WELDING METHOD AND DEVICE

Abstract

A TIG welding device (10) includes a welding robot (11), robot control device (12), welding torch (13), welding control device (14), gas feeder (15), and a height detection device (16). The welding torch (13) is set at a reference position, and the height detection device (16) detects the respective heights of two tip parts (4e). The robot control device (12) drives the welding robot (11) such that a torch electrode (13c) of the welding torch (13) abuts on central part of the higher tip part (4e). When the torch electrode (13c) is moved toward the reference position while power is supplied to the torch electrode (13c), and inert gas flows in the periphery of the torch electrode (13c), arc (AC) is generated in a gap between the tip parts (4e) and the torch electrode (13c). The overall two tip parts (4e) are melted and welded by this arc (AC).

Claims

1. A welding method for arc welding a first coil and a second coil by use of an energized electrode, the welding method comprising: a first step of detecting one of the first coil and the second coil, the one laving a shorter distance from a tip surface to be welded to a tip of the electrode; a second step of abutting the tip of the electrode on the tip surface of the one detected in the first step; and a third step of generating an arc by separating the tip of the energized electrode from the tip surface of the one detected in the first step, after the second step, and arc welding the first coil and the second coil.

2. The welding method according to claim 1, wherein in the third step, the tip of the energized electrode is displaced so as to be separated from the tip surface of the one detected in the first step, and approach the other to generate the arc.

3. The welding method according to claim 1, wherein in the second step, the tip of the electrode is made to abut on a central part of the tip surface of the one detected in the first step.

4. The welding method according to claim 2, wherein in the second step, the tip of the electrode is made to abut on a central part of the tip surface of the one detected in the first step.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0016] FIG. 1 is a perspective view illustrating a stator of a rotary electric machine welded by a TIG welding device of the present invention.

[0017] FIG. 2 is a perspective view illustrating a coil segment.

[0018] FIG. 3A is a perspective view illustrating a protruding portion of a U phase coil, a V phase coil, and a W phase coil of the coil segment.

[0019] FIG. 3B is a perspective view illustrating the protruding portion of the U phase coil of the coil segment.

[0020] FIG. 4 is a side view illustrating the TIG welding device.

[0021] FIG. 5 is a side view illustrating the TIG welding device in a state in which a torch electrode abuts on tip parts of the coil segments.

[0022] FIG. 6 is a side view illustrating the TIG welding device in a state in which an arc is generated between the tip parts of the two coil segments and the torch electrode.

[0023] FIG. 7 is a side view illustrating the TIG welding device in a state in which the tip parts of the two coil segments are weld.

DESCRIPTION OF EMBODIMENTS

[0024] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0025] First, an example of a structure of a rotary electric machine to be TIG-welded will be described.

[0026] As illustrated in FIG. 1, a rotary electric machine such as an electric motor and a generator includes a stator 1 formed in a cylindrical shape, and a rotor (not illustrated) rotatably disposed inside the stator 1.

[0027] The stator 1 includes a stator core 2 and a coil 3. The stator core 2 has a cylindrical shape, and a plurality of slots 2a that penetrate in the rotation axis direction are provided at intervals in the circumferential direction. Each slot 2a is formed such that a sectional shape in the radial direction of the stator core 2 radially extends from the center of the stator core 2 toward the radial direction, and communicates with an inner circumferential surface of the stator core 2 through slits 2b formed in the stator core 2. The slits 2b may not be provided.

[0028] A coil segment 4 illustrated in FIG. 2 is inserted into each of the slots 2a from one side, and a protruding portion protruding from the other side of the slot 2a is twisted and bended in the circumferential direction to be welded, so that the coil 3 is configured.

[0029] Each coil segment 4 is formed in a U-shape by aligning a plurality of (four in the embodiment) conductors (conducting wires of rectangular wires) each having a rectangular cross section such that surfaces having wider widths face each other, and forming the conductors into a U-shaped single bundle, and includes a pair of leg parts 4a, 4a, and a head part 4b that connects respective ends (upper ends in the drawing) of the both leg parts 4a, 4a.

[0030] The coil segment 4 may be any bundle obtained by aligning a plurality of rectangular wires in the width direction, and may be a bundle obtained by aligning a plurality of rectangular wires such that surfaces having narrower widths face each other, for example.

[0031] An S-shaped part 4c that is curved in an S-shape in the alignment direction of the rectangular wires is formed in the center of the head part 4b. The head part 4b is inclined downward from the center (center of the S-shaped part 4c) toward the both leg parts 4a, 4a. The leg part 4a of the coil segment 4 is inserted into the corresponding slot 2a from one side. The leg part 4a of the coil segment 4 protrudes from the other side of the slot 2a.

[0032] As illustrated in FIG. 3A, protruding portions 4d of the leg parts 4a protruding from the other side of the slots 2a are twisted in the circumferential direction of the stator 1 by a twisting device (not illustrated), and tip parts 4e of the corresponding protruding portions 4d are welded by a TIG welding device 10 (refer to FIG. 4) below described in detail. In this manner, the stator I including eight coil segments 4 stacked in the radial direction is completed. Herein, a first layer, a second layer, . . . , and an eighth layer are sequentially arranged from the outside to the inside in the radial direction.

[0033] The coil 3 of this embodiment is a three-phase coil composed of a U-phase, a V-phase, and a W-phase, and in the leg parts 4a of the coil segments 4 inserted in the respective slots 2a, the U-phase, the U-phase, the V-phase, the V-phase, the W-phase, and the W-phase are sequentially arranged in the circumferential direction. In FIG. 3B, only one phase coil (for example, U-phase coil) of the three phases is illustrated.

[0034] Now, the TIG welding device 10 that welds the respective tip parts 4e of the two coil segments 4 will be described.

[0035] As illustrated in FIG. 4, the TIG welding device 10 includes a welding robot 11, a robot control device 12, and a welding torch 13. Additionally, the TIG welding device 10 includes a welding control device 14, a gas feeder 15, and a height detection device 16. The TIG welding device 10 welds the respective tip parts 4e of the adjacent two coil segments 4.

[0036] The welding robot 11 is, for example, a multi-axes articulated welding robot, and is provided with arms 11a to 11d sequentially from a tip. The welding robot 11 is provided with a plurality of motors (not illustrated) that drive the respective arms 11a to 11d, and the driving is controlled by the robot control device 12. The arm 11a located on a tip side of the welding robot 11 is mounted with the welding torch 13.

[0037] The robot control device 12 drives the plurality of motors of the welding robot 11, so that the arms 11a to 11d are driven, and a position of the welding torch 13 mounted on the arm 11a is controlled. A mechanism for displacing the welding torch 13 is not limited to the welding robot 11, and can be appropriately changed.

[0038] The welding torch 13 includes a torch body part 13a mounted on the arm 11a, a torch nozzle 13b mounted on a tip part of the torch body part 13a, and a torch electrode 13c mounted on a tip part of the torch nozzle 13b and made of tungsten or tungsten alloy.

[0039] The gas feeder 15 is connected to the welding torch 13 through a supply pipe 18. Inert gas fed from the gas feeder 15 is fed to the welding torch 13 throng the supply pipe 18 to flow in the periphery of the torch electrode 13c. Driving of the gas feeder 15 is controlled by the welding control device 14.

[0040] The height detection device 16 detects the heights of the tip parts 4e of the two coil segments 4 by a known detection method using a laser, and transmits detection data to the robot control device 12 and the welding control device 14. The method for detecting the heights of the tip parts 4e can be appropriately changed.

[0041] In a case where the respective tip parts 4e of the two coil segments 4 are welded by the TIG welding device 10, the welding robot 11 is driven by the robot control device 12. and the welding torch 13 mounted on the arm 11a on the tip side is set at a reference position having a predetermined height between the two tip parts 4e, as illustrated in FIG. 4. The two tip parts 4e are clamped by a damper (not illustrated) to be tightly adhered to each other.

[0042] After the welding torch 13 is set at the reference position, the height detection device 16 detects the respective heights of the two tip parts 4e, and transmits detection data to the robot control device 12 and the welding control device 14. The welding control device 14 applies a voltage to the torch electrode 13c of the welding torch 13.

[0043] As illustrated in FIG. 5, the robot control device 12 drives the welding robot 11 such that the torch electrode 13c, to which the voltage is applied, moves along a moving route M1 (refer to FIG. 4), and abuts on a substantially central part of the tip surface of one of the two tip parts 4e, the one having a shorter distance from the tip part of the electrode, namely, having a higher protruding height of protruding from an end surface of stator core (left tip part 4e in FIG. 5) (hereinafter, referred to as a higher one, and the other of the tip parts 4e is referred to as a lower one). The route of the moving route M1 can he appropriately changed. Hereinafter, the left tip parts 4e in FIG. 4 to FIG. 7 is referred to as a higher tip part 4e (one having a shorter distance from the tip surface to the tip of the electrode 13c), and the right tip parts 4e in FIG. 4 to FIG. 7 is referred to as a lower tip part 4e. Herein, the torch electrode 13c preferably abuts on the central part of the higher tip part 4e, but may abut on a position offset from the central part due to a coil state or the like.

[0044] When the torch electrode 13c, to which the voltage is applied, abuts on the higher tip part 4e, a current flows, and the voltage drops. By this voltage drop, the welding control device 14 detects that the torch electrode 13c abuts on the higher tip part 4e. Before or after this abutting detection, the welding control device 14 drives the gas feeder 15 to feed inert gas to the welding torch 13 through the supply pipe 18. The fed inert gas flows in the petiphety of the torch electrode 13c.

[0045] After a predetermined time elapses in a state in which the torch electrode 13c abuts on the higher tip part 4e, the robot control device 12 drives the welding robot 11 such that the torch electrode 13c of the welding torch 13 moves along a moving route M2 to be returned to the reference position. The route of the moving route M2 can be appropriately changed. Additionally, the torch electrode 13c only needs to be moved upward from the state of abutting on the higher tip part 4e, and may be moved just above the higher tip part 4e, for example.

[0046] As illustrated in FIG. 6, when the torch electrode 13c is moved toward the reference position in a state in which the voltage is applied to the torch electrode 13c, and the inert gas flows in the periphery of the torch electrode 13c, an arc AC is generated in a gap between the tip parts 4e and the torch electrode 13c. A range of this arc AC is expanded, as the torch electrode 13c moves upward, and the gap between the tip parts 4e and the torch electrode 13c is increased. By such an arc AC whose range is gradually expanded, the overall two tip parts 4e are melted. FIG. 6 simply illustrates a state in which the two tip parts 4e are not melted.

[0047] As illustrated in FIG. 7, after the torch electrode 13c is returned to the reference position, the welding control device 14 stops voltage application to the torch electrode 13c.

[0048] Consequently, the arc AC is extinguished, and melted portions of the two tip parts 4e are solidified, and a weld bead BD is formed.

[0049] Unlike this embodiment, in a case where the torch electrode 13c is made to abut on the lower tip part 4e, and thereafter moves upward, the lower tip part 4e is melted, but the higher tip part 4e sometimes is in a melting detect state of not being melted. Furthermore, when the torch electrode 13c is move upward, the torch electrode 13c sometimes comes into contact with the higher tip part 4e, and the torch electrode 13c and the higher tip part 4e are welded to each other.

[0050] In this embodiment, the torch electrode 13c is made to abut on the substantially central part of the higher tip part 4e, and thereafter moved upward, so that the two tip parts 4e are TIG-welded. Therefore, a problem such as the aforementioned melting defect state, welding of the torch electrode 13c and the higher tip part 4e does not occur, and it is possible to secure welding stability at the time of welding start.

[0051] The higher tip part 4e is first melted by the arc AC, and therefore a melted portion of the higher tip part 4e covers the lower tip part 4e. Consequently, it is possible to promote the melting of the lower tip part 4e.

[0052] When the torch electrode 13c is made to abut on the substantially central part of the higher tip part 4e, and is moved upward, the torch electrode 13c is moved so as to be located between the two tip parts 4e, and therefore the two tip parts 4e are uniformly melted. Consequently, the weld bead BD can be uniformly and evenly formed on the two tip parts 4e.

[0053] In the above embodiment, the two coil segments 4 are welded. However, an object to be welded is not limited to the coil segments, and the present invention can be implemented as long as the object to be welded is a workpiece which is capable of being TIG-welded.

[0054] In the above embodiment, the tightly adhered two tip parts 4e are weld. However, the present invention is also applicable, in a case where two workpieces having a gap within a predetermined range are welded.

[0055] In the above embodiment, the torch electrode 13c is made to abut on the higher tip part 4e, and thereafter is moved to the reference position between the two tip parts 4e. However, the torch electrode 13c only needs to be moved so as to approach the lower tip part 4e.

REFERENCE SIGNS LIST

[0056] 1 stator [0057] 2 stator core [0058] 2a slot [0059] 2b slit [0060] 3 coil [0061] 4 coil segment [0062] 4a leg part [0063] 4b head part [0064] 4d protruding portion [0065] 4e tip part [0066] 10 TIG welding device [0067] 11 welding robot [0068] 12 robot control device [0069] 13 welding torch [0070] 13a torch body part [0071] 13b torch nozzle [0072] 13c torch electrode [0073] 14 welding control device [0074] 15 gas feeder [0075] 16 height detection device [0076] 18 supply pipe