CN116633104A - Method for manufacturing stator - 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

Method for manufacturing stator

Technical Field

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

Background

Conventionally, as a stator for a rotating electrical machine, there is a stator in which a sheet-like insulating member is disposed between a slot and a segment. In the case of manufacturing the stator, the insulating member is inserted into the slot, and then the segment is inserted into the slot provided with the insulating member. There is a technique of expanding an end portion of an insulating member so that the end portion of the segment is not easily interfered with the insulating member when inserting the segment (for example, patent document 1).

Prior art literature

Patent literature

Patent document 1: japanese patent laid-open No. 2000-308314

Disclosure of Invention

Problems to be solved by the invention

However, the thickness of the folded portion of the insulating member becomes thin due to the expansion of the insulating member, and there is a possibility that the insulation property may be lowered.

Means for solving the problems

The present disclosure can be achieved in the following manner.

(1) According to one aspect of the present disclosure, a method of manufacturing a stator having a core slot is provided. The manufacturing method comprises the following steps: 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 the steps of: 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. According to this aspect, the insulation paper is deformed by a method of reducing damage to the insulation paper before the insulation paper is inserted into the core groove, whereby the insulation properties of the insulation paper can be suppressed from being lowered.

(2) The manufacturing method of the above embodiment may include: 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 the expanding step of pushing a punch toward 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 expanding portion. According to this aspect, since the angle formed by the flat surface and the inclined surface of the die is smaller than 270 degrees, the stress applied to the boundary portion between the first portion and the second portion can be made smaller than 270 degrees or more in the deforming step. Therefore, the insulation property of the insulation paper can be suppressed from being lowered.

(3) In the above-described method for manufacturing a semiconductor device, the deforming step may be a first deforming step, and the first deforming step may be a step of: in the second portion, only 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 in a state of being inserted into the core groove, and the manufacturing method further includes a second deforming step of deforming the tubular insulating paper inserted into the core groove so that the other one of the inner diameter portion and the outer diameter portion is expanded in the radial direction between the first inserting step and the second inserting step. According to this aspect, when both the inner diameter portion and the outer diameter portion are expanded, the 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. Further, by using the second deforming step for any other of the inner diameter portion and the outer diameter portion, the positional accuracy of the portion deformed by the second deforming step with respect to the core groove can be improved. Therefore, damage to the insulating paper can be reduced, and the positional accuracy of the expanded portion of the insulating paper with respect to the core groove can be improved.

(4) In the manufacturing method according to the above aspect, the first deforming step may deform the inner diameter portion, and the second deforming step may deform the outer diameter portion. 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, the degree of freedom of the form of the jig can be improved when the jig is used to deform the insulating paper in the second deforming step.

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

(6) In the above-described manufacturing method, the segment inserted in the second insertion step may be a first segment, and the manufacturing method may further include: 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 distal ends of the first and second segments via a pipe inside the core groove, wherein the first segments inserted into one of the core grooves in the second insertion step are plural, the first segments are inserted side by side in the radial direction in the second insertion step, the second segments inserted into one of the core grooves in the third insertion step are plural, the second segments are inserted side by side in the radial direction, and the pipe is attached to the distal ends of the first segments which are opposite to the expansion portion during insertion. According to this aspect, when the edge of the tube is not tapered, the expansion portion is formed, so that the insulating paper can be prevented from being caught during insertion.

The present disclosure may be realized by various means other than the method of manufacturing the stator. For example, the stator may be realized by a manufacturing apparatus or the like.

Drawings

Fig. 1 is a flowchart of a stator manufacturing process.

Fig. 2 is a perspective view of a stator.

Fig. 3 is a view illustrating insertion of a segment into a stator core.

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

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

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

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

Fig. 8 is a perspective view of the mold.

Fig. 9 is a cross-sectional view of IX-IX of fig. 8.

Fig. 10 is a diagram illustrating the formation of the expansion portion.

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

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

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

Fig. 14 is a diagram illustrating the second modification 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 view illustrating formation of a second expansion portion according to the third embodiment.

Fig. 18 is a second diagram illustrating formation of a second expansion portion according to the third embodiment.

Detailed Description

A. First embodiment:

A1. the stator is formed by:

fig. 1 is a flowchart showing steps of a stator manufacturing process for implementing a method for manufacturing a stator 100 according to the present embodiment. Fig. 2 is a perspective view of the stator 100. Fig. 3 is a view illustrating insertion of the segment 130 into the stator core 110. Fig. 4 is a first diagram illustrating a joining method of the segment 130. Fig. 5 is a sectional view of the stator core 110 in which the segment 130 is inserted, after being cut at a radial cut surface. Fig. 6 is a second diagram illustrating a joining method of the segment 130. The Z-axis direction is shown in fig. 2. One direction of the Z-axis direction is defined as a +z-axis direction, and the other direction of the Z-axis direction is defined as a-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 up direction, and the-Z-axis direction is referred to as a down direction. The same is true for the directions shown in the figures that follow.

As shown in fig. 2, the stator 100 includes a stator core 110 and a plurality of segment coils 120. The stator core 110 is formed into a substantially cylindrical shape, for example, by laminating a plurality of non-oriented electromagnetic steel plates formed into an annular shape by press working. 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. The groove portion formed between two circumferentially adjacent teeth 111 is a core groove 112.

The segmented coil 120 has a plurality of segments 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 is an electric conductor having a rectangular cross section, the surface of which is covered with an insulating coating film made of, for example, enamel resin. The tube 140 serves to physically join the respective front ends of the two segments 130, thereby electrically connecting the two segments 130.

In the case of assembling the segmented 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 groups of segments 130 in which a plurality of segments 130 are combined into an annular ring. The first segment group 151 is disposed such that the tips of the segments 130 constituting the first segment group 151 face downward, and are combined in a circular shape so that the segments 130 can be inserted into the corresponding core grooves 112. The second segment group 152 is disposed such that the front ends of the segments 130 constituting the second segment group 152 face upward, and are combined in a circular shape so that the segments 130 are inserted into the corresponding core grooves 112.

In addition, a tube 140 (fig. 2) is attached to the tip end of either one of the segment 130 of the first segment group 151 and the segment 130 of the second segment group 152, which are connected to each other, before being inserted into the core groove 112. As shown in fig. 2, if the first segment group 151 and the second segment group 152 are inserted into the stator core 110, the front ends of each other are joined via the pipe 140 as an electric conductor inside the core groove 112. By disposing the joint portion of the segment 130 inside the core groove 112, the connection portion can be protected, and the reliability of the stator 100 can be improved, as compared with the case of joining outside the core groove 112.

As shown in fig. 4, the insulating coating of the front end 130a of the segment 130 is peeled off and formed to have a smaller sectional area than that of the body. The tube 140 has a hollow shape with a rectangular cross-sectional shape. The distal end 130a of the segment 130 is fitted into the hollow portion of the pipe 140. A tapered surface 130b that tapers toward the front end is formed at the front end 130a of the segment 130.

As shown in fig. 5, a plurality of segment members 130 are inserted into the same core slot 112. The plurality of segment members 130 inserted into the same core slot 112 from the same direction are also called 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 in such a manner that the respective front end positions become predetermined positions and are simultaneously inserted. As shown in fig. 6, every other one of the plurality of segment members 130 inserted into the same core slot 112 from the same direction is previously installed with a tube 140. The front end position of the segment 130 to which the pipe 140 is mounted and the front end position of the segment 130 to which the pipe 140 is not mounted are different in the Z-axis direction. Thereby, the adjacent two segment members 130 can be insulated from each other. The front end of the segment 130 where the tube 140 is not mounted protrudes more in the insertion direction than the front end of the tube 140. Accordingly, the distal end of the segment 130 does not contact the pipe 140 other than the pipe 140 to be connected, and therefore damage to the insulating coating of the segment 130 can be suppressed.

Although not shown in fig. 2, insulating paper 10 (fig. 6) is disposed between the core groove 112 and the segment 130. The insulating paper 10 shown in fig. 6 is configured to insulate the core slot 112 from the segment 130 inserted into the core slot 112. Fig. 7 is a diagram illustrating an outline of a stator manufacturing process. The insulating paper 10 is folded into a cylindrical shape in a step P30 described later to form a cylindrical insulating paper 15, and then inserted into the core groove 112. Then, in step P50 described later, the segment 130 is inserted into the inside of the cylindrical insulating paper 15 inserted into the core groove 112.

A cylindrical insulating paper 15 is inserted into one of the core grooves 112. Since the segment 130 is inserted into the inside of the cylindrical insulating paper 15, the opening of the cylindrical insulating paper 15 is preferably expanded in the radial direction of the core groove 112 so that the tip of the segment 130 does not easily interfere with the open end of the cylindrical insulating paper 15. Here, the inventors studied the deformation step of deforming the insulating paper 10 before inserting the insulating paper into the core groove 112 when deforming the insulating paper 10 so as to expand the opening. This can suppress damage to the insulating paper 10 caused by the deforming step, and can suppress a decrease in insulation properties. In the following description, as shown in step P50 of fig. 7, when the insulating paper 15 is inserted into the core groove 112, the surface of the two cylindrical insulating papers 15 located on the inner diameter side of the stator core 110 along the circumferential direction of the stator core 110 is referred to as an inner diameter portion, and the surface located on the outer diameter side of the stator core 110 is referred to as an outer diameter portion.

In the present embodiment, as shown in fig. 6, a tapered surface 130b is formed at the distal end 130a of the segment 130. In contrast, the distal end of the tube 140 has a distal end surface substantially perpendicular to the insertion direction. Therefore, the tube 140 is more likely to interfere with the open end portion of the cylindrical insulating paper 15 than the segment 130. Therefore, in the present embodiment, as shown in fig. 7, the opening portion 20 is formed by the inner diameter portion of the one end portion 15b and the outer diameter portion of the other end portion 15c which are opposed to the tube 140 during insertion of the coil group, in the opening end portion of the tubular insulating paper 15. In addition, the one end portion 15b and the other end portion 15c will be described later.

A2: the manufacturing method of the stator comprises the following steps:

in step P10 of fig. 1, a crease 11 is formed in the 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 cylinder, a crease 11 is formed in a portion to be a side. As the insulating paper 10, an insulating resin sheet, a nonwoven fabric sheet, a sheet in which these and foaming resins are laminated, or the like can be used. The process P10 may be performed by a machine or an operator.

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 cross-sectional view IX-IX of fig. 8 shown with a punch 90. Fig. 10 is a diagram illustrating the formation of the expansion portion 20. In fig. 8 to 10, three spatial axes orthogonal to each other, that is, XYZ axes are depicted. The directions of the arrows of the X axis, the Y axis and the Z axis represent the positive directions along the X axis, the Y axis and the Z axis, respectively. Positive directions along the X-axis, Y-axis, and Z-axis are respectively set to +x-axis direction, +y-axis direction, and +z-axis direction. The directions opposite to the directions of the arrows of the X axis, the Y axis and the Z axis are the negative directions along the X axis, the Y axis and the Z axis respectively. Negative directions along the X axis, the Y axis and the Z axis are respectively set as-X axis direction, -Y axis direction and-Z axis direction. The directions along the X-axis, Y-axis, and Z-axis, whether positive or negative, are referred to as the X-axis direction, the Y-axis direction, and the Z-axis direction, respectively. The +Z axis direction is also referred to as up, and the-Z axis direction is referred to as down. The same is true for the figures and description shown hereinafter.

As shown in fig. 8, the mold 80 is a rectangular parallelepiped having an upper surface 81 and a lower surface 82. The upper surface 81 is sized to 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 toward the end portion toward the lower surface 82. The inclined surface 81b is used to form the expansion portion 20.

In step P14 of fig. 1, the insulating paper 10 is placed on the mold 80. Specifically, the insulating paper 10 is disposed so as to cover the flat surface 81a and the inclined surface 81b of the mold 80. In addition, "covering" herein includes not only the case of covering the entire area of the cover surface but also the case of covering a part of the cover 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 15a, one end portion 15b, and the other end portion 15c. One end portion 15b and the other end portion 15c are disposed opposite 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, when the cylindrical insulating paper 15 is formed, the first portion 10a of the insulating paper 10 serving as the intermediate portion 15a is disposed so as to cover the flat surface 81a. When the cylindrical insulating paper 15 is formed, the second portion 10b of the insulating paper 10, which is the one end portion 15b, is disposed so as to cover the inclined surface 81b. When the cylindrical insulating paper 15 is formed, the third portion 10c of the insulating paper 10, which becomes the other end portion 15c, is disposed so as to cover the inclined surface 81b. As shown in fig. 9, after the insulating paper 10 is disposed on the mold 80, a plate 92 for suppressing positional displacement is disposed 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 disposed on the inclined surface 81b. Thereby, as shown in fig. 10, the second portion 10b disposed on the inclined surface 81b 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 between the first portion 10a and the second portion 10b disposed on the inclined surface 81b is greater than 180 degrees, thereby forming the expanded portion 20. Similarly, the insulating paper 10 is deformed such that the angle between the first portion 10a and the third portion 10c disposed on the inclined surface 81b is greater than 180 degrees, thereby forming the expanded portion 20. Thereby, the insulating paper 10 is deformed such that the opening of the one end portion 15b of the core groove 112 in the radial direction expands in a state where the cylindrical insulating paper 15 is disposed in the core groove 112. The term "deformed so that the opening of the one end portion 15b is widened" means that the outer shape of the opening of the one end portion 15b is deformed so as to be larger than the outer shape of the cross section of the intermediate portion 15a perpendicular to the axial direction.

An angle θ formed by the flat surface 81a and the inclined surface 81b shown in fig. 9 is greater than 180 degrees and less than 270 degrees. Therefore, in step P16, the stress applied to the boundary portion between the first portion 10a and the second portion 10b can be reduced to 270 degrees or more than the angle θ formed. Therefore, damage to the insulating paper 10 caused by deformation can be suppressed, and deterioration of insulation can be suppressed.

In step P30 of fig. 1, the insulating paper 10 is folded into a tube along the fold 11 to form a tube-shaped 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 cylindrical insulating paper 15 is inserted such that the surface of the cylindrical insulating paper 15 on which the insulating paper 10 is superimposed is positioned on the outer diameter side of the core groove 112 and the one end portion 15b is positioned in the +z axis direction of the core groove 112.

In step P60 of fig. 1, the first segment 130 included in the first segment group 151, that is, the first segment, is inserted into the cylinder insulating paper 15 inserted into the core groove 112 from the side of the one end 15b of the cylinder insulating paper 15, that is, from above. Here, since the tubular insulating paper 15 has the radially-expanded portion 20 at the inner diameter portion facing the tube 140 during insertion, interference between the first segment and the tubular insulating paper 15 during insertion can be suppressed.

In step P70 in fig. 1, the second segment 130 included in the second segment group 152, that is, the second segment, is inserted into the cylinder-shaped insulating paper 15 inserted into the core groove 112 from the other end portion 15c side of the cylinder-shaped insulating paper 15, that is, from below. In the same manner as in step P60, the tubular insulating paper 15 has the radially-expanded portion 20 at the outer diameter portion facing the tube 140, so that interference between the second segment and the tubular insulating paper 15 can be suppressed during insertion.

In step P80, the first segment and the second segment are joined via the pipe 140, and the present stator manufacturing process is completed. The process P12 is also called a preparation process, the process P14 is also called a placement process, the process P16 is also called an expanding process, and the processes P10 to P16 are also called deforming processes. The process P30 is also called a forming process, the process P40 is also called a first inserting process, the process P60 is also called a second inserting process, the process P70 is also called a third inserting process, and the process P80 is also called a bonding process.

According to the first embodiment described above, the deforming step includes the step P16 of deforming the insulating paper 10 so as to expand the opening of the one end portion 15b in the radial direction of the core groove 112 to form the expanded portion 20 when the cylindrical insulating paper 15 is disposed in the core groove 112. By deforming the insulating paper 10 with little damage before inserting the insulating paper 10 into the core groove 112, it is possible to suppress a decrease in the insulation properties of the insulating paper 10.

In step P16, the punch 90 is pushed toward the second portion 10b disposed on the inclined surface 81b, and the insulating paper 10 is deformed so that the angle between the first portion 10a and the second portion 10b is greater than 180 degrees, thereby forming the expansion portion 20. Since the angle θ formed by the flat surface 81a and the inclined surface 81b of the die 80 is smaller than 270 degrees, the stress applied to the boundary portion between the first portion 10a and the second portion 10b can be made smaller than the case where the angle θ is 270 degrees or more in the step P16. Therefore, damage to the insulating paper 10 can be suppressed, and deterioration of the insulating properties can be suppressed.

Further, 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 opposite to the expansion portion 20 during the insertion is mounted with the tube 140. Thus, when the edge of the tube 140 is not tapered, the expansion portion 20 is formed, whereby the insulating paper 10 can be prevented from being caught during insertion. 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 front end of the segment member 130 that is not opposed to the expansion portion 20 during the insertion process is not fitted with the tube 140. Since the tapered surface 130b is formed at the front end of the segment 130, the insulating paper 10 is not easily rolled up during insertion even if the expanded portion 20 is not formed. Since the opening portion 20 is not formed, damage caused by deformation of the insulating paper 10 for forming the opening portion 20 can be avoided.

B. Second embodiment:

fig. 11 is a flowchart showing 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 sectional view showing the segment 130 together, after the core groove 112 is cut off with a radial cut-off surface. Fig. 14 is a diagram illustrating the second modification step.

As shown in fig. 12, the tubular insulating paper 215 according to the present embodiment is different from the tubular insulating paper 15 according to the first embodiment in that the expansion portion 20 is formed at both the inner diameter portion and the outer diameter portion of the opening of the tubular insulating paper 215. The method of forming the expanded portion 20 of the inner diameter portion is different from the method of forming the expanded portion 20 of the outer diameter portion. In the present embodiment, the expanded portion 20 of the inner diameter portion of the one end portion 15b and the expanded portion 20 of the outer diameter portion of the other end portion 15c are formed in the same manner as in the deforming step according to the first embodiment. The expanded portion 20 of the outer diameter portion of the one end portion 15b and the expanded portion 20 of the inner diameter portion of the other end portion 15c are formed after the tubular insulating paper 215 is inserted into the core groove 112.

In order to distinguish between the two forming methods of the expanded portion 20, the deforming step according to the first embodiment is referred to as a first deforming step, and the step of forming the expanded portion 20 after insertion into the core groove 112 is referred to as a second deforming step. The expansion portion 20 formed in the first deforming step is referred to as a first expansion portion 20a, and the expansion portion 20 formed in the second deforming step is referred to as a second expansion portion 20b. The same steps and configurations as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted as appropriate.

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

As shown in fig. 14, the punch 290 has a head 290a and an insertion portion 290b extending in the axial direction from the head 290 a. The insertion portion 290b has a size to be able to be inserted into the core groove 112. A punch inclined surface 290c inclined so that the cross-sectional area thereof becomes smaller toward the tip is formed on a part of the side surface of the insertion portion 290b.

In step P50 (fig. 11), the insertion portion 290b is inserted from above the tubular insulating paper 215 disposed in the core groove 112. By inserting the punch 290, the outer diameter portion of the one end portion 15b of the tubular insulating paper 215 is deformed so as to expand outward along the punch inclined surface 290c. Thereby, the second expansion portion 20b can be formed at the one end portion 15 b. Similarly, by inserting the punch 290 from below the tubular insulating paper 215 disposed in the core groove 112, the inner diameter portion of the other end portion 15c of the tubular insulating paper 215 is deformed. Thereby, the second expansion portion 20b can be formed at the other end portion 15c. According to step P50, the second expansion 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 portion 20b with respect to the core groove 112 can be improved.

As shown in fig. 13, the second expansion SA2, which is the expansion amount of the second expansion portion 20b, is smaller than the first expansion SA1, which is the expansion amount of the first expansion portion 20a. The expansion amount is a distance between the inner surface of the intermediate portion 15a of the tubular insulating paper 215 and the tip end of the insulating paper 10 in the radial direction. By making the second expansion amount SA2 smaller than the first expansion amount SA1, damage to the insulating paper 10 in the 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 right angle. Therefore, when the expansion amount is large, the insulating paper 10 may be damaged. Therefore, by making the second expansion amount SA2 smaller than the first expansion amount SA1, damage to the insulating paper 10 can be suppressed.

After step P50 shown in fig. 11, steps P60 to P80 are performed as in the first embodiment, and the present stator manufacturing process 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 with respect to the one end portion 15b, and in the second deforming step, the outer diameter portion of the tubular insulating paper 215 is expanded. In the first deforming step, damage to the insulating paper 10 can be reduced. By using the second deforming step, the positional accuracy of the expansion portion 20 with respect to the core groove 112 can be improved. Therefore, damage to the insulating paper 10 can be reduced, and the positional accuracy of the expanded portion 20 of the insulating paper 10 with respect to the core groove 112 can be improved.

The second expansion SA2 of the insulating paper 10 in the second deforming step is smaller than the first expansion SA1 of the insulating paper 10 in the first deforming step. This can suppress damage to the insulating paper 10 caused by the second deforming step.

C. Third embodiment:

fig. 15 is a cross-sectional view of the core groove 112 after being cut at a radial cut surface. Fig. 16 is a perspective view of the guide jig 390. Fig. 17 is a first view illustrating formation of the second expansion portion 20b. Specifically, fig. 17 is a cross-sectional view of the core groove 112 provided with the guide jig 390, after being cut at a radial cut surface. Fig. 18 is a second diagram illustrating formation of the second expansion portion 20b. Specifically, fig. 18 is a cross-sectional view of the core groove 112 provided with the guide jig 390, as viewed from the inner diameter toward the outer diameter in the radial direction, with a cut surface perpendicular to the radial direction.

In the present embodiment, as shown in fig. 15, the number of the segment members 130 inserted into the same core groove 112 from the same direction is different from that of the second embodiment. Specifically, in the present embodiment, 5 segment members 130 are inserted into the same core groove 112 from the same direction. Further, the point different from the second embodiment is that the expanded portion 20 is formed only at one end portion 15b of the tubular insulating paper 315 inserted into the core groove 112.

In the present embodiment, the pipe 140 is attached to the segment 130 inserted into the same core groove 112 at both ends of the plurality of first segments included in the first segment group 151. Therefore, the expansion portion 20 is formed at both the inner diameter portion and the outer diameter portion of the one end portion 15b of the tubular insulating paper 315 facing the pipe 140 during the insertion in the second insertion step, i.e., step P60. On the other hand, the pipe 140 is not installed on the segment 130 inserted into the same core slot 112 at both ends of the plurality of second segments included in the second segment group 152. Therefore, the expansion portion 20 is not formed at the other end portion 15c of the tubular 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 by the first deforming process and the second deforming process. The content of the second deforming step is different from that of the second embodiment. Therefore, the steps other than the second deforming step will not be described. In the second deforming 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 moving mechanism 392. The guide jig 390 has a function for forming the expansion portion 20 and a function for 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 opposite to the circular 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 substantially an annular shape corresponding to the stator core 110. The blade 391 is 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 as indicated by the arrow in fig. 16.

As shown in fig. 17, in the case where the guide jig 390 is provided with respect to the stator core 110, the vane 391 has a vane bottom surface 391a opposite to the core groove 112. The blade bottom surface 391a is provided with two fin portions 391b, and the two fin portions 391b project toward the core groove 112 with the blade bottom surface 391a as a base. As shown in fig. 18, two fin portions 391b are disposed at both end portions of the vane bottom surface 391a in the circumferential direction of the stator core 110. The two fin portions 391b are provided at positions opposed to the respective end portions of the adjacent two core slots 112.

In step P50 (fig. 11) which is the second deforming step, as shown in fig. 17, the blade 391 moves from the inner diameter side to the outer diameter side in the radial direction, whereby the fin portion 391b presses the outer diameter portion of the tubular insulating paper 15 to the outer diameter side in the radial direction. Thereby, the insulating paper 10 is deformed starting from the edge of the stator core 110, and the second expansion portion 20b is formed on the cylindrical insulating paper 315.

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

The outer diameter portion of the core groove 112 has a larger pitch than the inner diameter side of the core groove 112. Therefore, in the case of deforming both the inner diameter portion and the outer diameter portion of the tubular insulating paper 315 inserted into the core groove 112, in the case of deforming one of them using a jig, the degree of freedom of the form of the jig can be improved by using the jig in the deformation of the outer diameter portion of the tubular insulating paper 315. Since the guide jig 390 used in the present embodiment is a mechanism for moving the blade 391 in the radial direction, it is assumed that the size of the blade 391 is limited when moving the blade 391 in the inner diameter direction. In this regard, the guide jig 390 used in the present embodiment is a mechanism for moving the blade 391 in the outer diameter direction. Therefore, the guide jig 390 can be preferably applied when the inner diameter portion of the tubular insulating paper 315 is deformed in the first deforming step and the outer diameter portion is deformed in the second deforming step.

In the process P60 (fig. 11), the segment 130 is inserted along the insertion space 391c formed between the adjacent two 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 deforming step, and the outer diameter portion is deformed in the second deforming step. This can improve the degree of freedom in the form of the jig for deforming the tubular insulating paper 315 inserted into the core groove 112.

D. Other embodiments:

(D1) In the second embodiment, the first deforming step and the second deforming step are performed in order to form the first and second expanded portions 20a and 20b. The manufacturing method of forming the first and second expansion portions 20a and 20b is not limited to the second embodiment, and both the first and second expansion portions 20a and 20b may be formed in the deforming process according to the first embodiment.

(D2) In the second embodiment, the inner diameter portion of one end portion 15b and the outer diameter portion of the other end portion 15c of the tubular insulating paper 215 are deformed by the first deforming step, and the outer diameter portion of one end portion 15b and the inner diameter portion of the other end portion 15c of the tubular insulating paper 215 are deformed by the second deforming step. In the case where the expanded portion 20 is formed at the inner diameter portion and the outer diameter portion of the tubular insulating paper 215, the formation using either the first deforming step or the second deforming step is not limited to the second embodiment. In the second embodiment, the outer diameter portion of the other end portion 15c of the tubular insulating paper 215 opposite to the segment 130 during insertion forms the first expanded portion 20a. In addition, the first expansion portion 20a may be formed at an inner diameter portion having a smaller pitch than an outer diameter portion of the core groove 112. The expansion portion 20 may be formed only at the outer diameter portion of the tubular insulating paper 215, or the expansion portion 20 may be formed only at the inner diameter portion of the tubular insulating paper 215. By forming the opening 20 using a deforming process when forming the opening 20, damage to the insulating paper 10 can be suppressed.

The present disclosure is not limited to the above embodiments, and may be implemented in various configurations within a range not departing from the gist thereof. For example, the technical features of the embodiments corresponding to the technical features of the embodiments described in the summary of the invention may be replaced or combined as appropriate to solve part or all of the above-described problems or to achieve part or all of the above-described effects. Further, if its technical features are not described as indispensable in the present specification, it may be deleted appropriately.

Description of the reference numerals

10 insulating paper, 10a first part, 10b second part, 10c third part, 11 folds, 15, 215, 315 barrel insulating paper, 15a middle part, 15b one end part, 15c other end part, 20 spreading part, 20a first spreading part, 20b second spreading part, 80 die, 81 upper surface, 81a flat surface, 81b inclined surface, 82 lower surface, 90, 290 punch, 92 plate, 100 stator, 110 stator core, 111 teeth, 112 core slot, 120 segmented coil, 130 segmented piece, 130a front end, 130b conical surface, 140 tube, 151 first segmented piece set, 152 second segmented piece set, 290a head, 290b insertion part, 290c inclined surface, 390 guiding clamp, 391 blade, 391a blade bottom surface, 391b fin part, 391c insertion space, 392 moving mechanism, P10-P80 process, SA1 first spreading amount, SA2 second spreading 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.