JP6622066B2 - Rotating electrical machine coil, rotating electrical machine, and manufacturing method of rotating electrical machine coil - Google Patents

Description

  Embodiments described herein relate generally to a rotating electrical machine coil, a rotating electrical machine, and a method for manufacturing a rotating electrical machine coil.

  A frame coil and an edgewise coil exist in a rotor coil of a rotating electrical machine. FIG. 11 is a diagram illustrating a configuration example of one turn of a general frame-shaped coil. The frame-shaped coil is generally formed by joining three of the four rectangular conductor plates 1 composed of two short sides 1a and two long sides 1b into a frame shape to form one turn. It is manufactured by joining a predetermined number of turns. TIG (Tungsten Inert Gas) welding, brazing, pressure welding or the like is used for joining the conductor plates.

  There is also a joining method called FSW (Friction Stir Welding) invented in the 1990s. This FSW is a kind of so-called solid-phase bonding method in which the maximum temperature reached during bonding is lower than the melting point of the material to be bonded and the material is bonded without melting. Specifically, the conductor plate is formed by the following method. Are joined.

FIG. 12 and FIG. 13 are diagrams for explaining joining by FSW. The groove shape of the conductor plate 2 and the conductor plate 3 to be joined shown in FIG. 12 is generally an I-shaped groove shape, and the I-shaped groove-shaped conductor plate 2 and the conductor plate 3 are joined together. A certain joining target part Z1 is joined using the FSW tool 4.
The FSW tool 4 includes a shoulder 5 and a probe (pin) 6 protruding from the center of the shoulder 5. Generally, the probe 6 has a screw-like spiral groove for increasing a stirring force. It is harder than the material to be joined. At the time of joining, the probe 6 penetrates into the joining target part Z1 while pressing the shoulder 5 against the joining target part Z1 with a predetermined load while rotating the columnar rotation shaft of the FSW tool 4 along the rotation direction M1.

  As a result, the temperature of the bonding target portion Z1 around the probe 6 rises to several hundred degrees Celsius due to frictional heat, the bonding target portion Z1 is softened, and the probe 6 is rotated along the rotation axis to thereby be bonded. A plastic flow portion Z2 is generated in Z1.

  If it is assumed that the shoulder 5 is not provided on the FSW tool, the plastic flow portion Z2 is discharged to the surface of the conductor plate. The shoulder 5 prevents this discharge and the surface of the base material of the conductor plates 2 and 3 By supplying frictional heat to S1, the plastic flow state is maintained and stabilized.

  Thereafter, as shown in FIG. 13, while maintaining the rotation axis of the FSW tool 4 along the rotation direction M1, the FSW tool 4 is moved, for example, to FIG. It moves from the start point to the end point of the joining target part Z1 while applying pressure with a predetermined load along the indicated feed direction M2. Due to this movement, the portion Z2a where plastic flow has occurred, that is, the portion Z2a that is no longer pressurized by the FSW tool, contacts the outside air after passing through the FSW tool 4 and is cooled and hardened.

Japanese Patent Laid-Open No. 10-80109 JP-A-8-168216 JP 2013-192439 A

  TIG welding, which is mainly used in the manufacture of frame-shaped coils, generally requires many man-hours because it piles up many times for each joint, and copper and copper alloys of common coil materials, or aluminum and An aluminum alloy is a difficult-to-weld material, and welding defects such as blow holes are likely to occur.

  In addition, since the base material is generally melted, the vicinity of the welded portion becomes high in temperature, and there is a concern of deterioration or deformation due to thermal effects. Moreover, since TIG welding and brazing are highly dependent on the skill of the worker, qualification management and skill level management of the worker are also required.

  Next, FSW is applied to the configuration of a total of four rectangular conductor plates in which one turn has a short side 1a (two pieces) and a long side 1b (two pieces), similar to the TIG welding shown in FIG. Will be described. FIG. 14 is a diagram illustrating an example of an overview when FSW is performed with a general frame-shaped coil.

  In FSW, the joining portion is joined at a temperature lower than the melting temperature of the base material, and since the time required for joining is short, there is little thermal influence, and welding defects such as blow holes are difficult to occur. Further, if FSW is used, the number of times of build-up on the bonding target portion can be reduced, and therefore the number of man-hours can be reduced. Further, since FSW is generally performed by an automatic machine, there are advantages such as low skill dependency and stable quality and productivity improvement.

However, on the principle that the FSW generates plastic flow by frictional heat and the rotational force of the FSW tool to knead the part to be joined, the end face S2 (rotary electric machine coil) in the conductor plate in the plastic flow part Z5 shown in FIG. Since the point on the side of the outer surface) of the probe 6 is the penetration point P1 and the FSW start point P2 of the probe 6, the section between the FSW start point P2 side and the conductor plate end surface S2 in the joining target portion is the non-joint portion Z3a.

Further, the point on the end surface S3 (end surface of the inner portion of the rotating electrical machine coil) side in the conductor plate in the plastic flow portion Z5 is the FSW end point P3. The FSW tool 4 is fed out of the long side 1b of the conductor plate, and the plastic flow range Z5 exceeds the end surface of the conductor plate (the end surface on the long side 1b side inside the coil) S3. In this case, the plastic flow portion Z2 shown in FIG. 12 is scraped out of the base material, and a large lacking portion is formed.
In order to prevent this, in general, the FSW tool 4 is not sent to the outside of the long side 1b of the conductor plate, the movement of the FSW tool 4 is stopped in the short side 1a and the long side 1b of the conductor plate, and the rotation is not stopped. In this state, the probe 6 is pulled out from the joint portion of the short side 1a and the long side 1b of the conductor plate.

  In this case, at a timing earlier than when the probe 6 is removed from the joint portion, the shoulder 5 does not function as the distance between the shoulder 5 and the conductor plate increases. Since it is limited to the vicinity very close to the surface, the trace (hole) Z6 of the probe 6 remains in the joint portion. Similarly to the FSW start point P2 side, a section between the FSW end point P3 side and the conductor plate end surface S3 in the joining target portion remains as the non-joint portion Z3b.

  The non-joint portion Z3a on the FSW start point P2 side, the non-joint portion Z3b on the FSW end point P3 side, and the withdrawal trace Z6 of the probe 6 on the FSW end point P3 side are notches that affect the mechanical strength of the base material, The range of the shaping target portions Z4a and Z4b including these is removed and shaped smoothly to prevent stress concentration on the notch.

  The shaping target portion Z4a is a range including the non-joined portion Z3a, and (a) an end portion on the FSW start point P2 side in the plastic flow range Z5, (b) a conductor plate end face (frame-shaped coil on the short side 1a) (C) an area surrounded by one part of the end surface S2 on the long side 1b, and this range is a removal target.

  Further, the shaping target portion Z4b is a range including the non-joined portion Z3b and the drawing trace Z6, and (a) the drawing trace Z6 in the plastic flow range Z5, (b) the end face on the long side 1b (inside the frame-shaped coil) (A part of the end face) S3, (c) an end face on the short side 1a (end face of the inner part of the frame-shaped coil) S4, (d) a range surrounded by the coil inner corner P4 in the vicinity of the extraction trace Z6 This range is a removal target.

  However, by removing the above-mentioned shaping target portions Z4a and Z4b, the effective joint line is shortened in the portion including the coil inner corner portion P4 where stress is likely to concentrate, and therefore the mechanical strength is reduced. Moreover, since the amount of shaping (removal) processing at the coil inner corner P4 with poor workability is large, it has been difficult to apply FSW to a conventional frame shape coil having a conductor plate shape.

  The problem to be solved by the present invention is to provide a rotating electrical machine coil, a rotating electrical machine, and a manufacturing method of the rotating electrical machine coil that have high productivity and excellent reliability of a joint.

The rotating electrical machine coils in the embodiment, a rotating electrical machine coils a combination of two conductive plates which two constituting a frame of the long sides of the conductor plate constituting the short sides of the frame to the frame shape, the long sides the conductive plate or the a shape of the conductive plate constituting the short side is concave, the line of one and the other part to match a conductor plate of the conductor plate constituting the long side and the conductor plate constituting the short side, said to be different from frame extension line of the inner end face, the relative concave portions different from two parts in the longitudinal portion of the concave portion side of the conductor plate of the concave, the conductive plate and the short sides constituting the long sides the other of the conductive plates forming a is two the shorter portion of the conductor plate butt on a one-to-one, Ri Na joined by friction stir welding a portion of the abutting portions of these, the portion of the joint Of these, the friction stirrer at the start of the friction stir welding It is a range including a non-joined portion that is a section between the starting point side of the friction stir welding that is the penetration point of the probe of the friction stir welding tool for joining and the end surface of the outer portion of the frame in the vicinity of the starting point. (A) an end on the starting point side in the plastic flow range generated by the friction stir welding, (b) one place on the end face of the outer portion of the conductor plate forming the short side, and (c) the long side. A range surrounded by one portion of the end face of the outer portion of the conductor plate formed is removed as the first shaping target portion, and among the joined portions, the end point side of the friction stir welding and the vicinity of the end point A range including a non-joined portion which is a section between the end face of the inner portion of the frame and further including a trace of the probe generated in the plastic flow range due to the end of the friction stir welding, 1) One end face of the inner portion of the conductor plate that does not include the coil inner corner portion in the vicinity of the pull-out trace among the conductor plate that forms the long side and the conductor plate that forms the short side. And (c) a rotating electrical machine coil in which a range surrounded by the coil inner corner is removed as a second shaping target portion .
The rotating electrical machine coil according to the embodiment is a rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame, One of the conductor plate forming the side and the conductor plate forming the short side is a convex shape, and a line of a portion where one of the conductor plate forming the long side and the conductor plate forming the short side abuts the other is The conductor plate forming the long side with respect to two portions different from the convex portion in the longitudinal portion on the convex portion side of the convex conductor plate so as to be different from the extension line of the inner end face of the frame Two conductor plates that are the other of the short side conductor plates are butted one-to-one, and a part of these butted portions are joined by one friction stir welding, The friction stir welding at the start of the friction stir welding A range including a non-joint portion which is a section between the start point side of the friction stir welding that is a penetration point of the probe of the friction stir welding tool and an end surface of the outer portion of the frame in the vicinity of the start point, (A) an end portion on the starting point side in a plastic flow range generated by the friction stir welding, (b) one portion of an end surface of the outer portion of the conductor plate forming the short side, and (c) a conductor forming the long side. A range surrounded by one end face of the outer part of the plate is removed as a first shaping target part, and the outer part in the vicinity of the end point side of the friction stir welding and the end point of the part to be joined A range including a non-joined portion that is a section between the end faces of the portion, and further including a withdrawal trace of the probe generated in the plastic flow range due to the end of the friction stir welding, and (a) the withdrawal A range surrounded by traces, (b) one place on the end face of the outer portion of the conductor plate forming the short side, and (c) one place on the end face of the outer portion on the conductor plate forming the long side. It is the rotary electric machine coil removed as 2 shaping process object parts.
The rotating electrical machine coil according to the embodiment is a rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame, When the conductor plate forming the side and the conductor plate forming the short side are joined by friction stir welding, the joining line is oblique to the longitudinal direction of the conductor plate forming the long side and the longitudinal direction of the conductor plate forming the short side The conductor plate that forms the long side and the coil inner corner on the end side of the friction stir welding are connected to the coil outer corner on the start side of the friction stir welding A conductor plate having a short side is abutted, and a part of these abutted parts is joined by friction stir welding, and among the joined parts, friction for the friction stir welding at the start of the friction stir welding Stir welding two A range including a non-joined portion that is a section between the starting point side of the friction stir welding that is the penetration point of the probe and the outer corner of the coil, and (a) in a plastic flow range generated by the friction stir welding. A range surrounded by the end portion on the start point side and (b) the outer corner portion of the coil is removed as a first shaping processing target portion, and the end point side and the inner coil corner portion of the joined portions are removed. Including a non-joined portion that is a section between the probe and a probe trace that is generated in the plastic flow range due to the end of the friction stir welding, and includes (a) the pull trace (b) ) One place on the end face of the inner part of the frame in the conductor plate forming the long side, (c) one place on the end face of the inner part in the conductor plate forming the short side, and (d) the inner corner of the coil, The range surrounded by It was removed as a second shaping work regions, a rotary electric machine coil.

Method of manufacturing a rotary electric machine coils in embodiments, to produce a rotating electric machine coils a combination of the two conductive plates 2 sheets forming the frame of the long sides of the conductor plate constituting the short sides of the frame to the frame shape a method, a line of one a portion matching and the other of the long conductor plate constituting the conductor plate and the short sides forming the sides, so as to be different from the extension line of the end face of the inside of the frame, the long sides butt conductive plate constituting the conductor plate and the short sides forming the, joined by friction stir welding the butted portion, of the portion the joint, the friction for the friction stir welding at the start of the friction stir welding A range including a non-joint portion which is a section between a starting point side of the friction stir welding which is a penetration point of the probe of the stir welding tool and an end surface of the outer portion of the frame in the vicinity of the starting point, (a) Above An end portion on the starting point side in a plastic flow range generated by friction stir welding, (b) one end surface of the outer portion of the conductor plate forming the short side, and (c) the outer side of the conductor plate forming the long side. The range surrounded by one part of the end face of the part is removed as the first shaping target part, and among the parts to be joined, the end point side of the friction stir welding and the inner part of the frame in the vicinity of the end point A range including a non-joined portion that is a section between the end face and the plastic flow range generated by the end of the friction stir welding, further including a pull-out trace of the probe, (a) the pull-out trace ( b) One place of the end face of the inner part in the conductor plate which does not include the coil inner corner near the drawing trace among the conductor plate which forms the long side and the conductor plate which forms the short side, and (c) Removing yl inner corner portion, in the enclosed range as a second shaping work regions, a method of manufacturing a rotary electric machine coils.
The method for manufacturing a rotating electrical machine coil in the embodiment is a rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame. The shape of one of the conductor plate forming the long side and the conductor plate forming the short side is a convex shape, and the portion where one of the conductor plate forming the long side and the conductor plate forming the short side abuts the other The conductor which makes the said long side with respect to the part of two places different from the convex part in the longitudinal part by the side of the convex part of the said convex-shaped conductor board so that a line of this may differ from the extension line of the inner end surface of the said frame The two conductor plates which are the other of the plate and the conductor plate forming the short side are butted one-to-one, a part of these butted portions are joined by one friction stir welding, The friction stir welding at the start of the friction stir welding A range including a non-joint portion which is a section between the start point side of the friction stir welding which is a penetration point of the probe of the friction stir welding tool for and an end surface of the outer portion of the frame in the vicinity of the start point, (A) the end on the starting point side in the plastic flow range generated by the friction stir welding, (b) one place on the end face of the outer portion of the conductor plate forming the short side, and (c) the long side. A range surrounded by one end face of the outer portion of the conductor plate is removed as a first shaping target portion, and among the portions to be joined, the end point side of the friction stir welding and the vicinity of the end point A range including a non-joined portion that is a section between the end face of the outer portion and further including a pullout trace of the probe generated in the plastic flow range due to the end of the friction stir welding, (a) the pulling A range surrounded by a trace, (b) one place on the end face of the outer part in the conductor plate forming the short side, and (c) one place on the end face of the outer part in the conductor plate forming the long side. It is the manufacturing method of a rotary electric machine coil removed as a 2nd shaping process object part.
The method for manufacturing a rotating electrical machine coil in the embodiment is a rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame. , When the conductor plate forming the long side and the conductor plate forming the short side are bonded by friction stir welding, the longitudinal direction of the conductor plate forming the long side and the longitudinal direction of the conductor plate forming the short side The conductor forming the long side so that the joint line is connected to the coil outer corner on the start point side of the friction stir welding and the coil inner corner on the end point side of the friction stir welding. A plate and a conductor plate that forms the short side are abutted, a part of the abutted part is joined by friction stir welding, and among the joined parts, the friction stir welding at the start of the friction stir welding is performed. Friction stir welding A range including a non-joined portion which is a section between the starting point side of the friction stir welding and the outer corner of the coil, which is a penetration point of the probe of the tool, and (a) plastic flow generated by the friction stir welding The range surrounded by the end on the start point side in the range and (b) the outer corner of the coil is removed as a first shaping target portion, and the end point side and the coil inner side of the joined portions A range including a non-joined portion that is a section between the corners, and further including a trace of the probe generated in the plastic flow range due to the end of the friction stir welding, (a) the trace of withdrawal, (B) one end face of the inner part of the frame in the conductor plate forming the long side, (c) one place of the end surface of the inner part in the conductor plate forming the short side, and (d) the coil inner angle. Range surrounded by Removed as a second shaping work regions, a method of manufacturing a rotary electric machine coils.

  ADVANTAGE OF THE INVENTION According to this invention, the rotary electric machine coil with high productivity and excellent reliability of a junction part is realizable.

The figure which shows the structural example of 1 turn of the frame shape coil using the concave shape conductor board in 1st Embodiment. The figure which shows an example of the general view of the FSW implementation part of the frame shape coil which used the concave shape conductor board in 1st Embodiment. The figure which shows the structural example of 1 turn of the frame shape coil using the convex-shaped conductor board in 2nd Embodiment. The figure which shows an example of the general view of the FSW implementation part of the frame shape coil using a convex-shaped conductor board in 2nd Embodiment. The figure which shows the structural example of 1 turn of the frame shape coil using the conductor board for diagonal joining in 3rd Embodiment. The figure which shows an example of the general view of the FSW implementation part of the frame shape coil using the conductor plate for diagonal joining in 3rd Embodiment. The figure which shows the structural example of 1 turn of the frame shape coil using the tab board in 4th Embodiment. The figure which shows an example of the general view of the FSW implementation part of the frame shape coil using a tab board in 4th Embodiment. The figure which shows an example in the case of producing a non-joining part in the surface on the opposite side with respect to the probe insertion side in normal FSW. The figure which shows an example in the case of installing a thin plate in the surface on the opposite side with respect to the probe insertion side in 5th Embodiment. The figure which shows the structural example of 1 turn of a general frame shape coil. The figure explaining joining by FSW. The figure explaining joining by FSW. The figure which shows an example of the external view at the time of implementing FSW with a general frame shape coil.

Each embodiment will be described below with reference to the drawings.
(First embodiment)
First, the first embodiment will be described. FIG. 1 is a diagram illustrating a configuration example of one turn of a frame-shaped coil using a concave conductor plate in the first embodiment.
In FIG. 1, the two short sides 7a of the conductor plate 7 constituting one turn of the frame-shaped coil have a concave shape (a U-shape facing the inside of the frame-shaped coil), and the two long sides 7b of the conductor plate Shows the case of a rectangle. A frame-shaped coil can be manufactured by joining the plurality of turns spirally. Note that the long side 7b may be concave instead of the short side 7a.

FIG. 2 is a diagram illustrating an example of an overview of an FSW implementation portion of a frame-shaped coil using a concave conductor plate in the first embodiment. Here, an overview of the joint after performing FSW is shown. As shown in FIG. 2, frame shape coil in the first embodiment, since the short side 7 a is concave, in the longitudinal portion of the concave portion side of the short sides 7 a of the concave (inner frame shape coil) concave portions and different parts lines to be joined portion as the abutting portion of the (portion facing the hollow portion of the frame shape coil) and the long side 7 b transverse section of rectangle, the frame shape coil of the inner end surface S4 extension and differently, butt short sides 7 a and the long 7 b, the butt portion formed by joining by FSW.

As a result of joining by the FSW, a non-joined portion Z3a is generated on the FSW start point P2 side, and a non-joined portion Z3b and a probe extraction trace Z6 are formed on the FSW end point P3 side. In the first embodiment, as compared with the case short side is not concave, in the position the position of the unjoined portion Z3b and probe withdrawal marks Z6 is away from the inner corner P4 of the frame shape coil in the long side 7 b close .
The non-joined portions Z3a and Z3b and the withdrawal trace Z6 are notches that affect the mechanical strength of the base material. Therefore, the shaping target portions Z4a and Z4b are removed and smoothed using a grinder or a file. Shape it. Note that the shaping target portion Z4b on the FSW end point P3 side may be left if there is no problem in mechanical strength.

  The shaping target portion Z4a is a range including the non-joined portion Z3a, and (a) an end portion on the FSW start point P2 side in the plastic flow range Z5, (b) an end surface on the short side 7a side (of the frame-shaped coil). This is a range surrounded by one place on the end face (S2) of the outer portion and (c) one place on the end face S2 on the long side 7b side, and this range is a removal target.

  Further, the shaping target portion Z4b is a range including the non-joined portion Z3b and the drawing trace Z6, and (a) the drawing trace Z6 in the plastic flow range Z5, (b) the end face on the long side 7b side (of the frame-shaped coil). (End face of inner part) One area in S3, (c) A range surrounded by the coil inner corner P4 in the vicinity of the extraction trace Z6, and this range is a removal target.

  As described above, in the first embodiment, these positions are located away from the inner corner P4 of the frame-shaped coil. For this reason, compared with the structure of the conventional conductor board as shown in FIG. 11, the stress concentration to the coil inner corner P4 can be reduced. Further, since the non-joined portions Z3a and Z3b and the drawing trace Z6 are separated from the coil inner corner portion P4, the workability of the shaping process is also improved.

  If the joint obtained by this is, for example, a copper alloy, the melting point of this joint is 1000 ° C. or higher, whereas the temperature during FSW construction is as low as 300 to 600 ° C. Since the time required for joining is also a short time of 1 to 2 minutes, the thermal influence is small, and deformation and a decrease in mechanical strength can be suppressed. The same applies to other embodiments.

(Second Embodiment)
Next, a second embodiment will be described. FIG. 3 is a diagram illustrating a configuration example of one turn of a frame-shaped coil using a convex conductor plate in the second embodiment. FIG. 4 is a diagram illustrating an example of an overview of an FSW implementation portion of a frame-shaped coil using a convex conductor plate in the second embodiment.
Here, the two short sides 8a of the conductor plate 8 constituting one turn of the frame-shaped coil are convex (facing the inside of the frame-shaped coil), and the two long sides 8b of the conductor plate 8 are rectangular. The case of making will be described. A frame-shaped coil can be manufactured by joining the plurality of turns spirally. The long side 8b may be convex instead of the short side 8a.

As shown in FIG. 3, frame shape coil in the second embodiment, since the short side 8 a is a convex, convex portions in the longitudinal portion of the short side 8 a of the convex (inner frame shape coil) and different portions (two) (portion facing the hollow portion of the frame shape coil) and two of the long side 8 b transverse section of a rectangular abutting a one-to-one, joining the butt portion by the FSW Do it. As a result, as in the first embodiment, the line of the joining target portion that becomes the butted portion is different from the extension line of the end surface S4 on the inner side of the frame-shaped coil.

  Further, as shown in FIG. 3, in the second embodiment, the portion inside the coil of the short side 8a, that is, the convex portion, which is the side where FSW is performed, has the same length as the length of the long portion. The holding jig 9 can be applied during the FSW operation. Thereby, the deformation | transformation by FSW of the part which face | matched the press jig | tool 9 in the part inside the coil of the short side 8a can be suppressed.

Next, the joint after the FSW will be described.
In the second embodiment, with respect to the convex portion of the short side 8a, the FSW tool is vertically cut while continuing the FSW, and this vertical portion is located from the vicinity of the end surface S2 side of the short side 8a to the end surface S5 (on the opposite side of S2). By setting the distance to the vicinity of the outer end surface of the frame-shaped coil, the number of joints (number of joint portions) between the short side 8a and the two long sides 8b is usually two on the end surface S2 side and the end surface S5 side. It is possible to make one part from the end face S2 side to the end face S5 side.

As a result, one non-joint portion Z3a on the FSW start point P2 side is generated on the end surface S2 outside the frame-shaped coil, and the non-joint portion Z3b and probe extraction trace Z6 on the FSW end point P3 side are on the end surface S5 (on the S2 of the frame-shaped coil). One location occurs on the opposite end surface. Thereby, compared with 1st Embodiment, the number of the non-joining parts produced when joining two long sides with respect to one short side can be halved.
These non-joined portions Z3a and Z3b and the withdrawal trace Z6 are removed as the shaping target portion Z4a on the end surface S2 side and the shaping target portion Z4b on the end surface S5 side using a grinder or a file as in the first embodiment. And shape it smoothly.

  The shaping target portion Z4a is a range including the non-joined portion Z3a, and (a) an end portion on the FSW start point P2 side in the plastic flow range Z5, (b) one place on the end surface S2 on the short side 8a side, (C) A range surrounded by one place on the end surface S2 on the long side 8b side, and this range is a removal target.

  Further, the shaping target portion Z4b is a range including the non-joined portion Z3b and the drawing trace Z6, (a) the drawing trace Z6 in the plastic flow range Z5, (b) the outer side of the rotating electrical machine coil on the short side 8a side. This is a range surrounded by one place on the end face S5 (opposite side of the end face S2) and one place on the end face S5 on the long side 8b side, and this range is a removal target.

  In the second embodiment, since the length of the joining target portion is longer than that in the first embodiment, the time required for one joining becomes longer, but the number of FSW setups can be reduced. The overall work time is not greatly affected.

If a non-joined portion remains between the convex portion P6 of the convex short side 8a and the long side 8b, the non-joined portion becomes a notch that affects the mechanical strength at the coil inner portion. Therefore, the interface Z7 between the short side (convex conductor plate) 8a and the long side (rectangular conductor plate) 8b in the convex portion P6 of the short side 8a is included in the plastic flow range Z5 by FSW.
For this reason, since the probe 6 of the FSW tool passes immediately near the inner end surface S4 (end surface of the convex portion P6) of the short side (convex conductor plate) 8a, the probe passage range Z8 within the plastic flow range Z5 is the conductor plate. There is a possibility that the inner side of the conductor plate is deformed under the condition that the short side 8a does not go outside. As a countermeasure against this, deformation of the inner side of the conductor plate can be prevented by holding the inner end surface S4 of the short side 8a of the conductor plate of the frame-shaped coil using the holding jig 9.

  The holding jig 9 has a thickness that does not contact the shoulder 5 during the FSW. There is no problem if the material of the holding jig 9 is a material having a tensile strength of 1.3 times or more of the material to be joined by FSW. For example, if the material of the conductor is a copper alloy, steel having a strength equivalent to that of general carbon steel is sufficient as the material of the holding jig 9.

(Third embodiment)
Next, a third embodiment will be described. FIG. 5 is a diagram illustrating a configuration example of one turn of a frame-shaped coil using a conductor plate for oblique bonding in the third embodiment. FIG. 6 is a diagram illustrating an example of an overview of an FSW implementation portion of a frame-shaped coil using a diagonal joining conductor plate in the third embodiment.
Here, the short side 10a and the long side 10b of the conductor plate 10 constituting one turn of the frame-shaped coil are cut obliquely with respect to the short side 10a longitudinal direction D1 and the long side 10b longitudinal direction D2. The case where the FSW joint line 11 is connected from the outer corner P5 of the frame-shaped coil to the inner corner P4 as shown in FIG. 6 will be described. A frame-shaped coil can be manufactured by joining the plurality of turns spirally.

  As shown in FIG. 6, in the third embodiment, after the FSW is performed, the non-joint portion Z3a is generated in the vicinity of the outer corner portion P5 on the FSW start point P2 side, and the frame coil on the FSW end point P3 side is formed. A non-joined portion Z3b and a probe extraction trace Z6 are generated in the vicinity of the inner corner portion P4.

The non-joined portion Z3a has a small processing area as the shaping target portion Z4a and has few obstacles, so it can be cut with a circular saw or the like, and is shaped with a grinder or a file after this cutting. Thereby, workability can be improved.
Further, since the non-joined portion Z3b and the probe extraction trace Z6 on the FSW end point P3 side are in the vicinity of the inner corner portion P4 of the frame-shaped coil, they are removed as the shaping target portion Z4b and smoothly shaped using a grinder or a file.

  The shaping target portion Z4a is a range including the non-joined portion Z3a, and (a) an end portion on the FSW start point P2 side in the plastic flow range Z5, and (b) a coil outer corner portion P5 near the FSW start point P2. It is an enclosed range, and this range is a removal target.

  Further, the shaping target portion Z4b is a range including the non-joined portion Z3b and the drawing trace Z6, and (a) the drawing trace Z6 in the plastic flow range Z5, (b) the end surface (rotation) on the long side 10b side of the conductor plate. (The end face of the inner part of the electrical coil) at one place on S3, (c) the end face on the short side 10a side of the conductor plate (the end face of the inner part of the rotating electrical machine coil) at one place on S4, (d) the inside of the coil near the extraction trace Z6 This is a range surrounded by the corner P4, and this range is a removal target.

In the third embodiment, since the FSW joint line 11 is inclined obliquely with respect to the longitudinal directions D1 and D2, the length of the FSW joint line 11 can be made longer than the width of the conductor plate 10. For this reason, it is sufficient to remove and shape the non-joint portion Z3a near the outer corner portion P5 of the frame coil, the non-joint portion Z3b near the FSW end point P3 near the inner corner portion P4 of the frame coil, and the probe extraction trace Z6. Strength can be secured.

  In the above example, the FSW start point P2 side is in the vicinity of the outer corner portion P5, and the FSW end point P3 is in the vicinity of the inner corner portion P4. However, the long side conductor plate and the short side conductor plate are joined by friction stir welding. If the joining line when joining is oblique with respect to the longitudinal direction of the long side and short side conductor plates, the FSW start point P2 under the condition that the length of the FSW joint line 11 is longer than the width of the conductor plate 10. And at least one of the FSW end point P3 may be separated from the corner portion.

(Fourth embodiment)
Next, a fourth embodiment will be described. FIG. 7 is a diagram illustrating a configuration example of one turn of a frame-shaped coil using a tab plate in the fourth embodiment. FIG. 8 is a diagram illustrating an example of an overview of an FSW implementation portion of a frame-shaped coil using a tab plate in the fourth embodiment.
Here, as shown in FIG. 7, the end surface S2 side and the end surface S3 side of the abutting portion between the short side 7a and the long side 7b of the conductor plate described in the first embodiment are sandwiched between two tab plates 12. To place.

  In the fourth embodiment, as shown in FIG. 8, the probe penetration point P1 and the FSW start point P2 are in the tab plate 12 on the end surface S2 side, and the FSW end point P3 is in the tab plate 12 on the end surface S3 side. As a result, the extraction trace Z6 is not generated on the contact portion of the conductor plate but on the tab plate 12 on the end surface S3 side.

  Here, a configuration has been described in which the butt portion described in the first embodiment is sandwiched between the tab plates 12, and the FSW start point P2 and the FSW end point P3 are provided on the tab plate 12. However, the present invention is not limited to this. It can also be set as the form which arrange | positions the tab board 12 on the one side or both sides of the butt | matching part demonstrated by embodiment of this.

  These tab plates 12 are joined to the end surface S2 side and the end surface S3 side of the butted portion when the FSW is performed. After the FSW is performed, the tab plate 12 can be cut as an unnecessary portion, and a predetermined shape of the frame-shaped coil can be obtained. A frame-shaped coil can be manufactured by joining the plurality of turns spirally. In addition, depending on the shape of the tab plate 12, the tab plate 12 may be left when there is no problem in the installation of the frame-shaped coil.

Next, the joint after the FSW will be described.
As shown in FIG. 8, the plastic flow range Z5 from the FSW start point P2 to the FSW end point P3 on the FSW joining line (joining target range) 13 is the same as the joining target range 13 of the short side 7a and the long side 7b of the conductor plate 7. Including all, the FSW start point P2 is in the tab plate 12 on the end surface S2 side, and the FSW end point P3 is in the tab plate 12 on the end surface S3 side. Further, although the probe withdrawal trace Z6 is generated at the FSW end point P3, the tab plate 12 is cut from the conductor plate and shaped so that a non-joint portion or a probe is formed at the joint portion between the short side 7a and the long side 7b of the conductor plate 7. It is possible to obtain a uniform coil shape without a portion obtained by shaping the drawing mark Z6.

  In addition, if the FSW is not sufficiently restrained to be joined, a linear defect may occur immediately after the start of the FSW. In the fourth embodiment, a tab plate 12 is provided, and the FSW start point P2 is provided on the tab plate 12. Since the distance from the FSW starting point P2 to the object to be joined (conductor plate) can be earned by providing, there is also an effect of reducing the occurrence of welding defects in the object to be joined.

(Fifth embodiment)
Next, a fifth embodiment will be described. FIG. 9 is a diagram illustrating an example of a case where a non-joined portion is formed on the surface opposite to the probe insertion side in a normal FSW. FIG. 10 is a diagram illustrating an example in which a thin plate is installed on a surface opposite to the probe insertion side in the fifth embodiment.
As shown in FIG. 9, in normal FSW bonding, the probe 6 is inserted to a depth that does not penetrate through the conductor plates 2 and 3 to be bonded. Since the flow portion Z2 does not reach the surface on the opposite side with respect to the surface on the probe insertion side, a non-joined portion Z3c may occur in the vicinity of the opposite surface.

  In order to prevent this, as shown in FIG. 10, a thin plate 14 made of the same material as that of the conductor plate is placed on the joining line of the surface opposite to the surface on the probe insertion side of the conductor plate, and the probe 6 is connected to the conductor plate. 2 and the conductor plate 3 and the thin plate 14 is joined to a depth not penetrating the thin plate 14.

By joining in this way, the vicinity of the joining target portion Z1 of the conductor plate 2 and the conductor plate 3 on the surface on the opposite side to the insertion side surface of the probe 6 becomes a plastic flow portion Z2, and Since the vicinity of the bonding target portion (bonding line) Z1 is bonded together with the thin plate 14, no non-bonded portion is generated on the bonding target portion Z1. Further, if the thin plate 14 is made of the same material as the conductor plate 2 and the conductor plate 3, there is no problem even if they are kneaded.
After the joining is completed, the predetermined shape of the frame coil can be obtained by removing the thin plate 14 and shaping the vicinity of the joining line of the conductor plates 2 and 3 with a grinder or a file.

  As described above, in each embodiment, the combination of the frame shape coil conductor plate shape suitable for FSW and the FSW, the productivity is higher than TIG welding and brazing, the skill dependency is low, and there are few welding defects. A highly reliable joint can be obtained, and a decrease in the strength of the material due to the influence of heat can be prevented.

  Further, by reducing the shaping (removal) processing portion around the non-joined portions Z3a and Z3b and the probe extraction trace Z6, the productivity is further improved, and the effective cross-sectional area of the joined portion is increased, so that the mechanical strength is further increased. The coil temperature can be reduced because the current density is improved.

  In addition, although several embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

  DESCRIPTION OF SYMBOLS 1a ... Short side of rectangular conductor plate, 4 ... FSW tool, 5 ... Shoulder, 6 ... Probe, 7a ... Short side of concave conductor plate, 8a ... Short side of convex conductor plate, 9 ... Holding jig, 10a ... Diagonal Short side of cut conductor plate, 12 ... tab plate, 14 ... thin plate, P2 ... FSW start point, P3 ... FSW end point, P4 ... inner corner of frame-shaped coil, P5 ... outer corner of frame-shaped coil, Z2 ... plastic flow Part, Z3a, Z3b ... non-joined part, Z4a, Z4b ... shaping target part, Z5 ... plastic flow range, Z6 ... probe withdrawal trace.

Claims (10)

An electric motor coil that combines the two conductive plates forming the two short sides of the frame and the conductive plate forming the frame of the long sides to the frame shape,
The shape of the conductor plate forming the long side or the conductor plate forming the short side is concave,
Lines whereas a portion matching and the other of the long conductor plate constituting the conductor plate and the short sides forming the sides, the so different from the extension line of the frame of the end face of the inner, concave portion of the concave conductor plate to concave portions different from two parts in the longitudinal portion of the side, and the other two shorter portion of the conductor plate of a conductive plate constituting the conductor plate and the short sides constituting the long side on a one-to-one butt, Ri Na joined by friction stir welding a portion of the abutting portions of these,
Out of the frame at the start point side of the friction stir welding and the vicinity of the start point, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding among the parts to be joined A range including a non-joint portion which is a section between the end faces of the portion,
(A) the end on the starting point side in the plastic flow range produced by the friction stir welding,
(B) one place on the end face of the outer portion of the conductor plate forming the short side; and
(C) one place on the end face of the outer portion of the conductor plate forming the long side,
The range surrounded by is removed as the first shaping object,
Among the parts to be joined, including a non-joined part that is a section between the end point side of the friction stir welding and the end surface of the inner part of the frame in the vicinity of the end point, and the plastic flow by the end of the friction stir welding A range that further includes a trace of the probe generated in the range,
(A) the withdrawal trace,
(B) one place of the end face of the inner part in the conductor plate which does not include the coil inner corner portion in the vicinity of the extraction trace among the conductor plate which forms the long side and the conductor plate which forms the short side;
(C) the inner corner of the coil;
The range surrounded by is removed as the second shaping target part,
Rotating electric machine coil. A rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame,
One design of the conductor plate constituting the conductor plate and the short sides constituting the long side is convex,
The convex conductor plate is protruded so that a line of a portion where one of the long side conductor plate and the short side conductor plate abuts the other is different from an extension line of the inner end face of the frame. The two conductor plates that are the other of the conductor plate that forms the long side and the conductor plate that forms the short side are abutted in one-to-one correspondence with two portions that are different from the convex portion in the longitudinal portion on the partial side. Ri Na joined part of the butt portion of these to at one of the friction stir welding,
Out of the frame at the start point side of the friction stir welding and the vicinity of the start point, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding among the parts to be joined A range including a non-joint portion which is a section between the end faces of the portion,
(A) the end on the starting point side in the plastic flow range produced by the friction stir welding,
(B) one place on the end face of the outer portion of the conductor plate forming the short side; and
(C) one place on the end face of the outer portion of the conductor plate forming the long side,
The range surrounded by is removed as the first shaping object,
Among the parts to be joined, including a non-joined portion that is a section between the end point side of the friction stir welding and the end surface of the outer part in the vicinity of the end point, and by the end of the friction stir welding, the plastic flow range A range that further includes the trace of the probe that has occurred,
(A) the withdrawal trace,
(B) one place on the end face of the outer portion of the conductor plate forming the short side; and
(C) one place on the end face of the outer portion of the conductor plate forming the long side,
The range surrounded by is removed as the second shaping target part,
Rotating electric machine coil. And the convex portion of the conductor plate which is the convex is a conductive plate to be bonded to the conductive plate is a convex type, the interface between the other conductor plate constituting the conductor plate and the short sides constituting the long sides, wherein rotating electric machine coil according to claim 2 that is part of the plastic flow range of the joint line by one of the friction stir welding. Ategai the jig to the convex portion of the conductor plate of the convex rotational electric machine coil according to the butted portion to claim 2 or 3 you joined by the friction stir welding. A rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame,
In the longitudinal direction of the conductor plate welding line forms the longitudinal and the short sides of the conductive plate forming the long side at the time of joining by friction stir welding and a conductor plate forming a conductor plate and the short sides constituting the long sides diagonal der against is,
The conductor plate that forms the long side and the short side are connected so that the joint line connects the coil outer corner on the starting point side of the friction stir welding and the coil inner corner on the end point side of the friction stir welding. The conductor plates made are joined together, and part of these joined parts are joined by friction stir welding,
Among the parts to be joined, between the starting point side of the friction stir welding and the outer corner of the coil, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding It is a range including a non-joining part that is a section,
(A) the end on the starting point side in the plastic flow range produced by the friction stir welding, and
(B) the outer corner of the coil;
The range surrounded by is removed as the first shaping object,
Among the parts to be joined, a non-joint part that is a section between the end point side and the coil inner corner part, and the trace of the probe drawn out in the plastic flow range due to the end of the friction stir welding Further including a range,
(A) the withdrawal trace,
(B) one place on the end face of the inner part of the frame in the conductor plate forming the long side,
(C) one place on the end face of the inner portion of the conductor plate forming the short side, and
(D) the inner corner of the coil;
The range surrounded by is removed as the second shaping target part,
Rotating electric machine coil. In the portion abutted to the conductor plate of the junction object, the same material of the thin plate and the conductive plate on the opposite side is provided with respect to the surface on the side of inserting the probe, a position reaching said sheet through said conductive plate rotating electric machine coil according to any one of claims 1, 2, 5 you joined by inserting the probe to. Rotating electrical machine using the rotating electric machine coil according to any one of claims 1 to 6. A method of manufacturing a rotary electric machine coils a combination of the two conductive plates forming the two short sides of the frame and the conductive plate forming the frame of the long sides to the frame shape,
The shape of the conductor plate forming the long side or the conductor plate forming the short side is concave,
Lines whereas a portion matching and the other of the long conductor plate constituting the conductor plate and the short sides forming the sides, the so different from the extension line of the frame of the end face of the inner, concave portion of the concave conductor plate to concave portions different from two parts in the longitudinal portion of the side, and the other two shorter portion of the conductor plate of a conductive plate constituting the conductor plate and the short sides constituting the long side on a one-to-one butt, joined by friction stir welding a portion of the abutting portions of these,
Out of the frame at the start point side of the friction stir welding and the vicinity of the start point, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding among the parts to be joined A range including a non-joint portion which is a section between the end faces of the portion,
(A) the end on the starting point side in the plastic flow range produced by the friction stir welding,
(B) one place on the end face of the outer portion of the conductor plate forming the short side; and
(C) one place on the end face of the outer portion of the conductor plate forming the long side,
The range surrounded by is removed as the first shaping target part,
Among the parts to be joined, including a non-joined part that is a section between the end point side of the friction stir welding and the end surface of the inner part of the frame in the vicinity of the end point, and the plastic flow by the end of the friction stir welding A range that further includes a trace of the probe generated in the range,
(A) the withdrawal trace,
(B) one place of the end face of the inner part in the conductor plate which does not include the coil inner corner portion in the vicinity of the extraction trace among the conductor plate which forms the long side and the conductor plate which forms the short side;
(C) the inner corner of the coil;
The range surrounded by is removed as the second shaping target part,
A method of manufacturing a rotating electrical machine coil. A rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame,
One shape of the conductor plate forming the long side and the conductor plate forming the short side is a convex shape,
The convex conductor plate is protruded so that a line of a portion where one of the long side conductor plate and the short side conductor plate abuts the other is different from an extension line of the inner end face of the frame. The two conductor plates that are the other of the conductor plate that forms the long side and the conductor plate that forms the short side are butted one-to-one with respect to two portions different from the convex portion in the longitudinal portion on the part side, Part of the butted part of the joint is joined by one friction stir welding,
Out of the frame at the start point side of the friction stir welding and the vicinity of the start point, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding among the parts to be joined A range including a non-joint portion which is a section between the end faces of the portion,
(A) the end on the starting point side in the plastic flow range produced by the friction stir welding,
(B) one place on the end face of the outer part in the conductor plate forming the short side, and (c) one place on the end face of the outer part in the conductor plate forming the long side,
The range surrounded by is removed as the first shaping target part,
Among the parts to be joined, including a non-joined portion that is a section between the end point side of the friction stir welding and the end surface of the outer part in the vicinity of the end point, and by the end of the friction stir welding, the plastic flow range A range that further includes the trace of the probe that has occurred,
(A) the withdrawal trace,
(B) one place on the end face of the outer part in the conductor plate forming the short side, and (c) one place on the end face of the outer part in the conductor plate forming the long side,
The range surrounded by is removed as the second shaping target part,
A method of manufacturing a rotating electrical machine coil. A rotating electrical machine coil in which two conductor plates forming a long side of a frame and two conductor plates forming a short side of the frame are combined in the shape of the frame,
Bonding lines when the conductor plate forming the long side and the conductor plate forming the short side are bonded by friction stir welding are in the longitudinal direction of the conductor plate forming the long side and the longitudinal direction of the conductor plate forming the short side. It is diagonal to
The conductor plate that forms the long side and the short side are connected so that the joint line connects the coil outer corner on the starting point side of the friction stir welding and the coil inner corner on the end point side of the friction stir welding. The conductor plates to be made are butted together, and part of these butted parts are joined by friction stir welding.
Among the parts to be joined, between the starting point side of the friction stir welding and the outer corner of the coil, which is the penetration point of the probe of the friction stir welding tool for the friction stir welding at the start of the friction stir welding It is a range including a non-joining part that is a section,
(A) an end portion on the starting point side in a plastic flow range generated by the friction stir welding, and (b) an outer corner portion of the coil,
The range surrounded by is removed as the first shaping target part,
Among the parts to be joined, a non-joint part that is a section between the end point side and the coil inner corner part, and the trace of the probe drawn out in the plastic flow range due to the end of the friction stir welding Further including a range,
(A) the withdrawal trace,
(B) one place on the end face of the inner part of the frame in the conductor plate forming the long side,
(C) one place on the end face of the inner part of the conductor plate forming the short side, and (d) the coil inner corner,
The range surrounded by is removed as the second shaping target part,
A method of manufacturing a rotating electrical machine coil.