JP2003259613A - Method of manufacturing stator winding in rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a stator winding of a rotary electric machine that can ensure the electrical insulation of a stator core and an electrical conductor. <P>SOLUTION: The method has: an insertion step wherein a plurality of segments 33 are inserted in slots formed in the stator core 32 in such a way that they overlap in the radial direction; a bending step wherein the segments 33 are bent so that they incline in mutually opposing directions; and a splicing step wherein ends of the bent segments are spliced together. In the bending step, the segments 33 are bent by auxiliary members 208 inserted in proximity to the surface of the stator core 32 in circumferential gaps of the segments 33 protruding from the stator core 33. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a stator winding of a rotary electric machine for manufacturing a stator winding of a rotary electric machine such as an automotive alternator mounted on an automobile or a truck.

[0002]

2. Description of the Related Art In recent years, along with an increase in electric loads such as safety control devices, an alternator for vehicles is required to have an improved power generation capacity. In order to meet the demand for improving the power generation capability, U-shaped electric conductors such as those disclosed in Japanese Patent No. 3196738 and Japanese Patent Laid-Open No. 2001-197709 are regularly arranged in the slots of the stator. A method of increasing the output by increasing the space factor of the electric conductor is known. This publication discloses a step of bending a U-shaped electric conductor inserted in a slot of a stator winding by using a stator twisting device, and the work speed is improved.

[0003]

By the way, when the electric conductor used in the stator of the above-described conventional vehicle alternator is bent by the stator twisting device, each electric conductor is attached to the stator core. Since it will be bent around the end of the slot provided as a fulcrum, it will be inserted between the stator core and the electric conductor for the purpose of insulating coating or electric insulation of the electric conductor that contacts the end of the slot. The member may be damaged, and there is a possibility that sufficient electric insulation cannot be secured between the stator core and the electric conductor.

FIG. 13 is a view showing a stator in which an electric conductor is bent by a conventional stator twisting device. As shown in FIG. 13, since the electric conductor 300 is abruptly bent at the root portion 304 near the slot end of the stator core 302, the insulating coating and the insulating member 306 formed around the root portion 304 are damaged. Easier to do.

The present invention has been made in view of the above points, and an object thereof is a method of manufacturing a stator winding of a rotating electric machine capable of ensuring electrical insulation between a stator core and an electric conductor. To provide.

[0006]

In order to solve the above-mentioned problems, a method for manufacturing a stator winding of a rotary electric machine according to the present invention comprises:
Inserting a plurality of electric conductors in slots formed in the stator core so as to overlap in the radial direction, and the end of the electric conductor inserted in the slot so that the other adjacent electric conductors face in opposite directions. It has a bending step of bending so as to incline, and a joining step of joining ends of adjacent electric conductors bent by the bending step.
In this bending step, the electric conductor is bent with the auxiliary member inserted in the circumferential gap of the electric conductor protruding from the slot and near the surface of the stator core. Since the electric conductor is bent around the position where it comes into contact with the auxiliary member as a fulcrum, it is possible to prevent damage to the insulating coating of the electric conductor corresponding to the end portion of the slot and the insulating member interposed in this portion, and thus the stator core And electrical insulation of the electrical conductor can be ensured. In particular, since the auxiliary member is arranged between the electric conductors arranged in a plurality of rows in the circumferential direction, and the electric member is bent and sandwiched from both sides of the electric conductor, positioning of the auxiliary member in the circumferential direction is facilitated and the auxiliary member is easily positioned. Since the mechanism for restraining the circumferential position of the member is unnecessary, the manufacturing apparatus can be simplified.

Further, it is desirable that the above-mentioned auxiliary member has a circular sectional shape. Alternatively, in the cross-sectional shape of the above-mentioned auxiliary member, it is desirable that at least a portion that comes into contact with the electric conductor has an arc shape. As a result, it is possible to prevent damage to the insulating coating of the electric conductor that comes into contact with the auxiliary member, ensure electric insulation between the stator core and the electric conductor, and also between the electric conductors or between the electric conductor and the rotary electric machine housing. It becomes possible to ensure electrical insulation between the same and the like.

Further, it is desirable that the above-mentioned auxiliary member is inserted between the electric conductors along the radial direction before the bending step and is pulled out in the radial direction after the bending step. As a result, it is possible to reliably prevent the occurrence of insulation failure in the step of bending the electric conductor. Further, in the stator winding manufactured in this manner, the space from which the auxiliary member is pulled out serves as a cooling air passage that penetrates in the radial direction, so that the cooling performance of the stator winding can be improved.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION A method of manufacturing a stator winding of a rotary electric machine according to an embodiment of the present invention will be described in detail below with reference to the drawings. FIG. 1 is a cross-sectional view showing the overall configuration of the vehicle AC generator of this embodiment. As shown in FIG. 1, the vehicle AC generator 1 of the present embodiment is configured to include a stator 2, a rotor 3, a housing 4, a rectifier 5, and the like.

The rotor 3 acts as a field, rotates integrally with the shaft 6, and has a Lundell type pole core 7, a field coil 8, slip rings 9 and 10, and a mixed flow fan 11 as a blower. And a centrifugal fan 12. The shaft 6 is connected to the pulley 20 and is rotationally driven by a traveling engine (not shown) mounted on the vehicle.

The Randell type pole core 7 is constructed by combining a set of pole cores. The Lundell-type pole core 7 includes a boss portion 71 attached to the shaft 6, a disk portion 72 extending in the radial direction from both ends of the boss portion 71,
It is composed of twelve claw-shaped magnetic pole portions 73.

The mixed flow fan 11 on the pulley side is a base plate 111 fixed to the end surface of the pole core 7 by welding or the like.
The blade has a blade having an acute angle with respect to the blade and a blade having a right angle, and rotates integrally with the rotor 3. The centrifugal fan 12 on the side opposite to the pulley has only blades that are perpendicular to the base plate 121 fixed to the end surface of the pole core 7 by welding or the like.

The housing 4 is a front housing 4a.
And a rear housing 4b. The suction holes 41 are formed on the axial end surfaces of the rear housing 4b, and the outer circumferential shoulders are arranged radially outward of the first coil end group 31a and the second coil end group 31b of the stator 2. A cooling air discharge hole 42 is provided corresponding to the above.

The rectifier 5 has a rectifying function for converting the AC voltage output from the stator 2 into DC, and is provided at the end of the vehicle AC generator 1 on the side opposite to the pulley. Next, details of the stator 2 will be described. FIG. 2 is a partial cross-sectional view of the stator 2. FIG. 3 is a perspective view showing a schematic shape of the segment 33 mounted on the stator core 32.

The stator 2 acts as an armature and is constituted by a stator core 32 and a fixed segment 33 as a plurality of electric conductors arranged in a plurality of slots 35 formed in the stator core 32. It is provided with a child winding 31, and an insulator 34 that electrically insulates between the stator core 32 and the stator winding 31.

As shown in FIG. 2, the stator core 32 has
A plurality of slots 35 having openings on the inner diameter side are formed so as to accommodate the multi-phase stator windings 31. In the present embodiment, 36 slots 35 are accommodated in order to accommodate the three-phase stator windings 31 corresponding to the number of magnetic poles of the rotor 3.
Are evenly spaced.

The stator windings 31 provided in the slots 35 of the stator core 32 can be grasped as individual electric conductors, and each of the plurality of slots 35 has an even number (main line). In the embodiment, four electric conductors are accommodated. The four electric conductors in one slot 35 are arranged from the inner side to the inner end layer in the radial direction of the stator core 32.
The inner middle layer, the outer middle layer, and the outer end layer are arranged in a line in this order.
A coating material such as polyamideimide is applied to these electric conductors as the insulating coating 37.

A stator winding 31 is formed by connecting these electric conductors in a predetermined pattern. In addition,
In the present embodiment, one end of the electric conductor in the slot 35 is connected on the first coil end group 31a side by arranging a continuous line, and the second coil end group 3
On the 1b side, they are connected by joining the other ends.

One electric conductor in each slot 35 is paired with another electric conductor in another slot 35 separated by a predetermined magnetic pole pitch. In particular, in order to secure a gap between the plurality of electric conductors in the coil end portion and arrange them in an aligned manner, the electric conductors of a predetermined layer in one slot 35 are arranged in another slot 35 separated by a predetermined magnetic pole pitch. Is paired with an electric conductor of another layer.

For example, the electric conductor 331a of the inner end layer in one slot is paired with the electric conductor 331b of the outer end layer in the other slot, which is one pole pitch away from the stator core 32 in the clockwise direction. I am doing it. Similarly, the electric conductor 332a of the inner-middle layer in one slot is paired with the electric conductor 332b of the outer-middle layer in the other slot, which is separated by one magnetic pole pitch in the clockwise direction of the stator core 32. The pair of electric conductors are connected to each other through the turn parts 331c and 332c by using a continuous wire at one end of the stator core 32 in the axial direction. Therefore, at one end of the stator core 32, a continuous line connecting the electric conductor of the outer middle layer and the electric conductor of the inner middle layer is connected to the electric conductor of the outer end layer and the electric conductor of the inner end layer. It will be surrounded by a continuous line. In this way, the stator core 32
At one end, the connection of the pair of electrical conductors is surrounded by the connection of the other pair of electrical conductors housed in the same slot. The middle layer coil end is formed by the connection between the outer middle layer electric conductor and the inner middle layer electric conductor,
The end layer coil end is formed by connecting the electric conductor of the outer end layer and the electric conductor of the inner end layer.

On the other hand, the electric conductor 332a of the inner-middle layer in one slot 35 is also the electric conductor 331a 'of the inner end layer in the other slot 35, which is separated by one magnetic pole pitch in the clockwise direction of the stator core 32. In pairs. Similarly, the electric conductor 331b ′ of the outermost layer in one slot 35 is paired with the electric conductor 332b of the outer middle layer in the other slot 35, which is one magnetic pole pitch away in the clockwise direction of the stator core 32. I am doing it. These electric conductors are used for the stator core 32.
Is connected by joining at the other end in the axial direction of.

Therefore, at the other end of the stator core 32, the joint for connecting the electric conductor of the outer end layer and the electric conductor of the outer middle layer, the electric conductor of the inner end layer and the electric conductor of the inner middle layer are connected. And a joint portion that connects to each other are arranged in the radial direction. The adjacent layer coil end is formed by the connection between the electric conductor of the outer end layer and the electric conductor of the outer middle layer, and the connection of the electric conductor of the inner end layer and the electric conductor of the inner middle layer.

Further, the plurality of electric conductors are provided by U-shaped segments formed by forming electric conductors having a substantially rectangular cross section (rectangular cross section) and a constant thickness into a predetermined shape. Figure 3
As shown in, the inner end layer electric conductors and the outer end layer electric conductors are provided by a large segment 331 formed by forming a series of electric conductors in a substantially U shape. Further, the inner middle layer electric conductor and the outer middle layer electric conductor are provided by a small segment 332 formed by molding a series of electric conductors in a substantially U-shape.

Large segment 331 and small segment 332.
And form a basic segment 33. Then, the basic segments 33 are regularly arranged in the slots 35 to form a coil that makes two turns around the stator core 32. However, the segments and 1 that make up the leader of the stator winding
The turn part that connects the first and second laps is the basic segment 3
3 is composed of odd-shaped segments having different shapes. In the case of this embodiment, the number of odd-shaped segments is three. 1
The connection between the first and second laps is the connection between the end layer and the middle layer,
A deformed coil end is formed by this connection.

The manufacturing process of the stator winding 31 will be described below. (Inserting Step) The basic segment 33 is aligned so that the turn portion 332c of the U-shaped small segment 332 is surrounded by the turn portion 331c of the U-shaped large segment 331, and one side of the stator core 32 on the axial side surface Inserted from. At this time, one electric conductor 331a of the large segment 331 is on the inner end layer of one slot 35 of the stator core 32, and one electric conductor 332a of the small segment 332 is one slot 3 of the stator core 32.
5 in the inner middle layer, and the other electric conductor 331b of the large segment 331 in the outer end layer of the other slot 35, which is one magnetic pole pitch away from the one slot 35 of the stator core 32 in the clockwise direction. The other electric conductor 332b
Is also inserted in the outer middle layer of the other slot 35.

As a result, as shown in FIG. 2, the linear portions 331a, 332a, 332b ', 331b' are arranged in a line in the one slot 35 from the inner end layer side as the above-mentioned electric conductors. Here, the straight line portions 332b ', 331b'
Are linear portions of large and small segments that are paired with the electric conductors in the other slots 35 that are offset by one magnetic pole pitch.

(Bending Step) After insertion, in the second coil end group 31b, the linear portion 33 located on the end layer side.
The joints 331d and 331e of 1a and 331b are bent by bending the joints 331d and 331e by a half magnetic pole pitch (1.5 slots in this embodiment) in the direction in which the large segment 331 opens. Then, the linear portions 332a and 332b located in the middle layer are
In the direction in which the small segment 332 closes, the joint portions 332d, 3
32e is twisted and bent by a half magnetic pole pitch. As a result, in the second coil end group 31b, the electric conductors adjacent in the radial direction are inclined in the opposite direction to the circumferential direction. The above operation is performed for all the segments 33 of the slots 35.

(Joining process) Then, in the second coil end group 31b, the outer end layer joint 331e 'and the outer middle layer joint 332e, and the inner middle layer joint 332d and the inner end layer joint 331d' are formed. Are joined by means such as welding, ultrasonic welding, arc welding, brazing, etc. so as to obtain electrical conduction, and the stator 2 as shown in FIG. 4 is obtained.

Next, details of the above-mentioned bending step will be described. FIG. 5 is a sectional view of a twisting device that twists the end side of the segment 33 in the bending step. The twisting device 200 of the present embodiment shown in FIG.
Clamper 204, work holder 206, auxiliary member 20
8, a twist shaping unit 210, a lifting shaft 212, rotation driving mechanisms 220, 222, 224, 226, a lifting driving mechanism 228, and a controller 230.

The work receiver 202 receives and fixes the outer peripheral portion of the stator core 32. The clamper 204 restrains the radial movement of the stator core 32 and holds the stator core 32. The work retainer 206 prevents the stator core 32 from rising. The auxiliary member 208 is for shaping the bent portion into a predetermined shape by inserting the auxiliary member near the base of the segment 33 when the segment 33 is twisted.

The twist shaping section 210 is for twisting the straight portion of the segment 33 protruding from one end of the stator core 32. The elevating shaft 212 includes the twist shaping unit 210.
Is driven in the axial direction. Rotation drive mechanism 220, 222, 2
24 and 226 rotationally drive the twist shaping unit 210 in the circumferential direction. The lifting drive mechanism 228 moves the lifting shaft 212 in the axial direction. The controller 230 controls the operations of the rotation drive mechanisms 220, 222, 224, 226 and the lifting drive mechanism 228.

FIG. 6 is a cross-sectional view taken along line VI-VI of FIG. 5, showing the cross-sectional shape of the twist shaping section 210. In the twist shaping section 210, four cylindrical twist jigs 240, 242, 244, 246 arranged concentrically are arranged with their tip surfaces aligned. Each twisting jig 240, 24
2, 244, 246 are the rotary drive mechanisms 220, 222,
224 and 226 enable independent rotation in the circumferential direction. Also, four twisting jigs 240, 242, 24
4, 246 can be lifted and lowered at the same time as rotating in the circumferential direction by moving the lifting shaft 212 up and down by the lifting drive mechanism 228.

As shown in FIG. 6, each twisting jig 240, 2
Inserted portions 241, 243, 2 into which the end portions of the segment 33 are inserted and held on the tip end surfaces of 42, 244, 246.
45 and 247 are provided. These inserts 24
1, 243, 245, and 247 are equal in number to the slots 35 formed in the stator core 32, and each twisting jig 24 has the same number.
0, 242, 244, 246 are formed side by side in the circumferential direction.

Next, the operation of the twisting device 200 will be described. The stator core 32, in which the segment 33 is inserted into the slot 35, is set on the work receiver 202. Then, the outer peripheral portion of the stator core 32 is fixed by the clamper 204. After that, the work holder 206 is used to upper the stator core 32 and the turn portion 33 of the large segment 331.
By pressing 1c, the vertical movement of the stator core 32 and the segment 33 is restricted. Further, in this state, the auxiliary member 208 is arranged from the radially outer side to the radially inner side at a position that is a gap formed between the segments 33 arranged in the circumferential direction and is substantially in contact with the end surface of the stator core 32.
Insert.

FIG. 7 is a view showing the auxiliary member 208 inserted between the segments 33, and shows the sectional shape of the twisting jig 240 along the circumferential direction. Further, FIG. 8 is a view of the state in which the auxiliary member 208 is inserted, seen from the end side of the segment. As shown in FIG. 7, the auxiliary member 208 is
It is an end surface of the stator core 32 and is inserted between the segments 33 that are adjacent to each other in the circumferential direction. This auxiliary member 208
Is a rod-shaped jig having a circular arc-shaped cross-section at the portion that abuts when the segment 33 is twisted, and has the same number as the slots 35 formed in the stator core 32.

After the auxiliary member 208 is inserted from the outside in the radial direction, the twist shaping section 210 is moved by the lifting shaft 212.
Rises, and each twisting jig 240, 242, 244, 246
The ends of the segments 33 are inserted into the insertion portions 241, 243, 245, 247 formed on the. The insertion portion 24
As shown in FIG. 7, only the end portion of the segment 33, which is used as a joint portion in a later joining step, is inserted into the first and the like.

Next, the twist shaping section 210 is moved up and down simultaneously with the rotation by the rotation drive mechanisms 220 to 226 and the elevation drive mechanism 228. It should be noted that the lifting and lowering of the twist shaping section 210 is performed simultaneously by all the twist jigs 240 to 246.
Regarding the rotation of the twist shaping unit 210, the twisting jigs 240 and 244 shown in FIG. 6 rotate clockwise by the same angle, and the twisting jigs 242 and 246 rotate counterclockwise by the same angle.

FIG. 9 is a view showing a state in which the twist shaping section 210 is rotated, and shows a cross-sectional shape of the twist jig 240 along the circumferential direction. As shown in FIG. 9, when the torsion jigs 240 to 246 are rotated to twist the segment 33, the presence of the auxiliary member 208 may cause the segment 33 to bend suddenly near the end surface of the stator core 32. Instead, the auxiliary member 208 bends gently according to the arc shape of the contact surface.

Thereafter, the auxiliary member 208 is pulled out to the outside in the radial direction, and the twist shaping section 210 is lowered together with the lifting shaft 212 by the lifting drive mechanism 228.
The restraint by the work receiver 202 and the clamper 204 is released, and the stator 2 before the joining process is taken out.

As described above, in the present embodiment, the auxiliary member 2
Since the segment 33 is bent with the position where it abuts on the fulcrum as the fulcrum, the shape of the corner of the segment 33 changes smoothly, and the slot 35 formed in the stator core 32
It is possible to prevent damage to the insulating coating 37 of the segment 33 corresponding to the end of the segment and the insulator 34 interposed in this portion, and to ensure electrical insulation between the stator core 32 and the segment 33. In particular, since the auxiliary member 208 is arranged between the segments 33 arranged in a plurality of rows in the circumferential direction and the segments 33 are bent and sandwiched from both sides in the circumferential direction, the auxiliary member 208 can be easily positioned in the circumferential direction. In addition, since the mechanism for restraining the circumferential position of the auxiliary member 208 is unnecessary, the twisting device 200 can be simplified.

The auxiliary member 208 includes the segment 33.
Since the portion that abuts on the arc is formed in an arc shape, it is possible to effectively prevent damage to the insulating coating 37 of the segment 33 that abuts on the auxiliary member 208. In addition, as shown in FIG. 10, the space A after the auxiliary member 208 is pulled out
Are secured so as to pass through in the radial direction, this space can be used as a cooling air passage, and the cooling performance of the stator winding 31 can be improved.

The present invention is not limited to the above embodiment, and various modifications can be made within the scope of the gist of the present invention. For example, in the embodiment described above,
Although the auxiliary member 208 in which only the portion contacting the segment 33 is formed in an arc shape is used, the auxiliary member 208 having a circular cross section (or an elliptical cross section) may be used as shown in FIG. An auxiliary member 208 having a rectangular cross section may be used.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an overall configuration of a vehicle AC generator according to an embodiment.

FIG. 2 is a partial cross-sectional view of a stator.

FIG. 3 is a perspective view showing a schematic shape of a segment mounted on a stator core.

FIG. 4 is a partial perspective view of a stator winding.

FIG. 5 is a cross-sectional view of a twisting device that twists the end side of the segment in the bending step.

6 is a sectional view taken along line VI-VI of FIG.

FIG. 7 shows an auxiliary member inserted between the segments.

FIG. 8 is a view of the state in which the auxiliary member is inserted, viewed from the end side of the segment.

FIG. 9 is a diagram showing a state where the twist shaping section is rotated.

FIG. 10 is a diagram showing the shape of a stator winding after shaping.

FIG. 11 is a cross-sectional view showing a modified example of the auxiliary member.

FIG. 12 is a cross-sectional view showing a modified example of the auxiliary member.

FIG. 13 is a diagram showing a stator in which an electric conductor is bent by a conventional stator twisting device.

[Explanation of symbols]

2 stator 31 Stator winding 32 Stator core 33 segments 34 insulator 35 slots 200 twisting device 202 Work receiving 204 clamper 206 Workpiece holder 208 Auxiliary member 210 Twist shaping section 212 Lifting shaft

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Claims (4)

[Claims] 1. An inserting step of inserting a plurality of electric conductors into slots formed in a stator core so as to overlap each other in a radial direction, and an end portion of the electric conductors inserted into the slots, which are adjacent to each other. A bending step in which the electric conductors are bent so as to incline in mutually opposite directions; In the manufacturing method, the bending step includes bending the electric conductor in a state where an auxiliary member is inserted in the vicinity of the surface of the stator core in a circumferential gap of the electric conductor protruding from the slot. A method of manufacturing a stator winding of a rotating electric machine, which is characterized. 2. The method for manufacturing a stator winding of a rotating electric machine according to claim 1, wherein the auxiliary member has a circular cross-sectional shape. 3. The method for manufacturing a stator winding of a rotating electric machine according to claim 1, wherein a cross-sectional shape of the auxiliary member is an arc shape at least in a portion in contact with the electric conductor. 4. The auxiliary member according to claim 1, wherein the auxiliary member is inserted between the electric conductors along the radial direction before the bending step, and is pulled out in the radial direction after the bending step. A method for manufacturing a stator winding of a rotating electric machine, comprising: