CN116633104A - Stator manufacturing method - Google Patents

Abstract

Subject (1): provided is a method for manufacturing a stator, wherein the insulation properties of insulation paper inserted into a core slot are prevented from being reduced. The solution is as follows: a method for manufacturing a stator having core slots, comprising: a deforming step of deforming an insulating paper for insulating the core groove from the segment inserted into the core groove; a forming step of folding the deformed insulating paper into a cylindrical shape to form a cylindrical insulating paper having a middle portion and one end portion and the other end portion disposed opposite to each other in the axial direction with the middle portion interposed therebetween; a first insertion step of inserting the cylindrical insulating paper into the core groove; and a second insertion step of inserting the segment from one end side into the inside of the cylindrical insulating paper inserted into the core groove, wherein the deforming step includes an expanding step of expanding the opening of one end in the radial direction of the core groove by deforming the insulating paper in a state where the cylindrical insulating paper is disposed in the core groove.

Description

Stator manufacturing method

technical field

The present disclosure relates to a method of manufacturing a stator.

Background technique

Conventionally, as a stator used in a rotating electrical machine, there is a stator in which a sheet-shaped insulating member is arranged between a slot and a segment. In the case of manufacturing the stator, insulating members are inserted into the slots, and then segment pieces are inserted into the slots provided with the insulating members. There is a technique of expanding the end of the insulating member when inserting the segment so that the end of the segment does not easily interfere with the insulating member (for example, Patent Document 1).

prior art literature

patent documents

Patent Document 1: Japanese Patent Laid-Open No. 2000-308314

Contents of the invention

The problem to be solved by the invention

However, due to the expansion of the insulating member, the thickness of the crease portion of the insulating member becomes thinner, and the insulation performance may be lowered.

Technical solutions for solving problems

The present disclosure can be realized in the following ways.

(1) According to one aspect of the present disclosure, there is provided a method of manufacturing a stator having core slots. The manufacturing method includes: a deforming step of deforming an insulating paper for insulating the core groove from a segment inserted into the core groove; and a forming step of folding the deformed insulating paper. Into a cylindrical shape, forming a cylindrical insulating paper with a middle part, and one end and the other end disposed opposite to each other in the axial direction across the middle part; the first insertion process is to insert the cylindrical insulating paper into the into the core groove; and a second inserting step of inserting the segmented member from the one end side into the inner side of the cylindrical insulating paper inserted into the core groove. The deforming step includes the step of deforming the insulating paper so that the opening of the one end portion in the radial direction of the core groove is expanded in a state where the cylindrical insulating paper is arranged in the core groove. , thus forming the expansion part. According to this aspect, before inserting the insulating paper into the core slot, the insulating paper can be deformed so as to cause less damage, thereby suppressing a reduction in the insulating properties of the insulating paper.

(2) The manufacturing method of the above mode may include: a preparatory step of preparing a mold having a flat surface and an inclined surface connected to the flat surface, and the angle formed by the inclined surface and the flat surface is greater than 180 degrees and less than 270 degrees. degree; disposing step, covering the flat surface and disposing the first part of the insulating paper as the middle part, covering the inclined surface and disposing the second part of the insulating paper as the one end part; and the In the expanding process, the punch is pushed to the second part arranged on the inclined surface, and the insulating paper is deformed so that the angle formed by the first part and the second part is greater than 180 degrees, Thus, the expanded portion is formed. According to this aspect, since the angle formed by the flat surface and the inclined surface of the mold is smaller than 270 degrees, the stress received at the boundary portion between the first portion and the second portion can be reduced in the deforming step compared to the case of 270 degrees or more. Therefore, the fall of the insulating property of an insulating paper can be suppressed.

(3) In the manufacturing method of the above aspect, the deforming step may be a first deforming step, and the first deforming step may be the following step: in the second part, the In the state in which only one of the inner diameter portion located on the inner diameter side of the core groove and the outer diameter portion located on the outer diameter side of the core groove is deformed, the manufacturing method is between the first inserting step and the A second deformation step is further provided between the second insertion step, and in the second deformation step, the cylindrical insulating paper inserted into the core groove is deformed so that the inner diameter part and the outer diameter Any other side of the radial portion expands along said radial direction. According to this aspect, when both the inner diameter portion and the outer diameter portion are expanded, damage to the insulating paper can be reduced by using the first deforming step for either the inner diameter portion or the outer diameter portion. In addition, by using the second deformation step on either the inner diameter portion or the outer diameter portion, the positional accuracy of the portion deformed by the second deformation step with respect to the core groove can be improved. Therefore, damage to the insulating paper can be reduced, and positional accuracy of the expanded portion of the insulating paper with respect to the core groove can be improved.

(4) In the manufacturing method of the above aspect, the inner diameter portion may be deformed in the first deforming step, and the outer diameter portion may be deformed in the second deforming step. According to this aspect, since the pitch of the outer diameter portion of the core groove is wider than the pitch of the inner diameter portion, when the insulating paper is deformed using the jig in the second deforming step, the degree of freedom of the shape of the jig can be increased.

(5) In the manufacturing method of the above aspect, the spreading amount of the insulating paper in the second deforming step may be smaller than the spreading amount of the insulating paper in the first deforming step. According to this aspect, since the spreading amount in the second deforming step is smaller than the spreading amount in the first deforming step, damage to the insulating paper caused by the second deforming step can be suppressed.

(6) In the manufacturing method of the above mode, the segment member inserted in the second inserting step may be a first segment member, and the manufacturing method further includes: a third inserting step, The other end side of the cylindrical insulating paper inserted into the core groove is inserted into a second segment member electrically connected to the first segment member; and a bonding process of placing the first segment member The front end of the member and the front end of the second segment member are joined via a tube inside the core groove, and the first segment member inserted into one core groove in the second insertion step is multiple In the second insertion process, the plurality of first segment members are inserted side by side in the radial direction, and in the third insertion process, the second There are a plurality of segmented parts, and the plurality of second segmented parts are inserted side by side along the radial direction. Among the plurality of first segmented parts, all the parts that are opposite to the expanded part during the insertion process The front end of the first segment piece is installed with the pipe. According to this aspect, when the edge of the tube is not tapered, the entanglement of the insulating paper during insertion can be suppressed by forming the flared portion.

The present disclosure can also be realized in various forms other than the stator manufacturing method. For example, it can be realized by means of a stator manufacturing device and the like.

Description of drawings

FIG. 1 is a flow chart of the stator manufacturing process.

Fig. 2 is a perspective view of a stator.

FIG. 3 is a diagram illustrating insertion of a segment piece into a stator core.

Fig. 4 is a first diagram illustrating a joining method of segment members.

Fig. 5 is a sectional view of a stator core.

Fig. 6 is a second diagram illustrating a joining method of segment members.

FIG. 7 is a diagram illustrating an outline of a stator manufacturing process.

Fig. 8 is a perspective view of a mold.

FIG. 9 is a sectional view taken along line IX-IX of FIG. 8 .

Fig. 10 is a diagram explaining the formation of an expanded portion.

FIG. 11 is a flowchart of a stator manufacturing process according to the second embodiment.

Fig. 12 is a perspective view of a cylindrical insulating paper according to a second embodiment.

Fig. 13 is a cross-sectional view of a core groove according to a second embodiment.

Fig. 14 is a diagram illustrating a second deformation step.

Fig. 15 is a cross-sectional view of a core groove according to a third embodiment.

Fig. 16 is a perspective view of a guide jig according to a third embodiment.

FIG. 17 is a first diagram illustrating formation of a second expanded portion according to the third embodiment.

FIG. 18 is a second diagram illustrating formation of a second expanded portion according to the third embodiment.

Detailed ways

A. The first embodiment:

A1. Composition of the stator:

FIG. 1 is a flowchart showing the steps of a stator manufacturing process for realizing a stator 100 manufacturing method according to the present embodiment. FIG. 2 is a perspective view of the stator 100 . FIG. 3 is a diagram illustrating insertion of the segmented piece 130 into the stator core 110. Referring to FIG. FIG. 4 is a first diagram illustrating a joining method of the segment members 130 . FIG. 5 is a cross-sectional view of stator core 110 into which segment member 130 is inserted, cut along a radial cut plane. FIG. 6 is a second diagram illustrating a joining method of the segment members 130 . The Z-axis direction is shown in FIG. 2 . One direction of the Z-axis direction is defined as +Z-axis direction, and the other direction of the Z-axis direction is defined as −Z-axis direction. The Z-axis direction is a direction parallel to the vertical direction, and the +Z-axis direction is also referred to as an upward direction, and the −Z-axis direction is also referred to as a downward direction. The same is true for the directions shown in subsequent figures.

As shown in FIG. 2 , the stator 100 includes a stator core 110 and a plurality of segment coils 120 . The stator core 110 has a substantially cylindrical shape, and is formed by laminating a plurality of annular non-oriented electrical steel sheets formed by press working, for example. The stator core 110 has a plurality of teeth 111 and a plurality of core slots 112 . Each tooth 111 is formed on the inner peripheral surface of the stator core 110 and protrudes radially inward. A groove portion formed between two circumferentially adjacent teeth 111 is a core groove 112 .

The segmented coil 120 has a plurality of segment pieces 130 and a plurality of tubes 140 . The segment 130 is formed by bending a flat wire into a substantially U-shape. Here, the flat wire refers to a conductor having a rectangular cross section whose surface is covered with an insulating coating made of, for example, enamel resin. The tube 140 is used to physically join the respective front ends of the two segmented pieces 130 to electrically connect the two segmented pieces 130 .

When assembling the segment coil 120 , as shown in FIG. 3 , the first segment group 151 is inserted from above the stator core 110 , and the second segment group 152 is inserted from below the stator core 110 . Here, the first segment group 151 and the second segment group 152 refer to a group of segment members 130 in which a plurality of segment members 130 are combined into an annular shape. The first segment group 151 is configured in such a way that the front ends of the segment members 130 constituting the first segment group 151 face down, and are combined into a ring shape, so that each segment member 130 can be inserted into the corresponding core groove 112. The second segment group 152 is configured in such a way that the front ends of the segment members 130 constituting the second segment group 152 face upward, and are combined into a ring shape, so that each segment member 130 is inserted into the corresponding core groove 112 .

In addition, before being inserted into the core groove 112, a pipe 140 ( figure 2). As shown in FIG. 2 , if the first segment group 151 and the second segment group 152 are inserted into the stator core 110 , inside the core slot 112 , the front ends of each other are joined via the tube 140 as a conductor. By arranging the joint portion of the segment 130 inside the core slot 112 , the connection portion can be protected and the reliability of the stator 100 can be improved compared to the case where the joint is outside the core slot 112 .

As shown in FIG. 4 , the insulating coating of the front end 130 a of the segment 130 is peeled off, and the cross-sectional area is formed to be smaller than that of the main body. The tube 140 has a hollow shape with a rectangular cross-sectional shape. Also, the front end 130 a of the segment 130 is of such a size as to be fitted into the hollow portion of the pipe 140 . In addition, a tapered surface 130b tapered toward the front end is formed at the front end 130a of the segment member 130 .

As shown in FIG. 5 , a plurality of segment pieces 130 are inserted into the same core groove 112 . A plurality of segment pieces 130 inserted into the same core slot 112 from the same direction is also referred to as a coil group. The plurality of segment members 130 inserted into the same core slot 112 from the same direction are aligned in the radial direction of the stator 100 and inserted at the same time so that the respective front end positions become predetermined positions. As shown in FIG. 6 , a plurality of segment pieces 130 inserted into the same core groove 112 from the same direction are preinstalled with tubes 140 every other one. The position of the front end of the section 130 to which the pipe 140 is attached differs in the Z-axis direction from the position of the front end of the section 130 to which the pipe 140 is not attached. Thereby, two adjacent segment members 130 can be insulated from each other. The front end of the segment member 130 to which the tube 140 is not attached protrudes further in the insertion direction than the front end of the tube 140 . Thereby, since the tip of the segment body 130 does not come into contact with the pipe 140 other than the pipe 140 to be connected, damage to the insulating coating of the segment body 130 can be suppressed.

In FIG. 2 , although illustration is omitted, insulating paper 10 is disposed between core groove 112 and segment 130 ( FIG. 6 ). The insulating paper 10 shown in FIG. 6 is configured to insulate the core groove 112 from the segment pieces 130 inserted into the core groove 112 . FIG. 7 is a diagram illustrating an outline of a stator manufacturing process. Insulating paper 10 is folded into a tube shape in step P30 described later to form tube-shaped insulating paper 15 , and then inserted into core groove 112 . Then, in step P50 described later, the segment material 130 is inserted inside the tubular insulating paper 15 inserted into the core groove 112 .

One cylindrical insulating paper 15 is inserted for one core groove 112 . Since the segmented piece 130 is inserted into the inner side of the cylindrical insulating paper 15, it is preferable to expand the opening of the cylindrical insulating paper 15 in the radial direction of the core groove 112, so that the front end of the segmented piece 130 is not easy to contact with the cylindrical insulating paper 15. Open ends interfere. Here, when deforming the insulating paper 10 so as to expand the opening, the inventors deformed the insulating paper 10 in a deforming step before inserting into the core groove 112 and studied the deforming step. Thereby, the damage of the insulating paper 10 by a deformation|transformation process can be suppressed, and the fall of an insulating property can be suppressed. In the following description, as shown in step P50 of FIG. The surface on the inner diameter side of the stator core 110 is called an inner diameter portion, and the surface on the outer diameter side of the stator core 110 is called an outer diameter portion.

In this embodiment, as shown in FIG. 6 , a tapered surface 130 b is formed at the front end 130 a of the segment member 130 . On the other hand, the front end of the tube 140 has a front end surface substantially perpendicular to the insertion direction. Therefore, the tube 140 is more likely to interfere with the open end of the cylindrical insulating paper 15 than the segmented piece 130 . Therefore, in the present embodiment, as shown in FIG. 7 , in the opening end of the cylindrical insulating paper 15 , the inner diameter portion of the one end 15 b opposite to the tube 140 and the inner diameter of the other end 15 c in the process of inserting the coil group are The outer diameter portion forms a flared portion 20 . In addition, the one end part 15b and the other end part 15c will be described later.

A2: The manufacturing method of the stator:

In step P10 of FIG. 1 , creases 11 are formed on insulating paper 10 cut to a predetermined size. As shown in step P10 of FIG. 7 , when the insulating paper 10 is folded into a rectangular parallelepiped tube shape, creases 11 are formed at portions that become sides. For the insulating paper 10, an insulating resin sheet, a nonwoven fabric sheet, a sheet laminated with these and a foamed resin, or the like can be used. Process P10 may be performed by a machine or by a worker.

In step P12 of FIG. 1 , a mold 80 is prepared. FIG. 8 is a perspective view of the mold 80 . FIG. 9 is a sectional view along line IX-IX of FIG. 8 shown together with the punch 90 . FIG. 10 is a diagram illustrating the formation of the expanded portion 20 . In FIGS. 8 to 10 , three spatial axes that are orthogonal to each other, that is, XYZ axes, are depicted. The directions of the arrows of the X-axis, Y-axis, and Z-axis indicate positive directions along the X-axis, Y-axis, and Z-axis, respectively. The positive directions along the X-axis, Y-axis, and Z-axis are respectively referred to as +X-axis direction, +Y-axis direction, and +Z-axis direction. The directions opposite to the directions of the arrows of the X-axis, Y-axis, and Z-axis are negative directions along the X-axis, Y-axis, and Z-axis, respectively. The negative directions along the X-axis, Y-axis, and Z-axis are respectively referred to as -X-axis direction, -Y-axis direction, and -Z-axis direction. The directions along the X-axis, Y-axis, and Z-axis are referred to as the X-axis direction, the Y-axis direction, and the Z-axis direction regardless of whether they are positive or negative. The +Z axis direction is also called up, and the -Z axis direction is called down. The same applies to the figures and descriptions shown thereafter.

As shown in FIG. 8 , the mold 80 is a cuboid having an upper surface 81 and a lower surface 82 . The size of the upper surface 81 is such that it can support the entire surface of the insulating paper 10 . The upper surface 81 has a flat surface 81a and three inclined surfaces 81b connected to the flat surface 81a. The flat surface 81a is inclined so as to approach the lower surface 82 toward the end. The inclined surface 81b is used to form the flared portion 20 .

In step P14 of FIG. 1 , insulating paper 10 is placed on mold 80 . Specifically, insulating paper 10 is arranged to cover flat surface 81 a and inclined surface 81 b of mold 80 . In addition, "covering" here includes not only covering the entire area of the surface, but also covering a part of the surface. As shown in step P30 of FIG. 7 , the tubular insulating paper 15 formed by folding the insulating paper 10 into a tubular shape has an intermediate portion 15 a, one end portion 15 b, and the other end portion 15 c. The one end portion 15b and the other end portion 15c are disposed opposite to each other in the axial direction of the tubular insulating paper 15 with the intermediate portion 15a interposed therebetween. As shown in FIG. 8 , in step P14 , first portion 10 a of insulating paper 10 serving as intermediate portion 15 a when forming tubular insulating paper 15 is arranged so as to cover flat surface 81 a. Moreover, the second part 10b of the insulating paper 10 which becomes the one end part 15b when the cylindrical insulating paper 15 is formed is arrange|positioned so that it may cover the inclined surface 81b. The third portion 10c of the insulating paper 10 serving as the other end portion 15c when the cylindrical insulating paper 15 is formed is arranged so as to cover the inclined surface 81b. As shown in FIG. 9 , after the insulating paper 10 is placed on the mold 80 , a plate 92 for suppressing displacement is placed on the first portion 10 a.

In step P16 of FIG. 1 , the insulating paper 10 is deformed to form the expanded portion 20 . Specifically, as shown in FIG. 9 , the punch 90 is pushed toward the second portion 10b of the insulating paper 10 arranged on the inclined surface 81b. Thereby, as shown in FIG. 10 , the second portion 10 b disposed on the inclined surface 81 b is pushed closer to the lower surface 82 than the first portion 10 a. Then, as shown in step P16 of FIG. 7 , the insulating paper 10 is deformed so that the angle formed by the first portion 10 a and the second portion 10 b disposed on the inclined surface 81 b is greater than 180 degrees, thereby forming the flared portion 20 . Similarly, the insulating paper 10 is deformed so that the angle formed by the first portion 10a and the third portion 10c arranged on the inclined surface 81b is larger than 180 degrees, thereby forming the flared portion 20 . As a result, the insulating paper 10 is deformed so that the opening of the one end portion 15 b in the radial direction of the core groove 112 expands in a state where the cylindrical insulating paper 15 is arranged in the core groove 112 . In addition, "deformed so that the opening of the one end portion 15b expands" means that the size of the outer shape of the end portion of the opening of the one end portion 15b becomes larger with respect to the size of the outer shape of the cross-sectional shape perpendicular to the axial direction of the intermediate portion 15a. Way out of shape.

The angle θ formed by the flat surface 81 a and the inclined surface 81 b shown in FIG. 9 is larger than 180 degrees and smaller than 270 degrees. Therefore, in step P16, the stress received at the boundary portion between the first portion 10a and the second portion 10b can be made smaller than when the formed angle θ is 270 degrees or more. Therefore, damage to insulating paper 10 due to deformation can be suppressed, and a reduction in insulating properties can be suppressed.

In step P30 of FIG. 1 , insulating paper 10 is folded into a tubular shape along crease 11 to form tubular insulating paper 15 . In step P40 of FIG. 1 , the cylindrical insulating paper 15 is inserted into the core groove 112 . Specifically, as shown in P50 of FIG. 7 , the surface of the cylindrical insulating paper 15 on which the insulating paper 10 is double-laid is positioned on the outer diameter side of the core groove 112 , and the one end 15 b is positioned in the +Z-axis direction of the core groove 112 . Insert the cylindrical insulating paper 15.

In step P60 of FIG. 1 , the first segment member 130 included in the first segment member group 151 is inserted into the inserted core groove 112 from the side of one end 15 b of the cylindrical insulating paper 15 , that is, from above. The inner side of the cylindrical insulating paper 15 in. Here, since the cylindrical insulating paper 15 has the expanded portion 20 expanding in the radial direction at the inner diameter portion opposite to the tube 140 during the insertion process, it is possible to prevent the first segment from contacting the cylindrical insulating paper during the insertion process. Interference of paper 15.

In step P70 of FIG. 1 , the second segment member 130 contained in the second segment member group 152 , that is, the second segment member, is inserted into the inserted core slot from the other end 15 c side of the cylindrical insulating paper 15 , that is, from below. 112 inside the cylindrical insulating paper 15. As in the process P60, since the cylindrical insulating paper 15 has a radially expanded expansion portion 20 at the outer diameter portion opposite to the tube 140, during the insertion process, it is possible to prevent the second segment from colliding with the cylindrical insulating paper. 15 interference.

In step P80, the first segment and the second segment are joined via the tube 140, and this stator manufacturing process ends. Step P12 is also called a preparation step, step P14 is also called an arrangement step, step P16 is also called an expanding step, and steps P10 to P16 are also called a deformation step. Step P30 is also called a forming step, step P40 is also called a first insertion step, step P60 is also called a second insertion step, step P70 is also called a third insertion step, and step P80 is also called a bonding step.

According to the first embodiment described above, the deforming step includes the step P16 of deforming the insulating paper 10 so that one end portion of the core groove 112 in the radial direction The opening of 15b expands to form a flared portion 20 . Before inserting the insulating paper 10 into the core slot 112 , deforming the insulating paper 10 so as to cause less damage can suppress a reduction in the insulating properties of the insulating paper 10 .

In addition, in step P16, the punch 90 is pushed toward the second portion 10b disposed on the inclined surface 81b to deform the insulating paper 10 so that the angle formed by the first portion 10a and the second portion 10b is greater than 180 degrees, thereby The expanded portion 20 is formed. Since the angle θ formed by the flat surface 81a and the inclined surface 81b of the mold 80 is smaller than 270 degrees, therefore, in the step P16, the angle θ formed by the ratio of the stresses received at the boundary portion between the first portion 10a and the second portion 10b can be The situation above 270 degrees is small. Therefore, the damage of the insulating paper 10 can be suppressed, and the fall of insulation can be suppressed.

In addition, among the plurality of first segment members included in the first segment member group 151 inserted into the same core groove 112, the front end of the segment member 130 opposed to the expanded portion 20 during insertion is installed. There are tubes 140. Accordingly, when the edge of the tube 140 is not tapered, the entanglement of the insulating paper 10 during insertion can be suppressed by forming the flared portion 20 . On the other hand, among the plurality of first segment members included in the first segment member group 151 that are inserted into the same core groove 112, the segment members 130 that are not opposed to the flared portion 20 during insertion The front end of the tube 140 is not installed. Since the tapered surface 130b is formed at the front end of the segment member 130, even if the flared portion 20 is not formed, the insulating paper 10 is less likely to be caught during insertion. Since the flared portion 20 is not formed, damage caused by deformation of the insulating paper 10 used to form the flared portion 20 can be avoided.

B. The second embodiment:

FIG. 11 is a flowchart showing the steps of the stator manufacturing process according to the present embodiment. FIG. 12 is a perspective view of a tubular insulating paper 215 according to the present embodiment. FIG. 13 is a cross-sectional view of the core groove 112 cut along a radially cut plane, showing the segment piece 130 together. Fig. 14 is a diagram illustrating a second deformation step.

As shown in FIG. 12 , the cylindrical insulating paper 215 according to the present embodiment differs from the cylindrical insulating paper 15 according to the first embodiment in that the inner diameter portion and the outer diameter portion of the opening of the cylindrical insulating paper 215 Both are formed with flared portions 20 . The method of forming the flared portion 20 of the inner diameter portion is different from the method of forming the flared portion 20 of the outer diameter portion. In this embodiment, the flared portion 20 of the inner diameter portion of the one end portion 15b and the flared portion 20 of the outer diameter portion of the other end portion 15c are formed in the same manner as the deformation process according to the first embodiment. Furthermore, the expanded portion 20 of the outer diameter portion of the one end portion 15 b and the expanded portion 20 of the inner diameter portion of the other end portion 15 c are formed after the tubular insulating paper 215 is inserted into the core groove 112 .

Here, in order to distinguish the two methods of forming the flared portion 20 , the deforming step according to the first embodiment is referred to as the first deforming step, and the step of forming the flared portion 20 after being inserted into the core groove 112 is called the second deforming step. deformation process. In addition, the expansion part 20 formed in the 1st deformation process is called 1st expansion part 20a, and the expansion part 20 formed in the 2nd deformation process is called 2nd expansion part 20b. The same reference numerals are assigned to the same steps and configurations as those of the first embodiment, and detailed description thereof will be appropriately omitted.

As shown in FIG. 11 , in the stator manufacturing process, as in the first embodiment, the process proceeds from process P10 to process P40 . In step P50 , the punch 290 ( FIG. 14 ) is pushed onto the cylindrical insulating paper 215 inserted into the core groove 112 to form the second expanded portion 20 b.

As shown in FIG. 14, the punch 290 has a head portion 290a and an insertion portion 290b axially extending from the head portion 290a. The insertion portion 290 b has a size that can be inserted into the core groove 112 . A part of the side surface of the insertion portion 290b is formed with a punch inclined surface 290c inclined so that the cross-sectional area becomes smaller toward the front end.

In step P50 ( FIG. 11 ), insertion portion 290 b is inserted into inner side from above cylindrical insulating paper 215 arranged in core groove 112 . By inserting the punch 290, the outer diameter portion of the one end 15b of the cylindrical insulating paper 215 is deformed so as to expand outward along the punch inclined surface 290c. Thereby, the 2nd expanded part 20b can be formed in the one end part 15b. Likewise, by inserting the punch 290 from below the cylindrical insulating paper 215 arranged in the core groove 112, the inner diameter portion of the other end portion 15c of the cylindrical insulating paper 215 is deformed. Thereby, the 2nd expanded part 20b can be formed in the other end part 15c. According to the step P50, the second expanded portion 20b can be formed after the cylindrical insulating paper 215 is disposed in the core groove 112. Therefore, the positional accuracy of the second expansion part 20b with respect to the core groove 112 can be improved.

As shown in FIG. 13, the second expansion amount SA2 which is the expansion amount of the second expansion part 20b is smaller than the first expansion amount SA1 which is the expansion amount of the first expansion part 20a. Here, the spread amount refers to the distance in the radial direction between the inner surface of the intermediate portion 15 a of the cylindrical insulating paper 215 and the front end of the insulating paper 10 . By making the second spreading amount SA2 smaller than the first spreading amount SA1, damage to the insulating paper 10 in step P50 can be suppressed. In step P50, the insulating paper 10 is deformed starting from the edge of the stator core 110 whose edge angle is substantially a right angle. Therefore, when the spreading amount is large, the insulating paper 10 may be damaged. Therefore, by making the second spreading amount SA2 smaller than the first spreading amount SA1, damage to the insulating paper 10 can be suppressed.

After step P50 shown in FIG. 11 , similar to the first embodiment, step P60 to step P80 are performed, and this stator manufacturing step ends.

According to the second embodiment described above, in the first deforming step, the inner diameter portion of the tubular insulating paper 215 is expanded in the first deforming step, and the outer diameter portion of the tubular insulating paper 215 is expanded in the second deforming step. . In the first deforming step, damage to insulating paper 10 can be reduced. By using the second deformation step, the positional accuracy of the expanded portion 20 relative to the core groove 112 can be improved. Therefore, the damage of the insulating paper 10 can be reduced, and the positional accuracy of the expanded part 20 of the insulating paper 10 with respect to the core groove 112 can be improved.

In addition, the second spreading amount SA2 of the insulating paper 10 in the second deforming step is smaller than the first spreading amount SA1 of the insulating paper 10 in the first deforming step. Accordingly, damage to insulating paper 10 caused by the second deforming step can be suppressed.

C. The third embodiment:

FIG. 15 is a cross-sectional view of the core groove 112 cut along a radially cut plane. FIG. 16 is a perspective view of the guide jig 390 . FIG. 17 is a first diagram illustrating the formation of the second expanded portion 20b. Specifically, FIG. 17 is a cross-sectional view of the core groove 112 in which the guide jig 390 is disposed along a radially cut plane. FIG. 18 is a second diagram illustrating the formation of the second expanded portion 20b. Specifically, FIG. 18 is a cross-sectional view in which the core groove 112 in which the guide jig 390 is disposed is cut along a cut plane perpendicular to the radial direction, and viewed from the inner diameter toward the outer diameter in the radial direction.

In this embodiment, as shown in FIG. 15 , the number of segment members 130 inserted into the same core groove 112 from the same direction is different from that of the second embodiment. Specifically, in this embodiment, five segment members 130 are inserted into the same core groove 112 from the same direction. In addition, the difference from the second embodiment is that the flared portion 20 is formed only at the one end portion 15 b of the tubular insulating paper 315 inserted into the core groove 112 .

In the present embodiment, pipes 140 are attached to the segment members 130 at both ends of the plurality of first segment members included in the first segment member group 151 inserted into the same core groove 112 . Therefore, the expanded portion 20 is formed on both the inner diameter portion and the outer diameter portion of the one end portion 15b of the tubular insulating paper 315 facing the tube 140 during the insertion process of the second insertion step, that is, the step P60. On the other hand, the pipes 140 are not installed on the segment pieces 130 at both ends of the plurality of second segment pieces included in the second segment piece group 152 inserted into the same core groove 112 . Therefore, the flared portion 20 is not formed at the other end portion 15 c of the cylindrical insulating paper 315 .

The stator manufacturing process according to the present embodiment is the same as the stator manufacturing process according to the second embodiment in that the expanded portion 20 is formed through the first deformation step and the second deformation step. Furthermore, the content of the second deformation step is different from that of the second embodiment. Therefore, descriptions of steps other than the second deformation step are omitted. In the second deformation step according to the present embodiment, a guide jig 390 shown in FIG. 16 is used instead of the punch 290 .

As shown in FIG. 16 , the guide jig 390 has a plurality of blades 391 and a movement mechanism 392 . The guide jig 390 has a function of forming the flared portion 20 and a function of guiding the segment 130 to the core groove 112 in the process of inserting the segment 130 into the core groove 112 . The guide jig 390 is provided at a position facing an annular surface perpendicular to the Z-axis direction of the stator core 110 ( FIG. 2 ), and is used. The outer shape of the moving mechanism 392 is roughly a ring shape corresponding to the stator core 110 . The blades 391 are provided corresponding to the teeth 111 ( FIG. 2 ). The blade 391 is fixed to the moving mechanism 392 . The moving mechanism 392 moves each blade 391 in the radial direction of the moving mechanism 392 indicated by the arrow in FIG. 16 .

As shown in FIG. 17 , with the guide jig 390 disposed relative to the stator core 110 , the blade 391 has a blade bottom surface 391 a opposite to the core slot 112 . The blade bottom surface 391 a is provided with two fin portions 391 b protruding toward the core groove 112 with the blade bottom surface 391 a as a base. As shown in FIG. 18 , the two fin portions 391 b are arranged at both ends of the blade bottom surface 391 a in the circumferential direction of the stator core 110 . The two fin portions 391b are provided at positions facing respective end portions of the adjacent two core grooves 112 .

In step P50 ( FIG. 11 ), which is the second deforming step, as shown in FIG. 17 , the blade 391 moves in the radial direction from the inner diameter side to the outer diameter side, whereby the fin portion 391 b wraps the outer surface of the cylindrical insulating paper 15 . The radial portion is pressed toward the radially outer diameter side. As a result, the insulating paper 10 is deformed starting from the edge of the stator core 110 , and the second expanded portion 20 b is formed on the cylindrical insulating paper 315 .

Like the second embodiment, the second expansion amount SA2 is smaller than the first expansion amount SA1. By making the second spreading amount SA2 smaller than the first spreading amount SA1, damage to the insulating paper 10 in step P50 can be suppressed.

The pitch of the outer diameter portion of the core grooves 112 is larger than the pitch of the inner diameter side of the core grooves 112 . Therefore, in the case of deforming both the inner diameter portion and the outer diameter portion of the cylindrical insulating paper 315 inserted into the core groove 112, and deforming one of them using a jig, by deforming the cylindrical insulating paper 315 Using a jig for deformation of the outer diameter portion of 315 can increase the degree of freedom of the shape of the jig. Since the guide jig 390 used in this embodiment is a mechanism for moving the vane 391 in the radial direction, the size of the vane 391 is supposed to be limited when the vane 391 is moved in the radially inner direction. In this regard, the guide jig 390 used in this embodiment is a mechanism for moving the blade 391 in the radially outer direction. Therefore, when the inner diameter portion of the cylindrical insulating paper 315 is deformed in the first deformation step and the outer diameter portion is deformed in the second deformation step, the guide jig 390 can be better applied.

In step P60 ( FIG. 11 ), the segment member 130 is inserted along the insertion space 391c formed between two adjacent blades 391 shown in FIG. 16 . The same applies to step P70 ( FIG. 11 ).

According to the third embodiment described above, the inner diameter portion of the cylindrical insulating paper 315 is deformed in the first deformation step, and the outer diameter portion is deformed in the second deformation step. Thereby, the degree of freedom of the shape of the jig for deforming the cylindrical insulating paper 315 inserted into the core groove 112 can be improved.

D. Other implementation methods:

(D1) In the second embodiment, in order to form the first expanded portion 20a and the second expanded portion 20b, the first deforming step and the second deforming step are performed. The manufacturing method for forming the first expanded portion 20a and the second expanded portion 20b is not limited to the second embodiment, and the first expanded portion 20a and the second expanded portion may be formed in the deformation step according to the first embodiment. 20b Both.

(D2) In the second embodiment, the inner diameter portion of the one end 15b of the tubular insulating paper 215 and the outer diameter portion of the other end 15c are deformed in the first deforming process, and the tubular insulating paper 215 is deformed in the second deforming process. The outer diameter portion of one end portion 15b and the inner diameter portion of the other end portion 15c are deformed. In the case where the inner diameter portion and the outer diameter portion of the cylindrical insulating paper 215 form the expanded portion 20, which one of the first deforming process and the second deforming process is used is not limited to the second embodiment. In the second embodiment, the outer diameter portion of the other end portion 15c of the cylindrical insulating paper 215 that is opposed to the section member 130 during insertion forms the first flared portion 20a. Alternatively, the first flared portion 20 a may be formed in an inner diameter portion whose pitch is smaller than that of the outer diameter portion of the core groove 112 . In addition, the flared portion 20 may be formed only on the outer diameter portion of the cylindrical insulating paper 215 , or may be formed only on the inner diameter portion of the cylindrical insulating paper 215 . By forming the expanded portion 20 using a deformation step when forming the expanded portion 20 , damage to the insulating paper 10 can be suppressed.

The present disclosure is not limited to the above-described embodiments, and can be implemented in various configurations without departing from the gist thereof. For example, the technical features in the embodiments corresponding to the technical features in the various modes described in the Summary of the Invention may be appropriately replaced or combined to solve part or all of the above-mentioned problems or achieve part or all of the above-mentioned effects. In addition, if its technical features are not described as essential in this specification, they may be appropriately deleted.

Explanation of reference signs

10...Insulating paper, 10a...First part, 10b...Second part, 10c...Third part, 11...Crease, 15, 215, 315...Tubular insulating paper, 15a...Middle part, 15b...One end, 15c... The other end, 20...expanded part, 20a...first expanded part, 20b...second expanded part, 80...mold, 81...upper surface, 81a...flat surface, 81b...inclined surface, 82...lower surface, 90, 290...punch, 92...plate, 100...stator, 110...stator core, 111...tooth, 112...core slot, 120...segmented coil, 130...segmented piece, 130a...front end, 130b...cone surface, 140…pipe, 151…first segment group, 152…second segment group, 290a…head, 290b…insertion portion, 290c…inclined surface of punch, 390…guiding jig, 391…blade, 391a… Blade bottom surface, 391b...fin part, 391c...insertion space, 392...moving mechanism, P10-P80...process, SA1...first expansion amount, SA2...second expansion amount.

Claims (6)

1. A method of manufacturing a stator having a core slot, the method comprising:

a deforming step of deforming an insulating paper for insulating the core groove from the segment inserted into the core groove;

a forming step of folding the deformed insulating paper into a cylindrical shape to form a cylindrical insulating paper having an intermediate portion and one end portion and the other end portion disposed opposite to each other in an axial direction with the intermediate portion interposed therebetween;

a first insertion step of inserting the cylindrical insulating paper into the core groove; and

a second insertion step of inserting the segment from the one end side into the inside of the cylindrical insulating paper inserted into the core groove,

the deforming step includes an expanding step of expanding the sheet material,

the cylindrical insulating paper is deformed in a state of being disposed in the core groove, so that an opening of the one end portion in the radial direction of the core groove is expanded to form an expanded portion.

2. The manufacturing method according to claim 1, wherein,

the deforming step includes:

a preparation step of preparing a mold having a flat surface and an inclined surface connected to the flat surface, wherein an angle between the inclined surface and the flat surface is greater than 180 degrees and less than 270 degrees;

a disposing step of disposing a first portion of the insulating paper to be the intermediate portion so as to cover the flat surface, and disposing a second portion of the insulating paper to be the one end portion so as to cover the inclined surface; and

and a spreading step of pushing a punch against the second portion disposed on the inclined surface to deform the insulating paper so that an angle between the first portion and the second portion is greater than 180 degrees, thereby forming the spreading portion.

3. The manufacturing method according to claim 2, wherein,

the deformation process is a first deformation process,

the first deforming process comprises the following steps: in the second portion, in a state of having been inserted into the core groove, either one of an inner diameter portion located on an inner diameter side of the core groove and an outer diameter portion located on an outer diameter side of the core groove is deformed,

the manufacturing method further includes a second deforming step of deforming the tubular insulating paper inserted into the core groove so that the other of the inner diameter portion and the outer diameter portion extends in the radial direction, between the first inserting step and the second inserting step.

4. The manufacturing method according to claim 3, wherein,

in the first deforming step, the inner diameter portion is deformed,

in the second deforming step, the outer diameter portion is deformed.

5. The manufacturing method according to claim 3 or 4, wherein,

the expansion amount of the insulating paper in the second deforming step is smaller than the expansion amount of the insulating paper in the first deforming step.

6. The manufacturing method according to any one of claims 1 to 5, wherein,

the segment inserted in the second insertion step is a first segment, and the manufacturing method further includes:

a third insertion step of inserting a second segment electrically connected to the first segment from the other end side of the cylindrical insulating paper inserted into the core slot; and

a joining step of joining the front end of the first segment and the front end of the second segment via a pipe inside the core groove,

the plurality of first segment members inserted into one of the core grooves in the second insertion process, the plurality of first segment members being inserted side by side in the radial direction in the second insertion process,

in the third insertion step, a plurality of the second segment members are inserted into one of the core grooves, the plurality of second segment members are inserted side by side in the radial direction,

among the plurality of first segment members, the front end of the first segment member opposite to the expanded portion during insertion is mounted with the tube.