 can be switched between a locked state and an unlocked state. Specifically, when the bolt is tightened, the bolt comes into contact with the cylindrical portion 120, restricting the rotation of the annular portion 210. When the bolt is loosened, the bolt moves away from the cylindrical portion 120, allowing the annular portion 210 to rotate.

[0037] The support portion 220 includes an expandable member 221 (first expandable member). The expandable member 221 is a member for expanding and contracting the support portion 220 in the radial direction. The expansion and contraction of the support portion 220 allows the base 230 and the conductive member 51 to move in the radial direction. The expandable member 221 can be fixed in the expanded or contracted state. This fixes the radial positions of the moved base 230 and the conductive member 51. The expandable member 221 includes, for example, a cylinder. Alternatively, the support portion 220 may include multiple rods inserted through one another. In this case, the support portion 220 expands or contracts as one rod moves relative to the other rod. The expansion and contraction of the support portion 220 may be performed by human force or by power from an actuator or the like.

[0038] 8B shows a jig 300a (an example of a second jig) for pressing the plurality of neutral points 41 toward the conductive member 51. The jig 300a includes an annular portion 310, a support portion 320, and a pressing portion 330.

[0039] The annular portion 310 and the support portion 320 have substantially the same structure as the annular portion 210 and the support portion 220, respectively. The cylindrical portion 120 is passed through the hole in the annular portion 310, and the annular portion 310 is disposed so as to overlap the annular portion 210. The support portion 320 is connected to the annular portion 310 and extends along the radial direction. The pressing portion 330 has an arc shape in a plan view and is connected to the support portion 320. In the illustrated example, the base 230 extends clockwise relative to the support portion 220, while the pressing portion 330 extends counterclockwise relative to the support portion 320.

[0040] The pressing portion 330 has a plurality of protrusions 331 that protrude toward the outer periphery. The protrusions 331 are arranged in the circumferential direction. Each protrusion 331 has an inclined surface 332 that is inclined with respect to the radial and circumferential directions. The spacing between the protrusions 331 corresponds to the spacing between the neutral points 41.

[0041] The annular portion 310 includes a locking mechanism 311, similar to the annular portion 210. The function and structure of the locking mechanism 311 are substantially the same as the function and structure of the locking mechanism 211. After the jig 300a is rotated in the circumferential direction, the locking mechanism 311 can fix the position of the jig 300a in the circumferential direction.

[0042] The support portion 320 includes an elastic member 321 (second elastic member) similar to the support portion 220. The function and structure of the elastic member 321 are substantially the same as the function and structure of the elastic member 221. The elastic member 321 causes the support portion 320 to expand and contract, thereby changing the radial position of the pressing portion 330.

[0043] 9A shows a jig 200b (another example of the first jig). A conductive member 52 (second conductive member) can be placed on the jig 200b. Like the jig 200a, the jig 200b includes an annular portion 210, a support portion 220, and a base 230. The function and structure of the jig 200b are substantially the same as those of the jig 200a.

[0044] 9B shows a jig 300b (another example of the second jig) for pressing the plurality of neutral points 42 toward the conductive member 52. Like the jig 300a, the jig 300b includes an annular portion 310, a support portion 320, and a pressing portion 330. The function and structure of the jig 300b are substantially the same as those of the jig 300a.

[0045] Figures 10(a), 10(b), 11, and 13 are plan views showing the state in which each jig is attached. Figure 12 is an enlarged plan view of a portion of Figure 11. First, the stator 10 is positioned so that the central axis of the stator 10 is aligned vertically. Next, the pole 100 is installed at the position of the central axis of the stator 10. As shown in Figure 10(a), jigs 200a and 300a are attached to the pole 100.

[0046] From the state shown in FIG. 10( a), the jigs 200a and 300a are rotated so that the jigs 200a and 300a face the multiple neutral points 41. As a result, as shown in FIG. 10( b), the multiple neutral points 41 are positioned radially between the jigs 200a and 300a. Alternatively, to achieve the state shown in FIG. 10( b), the jigs 200a and 300a may be slid from above to a position facing the multiple neutral points 41 and attached to the pole 100. In the state shown in FIG. 10( b), the telescopic member 221 of the jig 200a is extended so that the jig 200a does not come into contact with the neutral points 41. Furthermore, the telescopic member 321 of the jig 300a is contracted so that the jig 300a does not come into contact with the neutral points 41.

[0047] The conductive member 51 is placed on the jig 200a, which has been moved by rotating it in the circumferential direction or sliding it from above. The conductive member 51 is positioned so that the multiple recesses 51a fit into the multiple neutral points 41, respectively. Then, as shown in FIG. 11 , the jig 200a is rotated in the circumferential direction while the expandable member 221 is contracted. This causes the multiple recesses 51a to contact the multiple neutral points 41, respectively. Furthermore, the jig 300a is rotated in the circumferential direction while the expandable member 321 is extended. This causes the multiple inclined surfaces 332 to contact the multiple neutral points 41, respectively. At this time, the rotation direction of the jig 300a is opposite to the rotation direction of the jig 200a.

[0048] For example, as shown in FIG. 12 , in a plane perpendicular to the Z direction, the cross-sectional shape of each of the neutral points 41 and the recesses 51a is polygonal and has multiple sides. Due to the contraction of the expandable member 221 and the rotation of the base 230, the conductive member 51 is pressed against the multiple neutral points 41 in the direction indicated by arrow A1. Furthermore, due to the expansion of the expandable member 321 and the rotation of the pressing portion 330, the jig 300a is pressed against the multiple neutral points 41 in the direction indicated by arrow A2. The jigs 200a and 300a apply force to the multiple neutral points 41 and the conductive members 51 in a direction pressing them against each other. More specifically, a force is applied to two sides of the neutral point 41 and two sides of the recess 51a in a direction that brings them closer together. The two sides of the neutral point 41 and the two sides of the recess 51a are in close contact with each other. In this state, the jigs 200a and 300a are locked. The rotation of the jig 200a and the rotation of the jig 300a are restricted, and the conductive member 51 and the plurality of neutral points 41 are maintained in close contact with each other.

[0049] As shown in FIG. 13, the jig 200b shown in FIG. 9(a) and the jig 300b shown in FIG. 9(b) are also attached to the pole 100 in the same manner as the jig 200a and the jig 300a. The jig 200a, 200b, 300a, and 300b may be attached in any order. The jig 200b and the jig 300b apply a force to the multiple neutral points 42 and the conductive member 52 in a direction pressing them together, causing the neutral points 42 and the recesses 52a of the conductive member 52 to come into close contact with each other. In this state, the jig 200b and the jig 300b are locked, maintaining the close contact between the conductive member 52 and the multiple neutral points 42. While maintaining the state shown in FIG. 13, the conductive member 51 and the multiple neutral points 41 are welded, and the conductive member 52 and the multiple neutral points 42 are welded, as shown in FIG. 5.

[0050] Figures 14 and 15(a) to 15(c) are plan views showing other examples of jigs. The jigs shown in Figures 14 and 15(a) to 15(c) may be used instead of the jigs shown in Figures 8(a) to 9(b). The jig 400 shown in Figure 14 (another example of the first jig) includes an annular portion 410, a support portion 420, and a base 430.

[0051] A hole is provided in the center of the annular portion 410, and the cylindrical portion 120 of the pole 100 passes through the hole. The support portion 420 is a rod-shaped portion extending radially and connected to the annular portion 410. The base 430 is a plate-shaped portion extending circumferentially. The base 430 is arc-shaped in a plan view and connected to the tip of the support portion 420. The top surface of the base 430 has two recesses 431 and 432. The conductive member 51 and the conductive member 52 are placed in the recesses 431 and 432, respectively. The side surface of the recess 431 contacts the bottom of the side surface of the conductive member 51 to be placed therein. The side surface of the recess 432 contacts the bottom of the side surface of the conductive member 52 to be placed therein. This prevents the conductive members 51 and 52 from shifting in position. Instead of the recesses 431 and 432, protrusions similar to those of the jig 200a may be provided.

[0052] The annular portion 410 includes a locking mechanism 411, similar to the annular portion 210. The locking mechanism 411 can be switched between a locked state and an unlocked state. The locking mechanism 411 can fix the position of the jig 400 in the circumferential direction.

[0053] Jig 500a shown in FIG. 15(a) and jig 500b shown in FIG. 15(b) are another example of the second jig. Jig 500a and jig 500b each include an annular portion 510, a support portion 520, and a pressing portion 530. Jig 600 (an example of a third jig) shown in FIG. 15(c) includes an annular portion 610, a support portion 620, and a pressing portion 630. Jig 500a is a member that contacts the side surface of conductive member 51. Jig 500b is a member that contacts the side surface of conductive member 52. Jig 600 is a member that presses jig 500a and jig 500b in the radial direction.

[0054] The annular portion 510 and the annular portion 610 have substantially the same structure as the annular portion 410. The cylindrical portion 120 is passed through the holes of the annular portion 510 and the holes of the annular portion 610, and the annular portion 510 and the annular portion 610 are arranged to overlap the annular portion 410.

[0055] The support portion 520 is a rod-shaped portion extending radially and connected to the annular portion 510. The pressing portion 530 is a portion extending circumferentially and connected to the tip of the support portion 520. The pressing portion 530 includes a bent portion 531 and a bent portion 532 so that the pressing portion 530 contacts the side surface of the conductive member 51 or the conductive member 52. The bent portion 531 is bent from the circumferential direction toward the radial direction. The bent portion 532 is bent from the radial direction toward the circumferential direction. As shown in FIGS. 15( a) and 15(b), the bent portion 531 of the jig 500a and the bent portion 531 of the jig 500b are bent in opposite directions. The width (diameter dimension) of the pressing portion 530 becomes wider toward the tip in the circumferential direction.

[0056] The support portion 620 is a rod-shaped portion extending in the radial direction and is connected to the annular portion 610. The pressing portion 630 is a portion extending in the circumferential direction and is connected to the tip of the support portion 620. In the illustrated example, unlike the jigs 500a and 500b, the pressing portion 630 does not have a bent portion. The width of the pressing portion 630 becomes shorter as it approaches the tip in the circumferential direction.

[0057] The annular portion 510 includes a locking mechanism 511, and the locking mechanism 611 includes a locking mechanism 611. The locking mechanism 511 can fix the position of the jig 500a or the jig 500b in the circumferential direction. The locking mechanism 611 can fix the position of the jig 600 in the circumferential direction.

[0058] Figures 16(a), 16(b), 17(a), 17(b), 18(a), and 18(b) are plan views showing the jig attached. After the pole 100 is placed at the position of the central axis of the stator 10, the jig 400 is attached to the pole 100 as shown in Figure 16(a). The jig 400 is positioned so that the recesses 431 and 432 face the plurality of neutral points 41 and the plurality of neutral points 42, respectively. At this time, the jig 400 may be slid to the position from above, or the jig 400 may be attached to the pole 100 and then rotated to be placed in the position.

[0059] 16( a), conductive member 51 is placed on recess 431, and conductive member 52 is placed on recess 432. At this time, as shown in FIG. 16( b), conductive member 51 is placed so that the multiple neutral points 41 fit into the multiple recesses 51 a of conductive member 51, respectively. Similarly, conductive member 52 is placed so that the multiple neutral points 42 fit into the multiple recesses 52 a of conductive member 52, respectively.

[0060] As shown in FIG. 17( a), jigs 500a and 500b are attached to the pole 100. Then, as shown in FIG. 17( b), jigs 500a and 500b are rotated to contact the conductive members 51 and 52, respectively. At this time, the surface between the bent portions 531 and 532 comes into contact with the side surface of the conductive member 51 or the conductive member 52. As a result, the conductive member 51 is pressed circumferentially toward the plurality of neutral points 41. The conductive member 52 is pressed circumferentially toward the plurality of neutral points 42.

[0061] As shown in Fig. 18(a), the jig 600 is attached to the pole 100. Then, as shown in Fig. 18(b), the jig 600 is rotated and inserted into the gap between the jigs 500a and 500b. The side surfaces of the jig 600 come into contact with the side surfaces of the jigs 500a and 500b.

[0062] As described above, the width of the pressing portion 530 increases toward the circumferential tip. Therefore, the gap between the jigs 500a and 500b decreases toward the circumferential tip. Furthermore, the width of the pressing portion 630 decreases toward the circumferential tip. As the jig 600 is inserted into the gap between the jigs 500a and 500b, the gap between the jigs 500a and 500b is gradually widened. The jig 500a is pressed toward the radially inner periphery, and the jig 500b is pressed toward the radially outer periphery. As a result, the conductive member 51 is pressed toward the multiple neutral points 41 in the radial direction. The conductive member 52 is pressed toward the multiple neutral points 42 in the radial direction.

[0063] As a result, as in Fig. 12, a force is applied to the multiple neutral points 41 and the conductive member 51 in a direction that presses them against each other, so that two sides of the neutral point 41 and two sides of the recess 51a come into close contact with each other. A force is applied to the multiple neutral points 42 and the conductive member 52 in a direction that presses them against each other, so that two sides of the neutral point 42 and two sides of the recess 52a come into close contact with each other. In this state, each of the jigs 400, 500a, 500b, and 600 is locked. After locking, the conductive member 51 and the multiple neutral points 41 are welded, and the conductive member 52 and the multiple neutral points 42 are welded, as shown in Fig. 5.

[0064] The advantages of the embodiment will be described. As described above, in the manufacture of a rotating machine, the conductive member 50 is welded to the plurality of neutral points 40. During welding, for the sake of stability of the work and for improving the strength of the welded portion, it is preferable that the conductive member 50 and the plurality of neutral points 40 are arranged in a predetermined positional relationship. It is also preferable that the conductive member 50 be in close contact with the plurality of neutral points 40.

[0065] In response to this problem, the manufacturing method according to the embodiment uses a jig 200a, 200b, or 400. A conductive member 50 can be placed on these jigs. After the jig 200a, 200b, or 400 is placed on the stator 10, the conductive member 50 is placed on the jig 200a, 200b, or 400. Then, with the ends (neutral points 40) of the plurality of metal wires 31a fitted into the plurality of recesses 50a, at least one of the plurality of neutral points 40 and the conductive member 50 is pressed toward the other.

[0066] According to the embodiment, the jig 200a, 200b, or 400 can be used to position the conductive member 50 in a predetermined positional relationship with respect to the plurality of neutral points 40. Furthermore, by using the jig 200a, 200b, or 400, the plurality of neutral points 40 and the conductive member 50 can be brought into close contact with each other while maintaining the positional relationship between the conductive member 50 and the plurality of neutral points 40. This stabilizes the welding operation and sufficiently improves the strength of the welded portion.

[0067] When welding the neutral point 40 and the conductive member 50, a conductive member 50 having multiple recesses on the radially inner side may be used, or a conductive member 50 having multiple recesses on the radially outer side may be used. For example, as shown in FIG. 13 , a conductive member 51 has multiple recesses 51 a on the radially inner side and is disposed radially outward from the multiple neutral points 41. A conductive member 52 has multiple recesses 52 a on the radially outer side and is disposed radially inward from the multiple neutral points 42. For this reason, in the embodiment, a combination of jigs 200 a and 200 b, or a jig 400, is used for the two conductive members 51 and 52. According to the embodiment, whether a conductive member 50 having recesses on the inner side or a conductive member 50 having recesses on the outer side is used, the welding operation can be stabilized and the strength of the welded portion can be sufficiently improved.

[0068] The cross-sectional shape of each metal wire 31a is, for example, a rectangle, and the metal wire 31a has multiple sides. Each recess 50a also has multiple sides. When one of the neutral point 40 and the conductive member 50 is pressed against the other, it is preferable that a force be applied in a direction that moves the two sides of the metal wire 31a and the two sides of the recess 50a toward each other. This allows the neutral point 40 and the conductive member 50 to be welded with the two sides of the metal wire 31a and the two sides of the recess 50a in close contact with each other. As a result, the strength of the welded portion can be further increased.

[0069] The neutral point 40 has an end surface that intersects with the Z direction. The conductive member 50 has a lower surface (first surface) facing the jig and an upper surface (second surface) opposite the lower surface. When welding is performed, it is preferable that the position of the end surface of the neutral point 40 in the Z direction is the same as the position of the upper surface of the conductive member 50 in the Z direction. That is, it is preferable that the upper surfaces of the neutral point 40 and the conductive member 50 are flush with each other during welding. If the position of the end surface of the neutral point 40 in the Z direction is different from the position of the upper surface of the conductive member 50 in the Z direction, the laser may be blocked by the neutral point 40 or the conductive member 50 during welding, resulting in insufficient welding. By flushing the upper surfaces of the neutral point 40 and the conductive member 50, a laser with sufficient intensity can be irradiated onto the welded area, improving the strength of the welded area.

[0070] As described above, each jig preferably includes a locking mechanism for restricting movement in the circumferential direction. By using the locking mechanism, the conductive member 50 and the plurality of neutral points 40 can be easily maintained in a pressed state against each other. This further stabilizes the welding operation.

[0071] Furthermore, with jig 200a or jig 200b, the expandable member 221 allows the pedestal 230 to be moved in the radial direction. As a result, when attaching jig 200a or jig 200b, the radial position of pedestal 230 can be adjusted so that pedestal 230 does not come into contact with multiple neutral points 40. Similarly, with jig 300a or jig 300b, the expandable member 321 allows the pressing portion 330 to be moved in the radial direction. As a result, when attaching jig 300a or jig 300b, the radial position of pressing portion 330 can be adjusted so that pedestal 230 does not come into contact with multiple neutral points 40. According to the embodiment, the usability of jig 200a, 200b, 300a, or 300b can be improved.

[0072] 19 is a cross-sectional view illustrating a rotating machine manufactured by a manufacturing method according to an embodiment. For example, the rotating machine 1 shown in FIG. 19 is manufactured by the manufacturing method according to an embodiment. The rotating machine 1 is a permanent magnet motor. The rotating machine 1 includes a stator 2, a rotor 3, a housing 4, and a cover 5.

[0073] The stator 2 may be the stator 10 shown in Fig. 1. The rotor 3 is provided inside the stator 2 and is rotatable around an axis (central axis) C. The housing 4 accommodates the stator 2 and the rotor 3. The housing 4 has a substantially cylindrical inner circumferential surface, and the stator 2 is fixed to the housing 4. The cover 5 is fixed to the housing 4 and covers the opening of the housing 4.

[0074] The rotor 3 includes a rotating shaft 3a and a core 3b. The rotating shaft 3a extends in a direction parallel to the axis C. The rotating shaft 3a is rotatably supported by the housing 4 and the cover 5 via bearings 6a and 6b. The core 3b is provided around the rotating shaft 3a along a plane perpendicular to the axis C. A small gap is provided between the core 3b and the stator 2. The core 3b is fixed to the rotating shaft 3a and is rotatable together with the rotating shaft 3a.

[0075] According to the embodiment, it is possible to stabilize the welding work and sufficiently improve the strength of the welded portion. As a result, a more reliable stator can be manufactured. By using a stator manufactured by the manufacturing method according to the embodiment, the reliability of a rotating machine can also be improved.

[0076] Embodiments of the present invention include the following features: (Feature 1) A method for manufacturing a rotating machine, comprising: placing a first jig rotatable in a first direction on a stator having a cylindrical shape extending in a first direction and including a plurality of first metal wires lined up in the circumferential direction; placing a first conductive member having a plurality of depressions lined up in the circumferential direction on the first jig; and pressing at least one of the plurality of first metal wires and the first conductive member toward the other in a state in which ends of the plurality of first metal wires in the first direction are fitted into the plurality of depressions. (Feature 2) The method for manufacturing a rotating machine according to Feature 1, wherein each of the plurality of first metal wires and the plurality of depressions has a plurality of sides, and a force is applied in a direction in which two sides of each of the first metal wires and two sides of each of the depressions approach each other. (Feature 3) The method for manufacturing a rotating machine according to Feature 1 or 2, wherein each of the plurality of first metal wires has an end face intersecting the first direction, the first conductive member has a first surface facing the first jig and a second surface opposite to the first surface, and when the plurality of end portions are fitted into the plurality of recesses, a position of each of the plurality of end faces in the first direction is the same as a position of the second surface in the first direction. (Feature 4) The method for manufacturing a rotating machine according to any one of Features 1 to 3, wherein a second jig having a plurality of protrusions aligned in the circumferential direction is arranged so that the plurality of protrusions are positioned between the plurality of first metal wires, and by moving the first jig and the second jig in a state where the plurality of first metal wires and the first conductive member are positioned between the first jig and the second jig in a radial direction of the stator, a force is applied in a direction pressing the plurality of first metal wires and the first conductive member against each other. (Feature 5) The method for manufacturing a rotating machine according to Feature 4, wherein the first jig has an arc-shaped base on which the first conductive member is arranged, and the first jig is rotated in the circumferential direction or slid from the first direction to move the base to a position facing the plurality of first metal wires in the radial direction, and the first conductive member is arranged on the base of the moved first jig.(Feature 6) The method for manufacturing a rotating machine according to Feature 5, wherein the second jig is rotated in the circumferential direction or slid from the first direction to move the plurality of protrusions to positions where they face the plurality of first metal wires, and the moved plurality of protrusions are positioned between the plurality of first metal wires, respectively. (Feature 7) The method for manufacturing a rotating machine according to Feature 5 or 6, wherein the first jig has a first elastic member that changes the position of the base in the radial direction, and the first elastic member presses the first conductive member against the plurality of first metal wires in the radial direction by operation of the first elastic member. (Feature 8) The method for manufacturing a rotating machine according to any one of Features 4 to 7, wherein each of the plurality of protrusions has an inclined surface that is inclined with respect to the circumferential direction and the radial direction, and the plurality of inclined surfaces respectively contact the plurality of first metal wires. (Feature 9) The method for manufacturing a rotating machine according to Feature 8, wherein, with the plurality of first metal wires and the first conductive member positioned between the first jig and the second jig, the second jig is moved in the circumferential direction, thereby applying forces to the plurality of first metal wires from the plurality of inclined surfaces in the circumferential direction and the radial direction, respectively. (Feature 10) The method for manufacturing a rotating machine according to any one of Features 4 to 9, wherein the second jig includes a second expandable member capable of changing positions of the plurality of protrusions in the radial direction, and the plurality of protrusions are inserted into a plurality of gaps between the plurality of metal wires by operation of the second expandable member. (Feature 11) The method for manufacturing a rotating machine according to any one of Features 4 to 10, wherein the stator further includes a plurality of second metal wires lined up in the circumferential direction, and a position in the radial direction of each of the plurality of second metal wires is different from a position in the radial direction of each of the plurality of first metal wires, and further comprises: disposing another first jig rotatable in the circumferential direction relative to the stator; disposing a second conductive member having a plurality of depressions lined up in the circumferential direction on the other first jig; and pressing at least one of the plurality of second metal wires and the second conductive member toward the other in a state in which end portions of the plurality of second metal wires in the first direction are fitted into the plurality of depressions of the second conductive member, respectively.(Feature 12) The method for manufacturing a rotating machine according to any one of Features 1 to 3, further comprising: placing a second jig on the first jig on which the first conductive member is placed, the second jig contacting a side surface of the first conductive member; and pressing the first conductive member against the plurality of first metal wires via the second jig. (Feature 13) The method for manufacturing a rotating machine according to Feature 12, further comprising: placing a second metal wire arranged in the circumferential direction; (Feature 14) The method for manufacturing a rotating machine according to Feature 13, further comprising: placing another second jig on the first jig in contact with a side surface of the second conductive member; and inserting a third jig between the second jig and the other second jig, thereby pressing the second jig against the plurality of first metal wires and pressing the other second jig against the plurality of second metal wires. (Feature 15) The method for manufacturing a rotating machine according to any one of Features 1 to 14, wherein the first jig has a protrusion or a depression into which the first conductive member can be fitted, and when the first conductive member is placed on the first jig, the first conductive member is fitted into a region defined by the depression or into the depression. (Feature 16) The method for manufacturing a rotating machine according to any one of Features 1 to 15, wherein the first conductive member is pressed against the plurality of first metal wires by moving the first jig in at least one of the circumferential direction and the radial direction of the stator. (Feature 17) The method for manufacturing a rotating machine according to any one of Features 1 to 16, wherein the first metal wires and the first conductive member are welded together in a state where the end portions are fitted into the recesses, respectively.

[0077] As used herein, "or" indicates that "at least one or more" of the items listed in the sentence may be employed.

[0078] 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.

[0079] REFERENCE SIGNS LIST 1: Rotating machine, 2: Stator, 3: Rotor, 3a: Rotating shaft, 3b: Core, 4: Housing, 5: Cover, 6a, 6b: Bearing, 10: Stator, 20: Core, 21: Yoke, 22: Teeth, 23: Slot, 30: Coil, 31: Segment, 31a: Metal wire, 31b: Insulating film, 31c: Welded portion, 40-42: Neutral point, 50-52: Conductive member, 50a-52a: Recess, 60-63: Terminal, 100: Pole, 110: Base, 120: Cylindrical portion, 130: Protrusion, 200a, 200b: Jig, 210: Annular portion, 211: Locking mechanism, 220: Support portion, 221: Expandable member, 230: Pedestal 231: Protrusion, 300a, 300b: Jig, 310: Annular portion, 311: Locking mechanism, 320: Support portion, 321: Elastic member, 330: Pressing portion, 331: Protrusion, 332: Inclined surface, 400: Jig, 410: Annular portion, 411: Locking mechanism, 420: Support portion, 430: Base, 431, 432: Recess, 500a, 500b: Jig, 510: Annular portion, 511: Locking mechanism, 520: Support portion, 530: Pressing portion, 531, 532: Bent portion, 600: Jig, 610: Annular portion, 611: Locking mechanism, 620: Support portion, 630: Pressing portion, L: Laser

Claims

1. A method for manufacturing a rotating machine, comprising: placing a first jig that can rotate in a first direction on a stator having a cylindrical shape extending in a first direction and including a plurality of first metal wires lined up in the circumferential direction; placing a first conductive member having a plurality of recesses lined up in the circumferential direction on the first jig; and pressing at least one of the plurality of first metal wires and the first conductive member toward the other with the ends of the plurality of first metal wires in the first direction fitted into the plurality of recesses.

2. A method for manufacturing a rotating machine according to claim 1, wherein each of the plurality of first metal wires and the plurality of recesses has a plurality of sides, and a force is applied in a direction in which two sides of each of the first metal wires and two sides of each of the recesses approach each other.

3. A method for manufacturing a rotating machine as described in claim 1, wherein each of the plurality of first metal wires has an end face that intersects with the first direction, the first conductive member has a first face facing the first jig and a second face opposite to the first face, and when the plurality of end portions are fitted into the plurality of recesses, the positions of each of the plurality of end faces in the first direction are the same as the position of the second face in the first direction.

4. A method for manufacturing a rotating machine as described in claim 1, wherein a second jig having a plurality of protrusions arranged in the circumferential direction is arranged so that the plurality of protrusions are respectively positioned between the plurality of first metal wires, and in a state where the plurality of first metal wires and the first conductive member are positioned between the first jig and the second jig in the radial direction of the stator, a force is applied in a direction pressing the plurality of first metal wires and the first conductive member against each other by moving the first jig and the second jig.

5. A method for manufacturing a rotating machine as described in claim 4, wherein the first jig has an arc-shaped base on which the first conductive member is placed, and the first jig is rotated in the circumferential direction or slid from the first direction to move the base to a position facing the multiple first metal wires in the radial direction, and the first conductive member is placed on the base of the moved first jig.

6. A method for manufacturing a rotating machine as set forth in claim 4, wherein the stator further includes a plurality of second metal wires arranged in the circumferential direction, and the radial positions of each of the plurality of second metal wires are different from the radial positions of each of the plurality of first metal wires, and another first jig rotatable in the circumferential direction is further disposed relative to the stator, and a second conductive member having a plurality of recesses arranged in the circumferential direction is disposed on the other first jig, and at least one of the plurality of second metal wires and the second conductive member is pressed toward the other in a state where the ends of the plurality of second metal wires in the first direction are fitted into the plurality of recesses of the second conductive member, respectively.

7. A method for manufacturing a rotating machine as described in claim 1, wherein a second jig is placed on the first jig on which the first conductive member is placed, the second jig contacting the side of the first conductive member, and the first conductive member is pressed against the plurality of first metal wires via the second jig.

8. A method for manufacturing a rotating machine as set forth in claim 7, wherein the stator further includes a plurality of second metal wires arranged in the circumferential direction, the positions of each of the plurality of second metal wires in the radial direction of the stator being different from the positions of each of the plurality of first metal wires in the radial direction, a second conductive member having a plurality of recesses is further placed on the first jig, and at least one of the plurality of second metal wires and the second conductive member is pressed toward the other with the ends of the plurality of second metal wires in the first direction respectively fitted into the plurality of recesses of the second conductive member.

9. A method for manufacturing a rotating machine as described in claim 8, wherein a second jig is placed on top of the first jig in contact with the side of the second conductive member, and a third jig is inserted between the second jig and the second jig, thereby pressing the second jig against the plurality of first metal wires and pressing the second jig against the plurality of second metal wires.

10. A method for manufacturing a rotating machine according to any one of claims 1 to 9, wherein the first metal wires are welded to the first conductive member with the end portions fitted into the recesses, respectively.

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