JP2004254362A - Method for manufacturing stator of rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a stator of a rotary electric machine in which a connecting part can be surely positioned and the occurrence of a connecting fault can be prevented. <P>SOLUTION: The electric conductor of a segment 33 for constituting a stator winding is crossed with the connecting part of the adjacent electric conductor in a state that the connecting part of a tip is inclined. The connecting parts are connected by welding, etc. Each electric conductor is crossed with the other electric conductor at an end face side intersecting part nearer to the end face of a stator core from the connecting part of the distal end. A skewer-like restricting member 112c is attached to the end face side intersecting part. A connecting step is performed in a state that the respective electric conductors are constrained. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a stator of a rotating electric machine such as an automotive alternator mounted on an automobile or a truck.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, in order to join a stator winding of a rotating electric machine, arc welding in which an arc discharge is generated between an electrode and a winding welding portion and the heat is used to melt-join the windings has been generally adopted. For example, after inserting a U-shaped electric conductor into a plurality of slots formed in the stator core, the tip end side is inclined in the circumferential direction, and then the adjacent tip ends are joined by arc discharge. 2. Description of the Related Art A winding joining method for an electric machine is known (for example, see Patent Document 1).
[0003]
FIG. 16 is a partial perspective view showing the structure of a conventional stator to be subjected to the above-described joining method. FIG. 17 is a plan view showing the arrangement of the joining portions of the stator windings shown in FIG. FIG. 18 is a diagram showing a main part of a conventional bonding apparatus.
As shown in FIG. 16, when four electric conductors 404 protrude from each slot of the stator core 400, the protruding portions are alternately inclined in the opposite circumferential direction when viewed in the radial direction. The ends of these electric conductors 404 are joints 406, and as shown in FIG. 17, two of the four joints 406 arranged in the radial direction form a set, and the joining operation is performed.
[0004]
Specifically, as shown in FIG. 18, in this joining operation, the inner diameter side and the outer diameter side of the joining portion 406 are restrained by the inner diameter side positive electrode 410 and the outer diameter side positive electrode 412, and are adjacent in the circumferential direction. This is performed in a state where the rod-shaped plus electrode 414 is arranged between the joints 406. In such a state, by joining the torch 420 as a welding electrode to the joint 406, the joint of the joint 406 is welded.
[0005]
[Patent Document 1]
Japanese Patent No. 3104700 (page 4-6, FIG. 1-5)
[0006]
[Problems to be solved by the invention]
By the way, according to the conventional joining method disclosed in Patent Document 1, when there is a gap between joining portions arranged in a line in the radial direction, the inner diameter side plus electrode 410 and the outer diameter side plus electrode 412 allow the inner side and the outer side to be connected. There is a problem that positioning of the joint 406 is not easy because each joint 406 moves toward the gap even if the radial side is restricted. In addition, when the joints 406 move, the electrical contact between each joint 406 and the inner diameter-side plus electrode 410 or the outer diameter-side plus electrode 412 becomes insufficient, and there is a possibility that a joint failure may occur. was there.
[0007]
SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and an object of the present invention is to provide a rotating electric machine stator that can reliably perform positioning of a joint portion and prevent occurrence of joint failure. It is to provide a manufacturing method.
[0008]
[Means for Solving the Problems]
In order to solve the above-described problems, a method for manufacturing a stator of a rotating electrical machine according to the present invention includes a stator core having a plurality of slots formed in a circumferential direction, A stator winding having a plurality of electric conductors exposed to the outside, wherein the electric conductor has a first electric conductor having an exposed portion inclined in one circumferential direction from the slot and an exposed portion having a first electric conductor. A second electric conductor, which extends from the slot at a position circumferentially different from the slot in which the electric conductor is accommodated to the other in the circumferential direction and has a tip joined to the tip of the first electric conductor; An end surface side closer to the end surface of the stator core than the joint position between the first and second electric conductors, extending from the slot different from the slot in which each of the second electric conductors is accommodated to the other in the circumferential direction. Intersection A method of manufacturing a stator of a rotating electrical machine having a first electric conductor and a third electric conductor crossing the first electric conductor, wherein the position of the stator core is closer to the end face of the stator than to the joint position between the first and second electric conductors. The first electric conductor and the third electric conductor are constrained by a close constraining portion, and the end of the first electric conductor and the end of the second electric conductor are joined. Since the joint at each end of the first electric conductor and the second electric conductor is constrained by the constraining portion closer to the end face of the stator core than the end, the coil end height required for constraining at the joint at the front end Becomes unnecessary, and the height of the coil end can be reduced.
[0009]
Further, it is desirable that the above-described restraining portion is an end surface side intersection. With this, both the first electric conductor and the third electric conductor are positioned at once in the radial direction and the axial direction at the end face side intersection, so that the joint of the tip end of the first electric conductor to be joined is formed. The positioning in the radial direction, the circumferential direction, and the axial direction can be reliably performed, and the occurrence of poor joining can be prevented.
[0010]
In addition, a plurality of conductor sets each including a first electric conductor and a second electric conductor whose ends are joined to each other are provided in a radial direction to form a stator winding, and a conductor set is formed between the radially arranged conductor sets. It is desirable that a restraining member provided with a projection projecting into the space restrains the first electric conductor and the third electric conductor. Thus, with a simple jig shape, it is possible to prevent the occurrence of defective joints by reliably positioning each joint, and at the same time, secure clearance between conductor sets and prevent contact between adjacent joints. Will be possible.
[0011]
In addition, the above-described restraining member has a concave portion disposed adjacent to the protrusion, and the first electric conductor and the third electric conductor are accommodated in the concave portion so that these electric conductors can be restricted. desirable. Thus, the electric conductor can be more reliably restrained.
[0012]
In addition, it is preferable that the above-mentioned concave portion has a side surface on which the first electric conductor and the third electric conductor are arranged, the side being wider. Since the electric conductors are accommodated along the inclined side surfaces, each electric conductor can be guided to a predetermined position when the restraining member is attached, and each electric conductor can be guided without a radial and axial displacement. The electrical conductor can be accommodated in a predetermined position of the recess.
[0013]
Further, it is desirable that the bottom surface of the recess has the same width as the conductor width of the first electric conductor and the third electric conductor. Thereby, the displacement of the electric conductor at the time of accommodation can be eliminated, and the positioning accuracy of the joint can be improved.
Further, the method for manufacturing a stator of a rotating electric machine according to the present invention includes a stator core in which a plurality of slots are formed in a circumferential direction, and an electric conductor partially accommodated in each of the slots and the remaining exposed outside the slots. A plurality of stator windings, wherein the electric conductor includes a first electric conductor having an exposed portion extending from the slot in one circumferential direction and a slot in which the exposed portion accommodates the first electric conductor. A second electrical conductor extending from the slot at a different position in the circumferential direction to the other in the circumferential direction and having a distal end joined to the distal end of the first electrical conductor; and a first electrical conductor and a second electrical conductor, respectively. Extends from a slot different from the slot in which it is accommodated in the circumferential direction to the other in the circumferential direction, and at the end face side intersection closer to the end face of the stator core than the joint position between the first and second electric conductors. Conductor and A method for manufacturing a stator of a rotating electric machine having a third electric conductor to be inserted, wherein the first electric conductor and the third electric conductor are constrained in a radial direction by a constraining member, Is joined to the tip of the second electric conductor. Since the first electric conductor and the second electric conductor are joined while the first electric conductor and the third electric conductor are constrained by the constraining member in the radial direction, the tip of the first electric conductor to be joined is formed. The joint can be reliably positioned in the radial direction, and the occurrence of poor joint can be prevented.
[0014]
Further, the first electric conductor, the second electric conductor, and the third electric conductor described above are provided in the slot in a plurality in the radial direction, respectively, and the restraining member extends in the radial direction, and the plurality of the first electric conductors extend in the radial direction. It is desirable that the electric conductor and the plurality of third electric conductors are simultaneously restrained in the radial direction. This makes it possible to simultaneously restrain each of the plurality of first electrical conductors and the plurality of third electrical conductors arranged in the radial direction, thereby simplifying the process of restraining the electrical conductors.
[0015]
Further, it is preferable that the above-described restraining member restrains the first and third electric conductors at a position closer to the end face of the stator core than the joint position between the first and second electric conductors. Since the joint is restricted at a position closer to the end face of the stator core than the joint position between the first electric conductor and the second electric conductor, the coil end height required for the joint at the tip end is unnecessary, and the coil is not required. The end height can be reduced.
[0016]
Further, it is desirable that the above-described restraining member restrains the first and third electric conductors at the end surface side intersection. Thus, the first and third electrical conductors can be simultaneously restrained, and the process of restraining the electrical conductors can be further simplified.
[0017]
In addition, the above-described restraining member has a skewer shape in which a recess is partially formed, and the recess is located at a position slightly apart in the axial direction from the radially restrained position between the first electric conductor and the third electric conductor. An insertion step of inserting the restraining member in the radial direction so as to move the restraining member in the axial direction, a restraining step of restraining the first electric conductor and the third electric conductor in the concave portion by moving the restraining member, and a first electric conductor. The method may include a joining step of joining the second electric conductor, a constraint release step of moving the constraint member in the axial direction to release the constraint in the radial direction, and a removing step of moving the constraint member in the radial direction to take out the constraint member. desirable. As described above, the electric conductors are constrained by inserting the restricting members in the radial direction before the joining, and the restriction by the restricting members is disclosed after the joining, so that the joints of the electric conductors can be easily and reliably positioned. This makes it possible to prevent the occurrence of defective bonding.
[0018]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a method for manufacturing a stator of a rotating electric machine according to an embodiment of the present invention will be described in detail with reference to the drawings.
(1st Embodiment)
FIG. 1 is a cross-sectional view illustrating the overall configuration of a vehicle alternator as a rotating electric machine according to the first embodiment. As shown in FIG. 1, an automotive alternator 1 according to the present embodiment includes a stator 2, a rotor 3, a housing 4, a rectifier 5, and the like.
[0019]
The rotor 3 acts as a magnetic field and rotates integrally with the shaft 6. The rotor 3 has a Landel type pole core 7, a field coil 8, slip rings 9 and 10, a mixed flow fan 11 as a blower, and a centrifugal fan. 12 are provided. The shaft 6 is connected to a pulley 20 and is rotationally driven by a traveling engine (not shown) mounted on the vehicle.
[0020]
The Landel type pole core 7 is configured by combining a pair of pole cores. The Lundell-type pole core 7 includes a boss 71 assembled to the shaft 6, disk portions 72 extending radially from both ends of the boss 71, and twelve claw-shaped magnetic pole portions 73.
[0021]
The diagonal flow fan 11 on the pulley side has a blade having an acute inclination with respect to the base plate 111 fixed to the end face of the pole core 7 by welding or the like, and a blade at a right angle, and rotates integrally with the rotor 3. I do. The centrifugal fan 12 on the side opposite to the pulley has only blades perpendicular to the base plate 121 fixed to the end face of the pole core 7 by welding or the like.
[0022]
The housing 4 includes a front housing 4a and a rear housing 4b. A suction hole 41 is formed on an axial end face thereof, and a first coil end group 31a and a second coil end group of the stator 2 are provided on both outer peripheral shoulders. A cooling air discharge hole 42 is provided corresponding to each radially outer side of 31b.
[0023]
The rectifier 5 performs a rectification function of converting an AC voltage output from the stator 2 to a DC, and is provided at an 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 sectional view of the stator 2. FIG. 3 is a perspective view showing a schematic shape of a segment 33 mounted on the stator core 32.
[0024]
The stator 2 acts as an armature, and is constituted by a stator core 32 and a plurality of segments 33 as electric conductors arranged in a plurality of slots 35 formed in the stator core 32. 31 and an insulator 34 for electrically insulating the stator core 32 and the stator winding 31 from each other.
[0025]
As shown in FIG. 2, a plurality of slots 35 having openings on the inner diameter side are formed in the stator core 32 so as to accommodate the multi-phase stator winding 31. 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 (in the present embodiment, (8) electrical conductors. The eight electric conductors in one slot 35 are arranged in a line from the first layer to the eighth layer in order from the inside in the radial direction of the stator core 32. These electric conductors are coated with a coating material such as polyamide imide as an insulating coating 37.
[0026]
The stator windings 31 are formed by connecting these electric conductors in a predetermined pattern. In the present embodiment, one end of the electric conductor in the slot 35 is connected by arranging a continuous line on the first coil end group 31a side, and other electric conductors are provided on the second coil end group 31b side. They are connected by joining the ends. Further, in the stator winding 31 of the present embodiment, the relationship between the electric conductors in the first to fourth layers is basically the same as the relationship between the electric conductors in the fifth to eighth layers. Therefore, the electric conductors of the first to fourth layers will be described in detail below.
[0027]
One electric conductor in each slot 35 is paired with one other 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 separated from the other conductors 35 by a predetermined magnetic pole pitch. Paired with electrical conductors of other layers.
[0028]
For example, the electric conductor 331a of the first layer in one slot is paired with the electric conductor 331b of the fourth layer in another slot, which is one magnetic pole pitch away from the stator core 32 in the clockwise direction. . Similarly, the electric conductor 332a of the second layer in one slot is paired with the electric conductor 332b of the third layer in the other slot which is separated by one pole pitch in the clockwise direction of the stator core 32. . These pairs of electric conductors are connected by using a continuous wire at one end of the stator core 32 in the axial direction, and passing through the turn parts 331c and 332c. Therefore, at one end of the stator core 32, a continuous line connecting the third-layer electric conductor and the second-layer electric conductor is connected to the fourth-layer electric conductor and the first-layer electric conductor. The connecting continuous line will be surrounded. Thus, at one end of the stator core 32, the connection of the pair of electric conductors is surrounded by the connection of the other pair of electric conductors housed in the same slot. The middle layer coil end is formed by connecting the third layer electric conductor and the second layer electric conductor, and the end layer coil end is formed by connecting the fourth layer electric conductor and the first layer electric conductor.
[0029]
On the other hand, the electric conductor 332a of the second layer in one slot 35 is also paired with the electric conductor 331a 'of the first layer in the other slot 35 separated by one pole pitch in the clockwise direction of the stator core 32. No. Similarly, the electric conductor 331b ′ of the fourth layer in one slot 35 is paired with the electric conductor 332b of the third layer in the other slot 35 that is separated by one pole pitch in the clockwise direction of the stator core 32. I am doing. These electric conductors are connected by joining at the other axial end of the stator core 32.
[0030]
Therefore, at the other end of the stator core 32, a joint for connecting the electric conductor of the fourth layer and the electric conductor of the third layer, and the electric conductor of the first layer and the electric conductor of the second layer are connected. The joints to be connected are arranged in the radial direction. An adjacent layer coil end is formed by the connection between the electric conductor of the fourth layer and the electric conductor of the third layer, and the connection between the electric conductor of the first layer and the electric conductor of the second layer.
[0031]
Further, the plurality of electric conductors are provided by U-shaped segments formed by shaping electric conductors having a substantially rectangular cross section (flat cross section) and having a constant thickness into a predetermined shape. As shown in FIG. 3, the first layer electrical conductor and the fourth layer electrical conductor are provided by a large segment 331 formed by forming a series of electrical conductors into a substantially U-shape. Also, the second layer electric conductor and the third layer electric conductor are provided by small segments 332 formed by forming a series of electric conductors into a substantially U-shape.
[0032]
The large segment 331 and the small segment 332 form the 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 (a total of four turns including the electric conductors of the fifth to eighth layers). Is done.
[0033]
FIG. 4 is a partial side view of the stator winding 31 as viewed from the outside in the radial direction. FIG. 5 is a diagram of the stator winding 31 viewed from the tip end side of the segment 33, and is a diagram in which only a part of the segments 33 arranged in the radial direction are extracted and developed in the circumferential direction. As shown in FIGS. 4 and 5, the segment 33 of the present embodiment crosses adjacent electric conductors at an angle larger than 0 °, and makes the side surfaces of the tip portions contact each other at this crossing portion. Welding or the like is performed in this state to form a joint. Specifically, as shown in FIG. 5, the tip 331 d of the first-layer electric conductor 331 a and the tip 332 d of the second-layer electric conductor 332 a protruding from the stator core 32 pass through each other's side surfaces. They are in contact, and welding or the like is performed on this contact portion. Further, the tip 332e of the third-layer electric conductor 332b and the tip 331e of the fourth-layer electric conductor 331b are in contact with each other via side surfaces, and welding is performed on this contact portion. The same applies to each electric conductor in the fifth and sixth layers and each electric conductor in the seventh and eighth layers.
[0034]
Next, a 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 axial side surface of the stator core 32. Inserted from. At that time, large segment
One electrical conductor 331a of the small segment 331 is on the first layer of one slot 35 of the stator core 32, one electrical conductor 332a of the small segment 332 is on the second layer of the one slot 35, and The other electric conductor 331b is provided on the fourth layer of the other slot 35 one clock pitch away from one slot 35 of the stator core 32 in the clockwise direction, and the other electric conductor 332b of the small segment 332 is also provided on the fourth layer of the other slot 35. Inserted in three layers.
[0035]
As a result, as shown in FIG. 2, the above-described electric conductors 331a, 332a, 332b ', and 331b' are arranged in a line in one slot 35 from the first layer side. Here, the electric conductors 332b 'and 331b' are large and small segment electric conductors which are paired with the electric conductors in the other slots 35 shifted by one magnetic pole pitch.
[0036]
The same applies to the electric conductors of the fifth to eighth layers, and the electric conductors of the fifth to eighth layers are simultaneously formed with the electric conductors of the first to fourth layers or after the insertion of these electric conductors is completed. The insertion of the electrical conductor takes place.
(Bending step) After the insertion, in the second coil end group 31b, the electric conductors 331a and 331b of the first and fourth layers are bent by twisting the joining portions 331d and 331e at the ends in the direction in which the large segment 331 opens. Can be The electric conductors 332a and 332b of the second and third layers are bent by twisting the leading ends 332d and 332e in the direction in which the small segment 332 closes. As a result, in the second coil end group 31b, the electric conductors adjacent in the radial direction are inclined in the circumferential opposite direction. The above configuration is repeated for the segments 33 of all the slots 35 and for the segments 33 composed of the electric conductors of the fifth to eighth layers. Thus, a pair of joints formed by the joints 331d and 332d and a pair of joints formed by the joints 331e and 332e are arranged concentrically in four rows along the radial direction.
[0037]
(Joining Step) Then, in the second coil end group 31b, the joints of the first and second layers of the electric conductors, the joints of the third and fourth layers of the electric conductors, and the fifth and sixth layers of the electric conductors. The joints of the conductors and the joints of the electric conductors of the seventh and eighth layers are joined so as to obtain electrical continuity by means of welding, ultrasonic welding, arc welding, brazing, or the like, and the stator 2 is formed. can get.
[0038]
Next, details of the joining step will be described. FIG. 6 is a diagram showing the appearance and configuration of the winding joining apparatus of the present embodiment used in the joining step.
6 includes a torch 102 including a welding electrode as a welding tool, a robot arm 104 for moving the torch 102, a welding power supply 106 for supplying power to the torch 102, and an inactive state for the torch 102. A gas supply device 108 for supplying gas, a fixed base 110 for fixing the stator 2 provided with the segments 33 to be joined, a constraining device 112 for constraining the segments 33 of the stator 2, and a rotation of the fixed base 110 And a control device 116 for controlling the robot arm 104, the rotation drive device 114, the welding power source 106 and the gas supply device 108.
[0039]
The torch 102 is formed of tungsten, and is provided at the tip of the robot arm 104. The torch 102 is connected to a negative terminal of the welding power source 106 and includes a welding electrode as a welding tool. Further, an inert gas such as argon or helium is supplied to the torch 102 from a gas supply device 108 in order to stabilize the arc during welding and prevent oxidation of the welded portion. In addition, such a configuration in which welding is performed while supplying an inert gas such as argon using tungsten for one electrode is generally known as TIG (Tungsten Inert Gas arc welding).
[0040]
The robot arm 104 receives the control signal from the control device 116, and moves the tip provided with the torch 102 in the direction in which the joints are arranged along the joint at the segment tip to be welded.
FIG. 7 is a plan view showing various restraining members used in the restraining device 112 shown in FIG. FIG. 8 is a side view showing details of a skewer-shaped restraining member in the restraining member shown in FIG. FIG. 9 is a view of the skewer restraint member shown in FIG. FIG. 10 is a view of the skewer-shaped restraining member shown in FIG. FIG. 11 is a perspective view showing a state in which a skewer-shaped restraining member is attached to the segment 33 to restrain each electric conductor.
[0041]
The restraining device 112 includes an annular inner circumferential restraining member 112a and an outer circumferential restraining member 112b, and a skewer restraint disposed at an end face side crossing portion closer to an end face of the stator core 32 than a joint position between the electric conductors. And a member 112c. Although only one skewer restraint member 112c is shown in FIGS. 7 and 8, actually, the skewer restraint member 112c having the same shape is provided between the joints adjacent in the circumferential direction. It has the same number as the number.
[0042]
The inner peripheral side restricting member 112a is arranged on the inner peripheral side of the innermost peripheral (first layer) electric conductor, and restricts the movement of this electric conductor toward the inner peripheral side. The outer peripheral side restraining member 112b is arranged on the outer peripheral side of the innermost peripheral (eighth layer) electric conductor, and restricts the movement of the electric conductor on the outer peripheral side.
[0043]
As shown in FIG. 8, the skewer-shaped restraining member 112c has a triangular cross section, and one side of the upper surface of an electric conductor extending obliquely from the slot 35 to one side in the circumferential direction (the end surface of the stator core 32 and The other side has an angle along the upper surface of another electric conductor extending from the other slot 35 to the other side in the circumferential direction.
[0044]
For example, in FIG. 7, attention is paid to the first-layer electric conductor 331a, the second-layer electric conductor 332a, and the third-layer electric conductor 332b. The exposed portion of the first-layer electric conductor 331a (the second electric conductor in the present invention) extends from the slot 35 of the stator core 32 so as to be inclined in one circumferential direction. The second-layer electric conductor 332a (the first electric conductor in the present invention) has a portion exposed from another slot 35 at a position different in the circumferential direction from the slot 35 in which the first-layer electric conductor 331a is accommodated. The tip extends to the other side and is joined to the joining portion 331d at the tip of the first-layer electric conductor 331a. The third-layer electric conductor 332b (third electric conductor in the present invention) is formed around another slot 35 different from any of the slots 35 in which the first-layer and second-layer electric conductors 331a and 332a are accommodated. The first layer and the second layer of the electric conductors 331a and 332a extend at an end surface side intersection C closer to the end face of the stator core 32 than the joining position of the first and second electric conductors 331a and 332a. 332a. Such a relationship is established for each adjacent electric conductor among the electric conductors in the first to eighth layers.
[0045]
The skewer-shaped restraining member 112c described above is arranged at the end face side intersection C where these electric conductors intersect each other.
In the skewer-shaped restraining member 112c, a concave portion 210 is formed at a position where the electric conductor of the segment 33 contacts, and a protrusion 212 is formed between the adjacent concave portions 210. Considering a conductor set composed of two electric conductors whose tips are joined to each other, the concave portion 210 is formed at a position corresponding to each conductor set, and the projections 212 are formed in two sets adjacent to each other in the radial direction. Are formed so as to protrude into a space between the conductor sets.
[0046]
In addition, the concave portion 210 formed in the skewer-shaped restraining member 112c has a tapered inclined side surface 214. The inclined side surface 214 has a function of a guide for accommodating the electric conductor in the concave portion 210 when the skewer-shaped restricting member 112c is attached to restrict the electric conductor of the segment 33. Therefore, as shown in FIG. 11, by attaching the skewer-shaped restraining member 112c from the joint portion side of each segment 33, each electric conductor is accommodated in a predetermined position of the concave portion 210 without causing displacement in the radial and axial directions. Is done.
[0047]
In addition, the recess 210 has the same width as the conductor width of the electric conductor of each segment 33. Accordingly, it is possible to eliminate the displacement of the electric conductor when the electric conductor is accommodated in the concave portion 210, and it is possible to improve the positioning accuracy of the joint.
Note that the above-described inner peripheral side restraining member 112a, outer peripheral side restraining member 112b, and skewer restraining member 112c also serve as one electrode during arc welding.
[0048]
12 and 13 are views showing a configuration and an operation procedure relating to a mounting / releasing mechanism of the skewer-shaped restraining member 112c included in the restraining device 112. FIG. 14 is a view showing a state in which the skewer-shaped restraining member 112c is inserted into the skewer pushing-down member 126.
The attachment / release mechanism 120 shown in FIGS. 12 and 13 is for attaching the skewer-shaped restraining member 112c after setting the stator core 32 accommodating the segment 33 that has been completed up to the bending step. In a state where the skewer-shaped restraining member 112c is attached and each electric conductor is restrained at the end face side intersection C, the joining process is performed by the winding joining device 100 illustrated in FIG. After that, the skewer-shaped restraining member 112c is removed to release the restraint of each electric conductor after the joining process.
[0049]
The attachment / release mechanism 120 includes a cylindrical holding jig 122 and an annular holding jig 124 for holding and fixing the stator core 32 from the inside diameter side and the outside diameter side, and each skewer inserted from the outside in the radial direction. A skewer pushing member 126 which presses the upper surface of the skewer restraining member 112c toward the end face side of the stator core 32 and pushes it toward the end face side intersection C of each segment 33, and a lower surface of each skewer restraining member 112c after the joining process is completed. And a skewer releasing member 128 for pressing the stator core 32 away from the end face to release the attached state of the skewer-shaped restraining member 112c.
[0050]
The operation of restraining and releasing the electric conductor of each segment 33 by the mounting / releasing mechanism 120 having the above-described structure is performed as follows.
(Step of Inserting Skewed Restraint Member) First, the stator core 32 in which the segment 33 that has been bent up to the end is accommodated is set in the mounting / releasing mechanism 120, and the skewered restraint member 112c is inserted from the outside in the radial direction. (FIGS. 12A and 12B). As shown in FIG. 14, the skewer-shaped restraining member 112 c has a tapered tip side so that the skewer-shaped restraining member 112 c can be easily inserted into a gap between the skewer pressing member 126 and the holding jig 122. Has become. Further, in this state, the skewer-shaped restraining member 112c is inserted in the radial direction such that the concave portion 210 is located at a position slightly separated in the axial direction from the end surface side intersection C where the electric conductors of the segments 33 intersect. Therefore, a sufficient gap is also formed between the skewer restraint member 112c and the end face side intersection C where the electric conductor of each segment 33 intersects, which is high for the insertion work of the skewer restraint member 112c. No precision is required.
[0051]
(Restriction Step) Next, the push-down member 126 is lowered to the end face side of the stator core 32 (FIG. 13A). Thus, the skewer-shaped restraining member 112c restrains each electric conductor at the end face side intersection C.
(Joint Step) In this state, arc welding is performed on each joint at the tip of the electric conductor.
[0052]
(Restraining Release Step) Thereafter, the skewer releasing member 128 is lifted to separate the skewer restraining member 112c from each electric conductor and release the restrained state (FIG. 13B). Is extracted radially outward.
As described above, since the electric conductors of the segment 33 are constrained at the end surface side intersection C where the electric conductors intersect with each other, the radial direction, the circumferential direction, and the axis of the joint of the two electric conductor tips to be joined are joined. The positioning in the direction can be reliably performed, and the occurrence of poor bonding can be prevented. In addition, since the electric conductors are constrained and joined at a position closer to the end face of the stator core 32 than the joint, rather than near the joint, the coil end height required for the constraint at the joint at the tip is reduced. This is unnecessary, and the coil end can be reduced.
[0053]
Also, by using a skewer-like restraining member 112c having a simple shape in which the recess 210 is formed at a position in contact with the electric conductor and the projection 212 is formed at a position corresponding to each electric conductor, a simple jig shape is obtained. As a result, it is possible to prevent the occurrence of poor connection by reliably positioning the joints of the electric conductors, and at the same time, it is possible to secure the clearance between the conductor sets and prevent the contact between the adjacent joints. In particular, by accommodating the electric conductor of the segment 33 in the concave portion 210 formed between the adjacent protrusions 212, the electric conductor can be more reliably restrained.
[0054]
Further, since a plurality of electric conductors arranged in the radial direction and two kinds of electric conductors inclined in different directions are simultaneously restrained by using one skewer-like restraining member 112c, each of the electric conductors is separated. The process of restraining the electric conductor can be simplified as compared with the case of restraining the electrical conductor.
[0055]
(Second embodiment)
By the way, in the first embodiment described above, two types of electric conductors having different inclination directions are arranged such that one skewer-shaped restraining member 112c having a triangular cross section is located at the end face side intersection C of these electric conductors. However, it is possible to use a restraining member having a cross section other than a triangular shape, or to restrain two types of electric conductors having different inclination directions by using separate subsequent members, or to use a restraining portion other than the end face side intersection C. You may be restrained.
[0056]
FIG. 15 is a diagram illustrating a constraint member according to the second embodiment in which the cross-sectional shape, the constraint position, and the like are changed.
The restricting member 112d of the present embodiment has a circular cross section as shown in FIG. 15, and a concave portion for restricting an electric conductor extending from the slot 35 to one side in the circumferential direction is provided with a concave portion. It is formed at a position corresponding to the conductor. When the restricting member 112d is viewed from the direction D shown in FIG. 15, a concave portion for accommodating the electric conductor of the segment 33 is formed similarly to the shape of the skewered restricting member 112c shown in FIG. In addition, the restraining member 112d restrains the electric conductor housed in the concave portion at a restricting portion closer to the distal end side of the electric conductor than the end face side intersection C where two types of electric conductors having different inclination directions intersect. .
[0057]
Similarly, the restricting member 112e has a circular cross section, and a concave portion for restricting the electric conductor extending obliquely from the slot 35 to the other in the circumferential direction is formed at a position corresponding to the electric conductor. Have been. The restricting member 112e restricts the electric conductor accommodated in the concave portion at a restricting portion closer to the distal end side of the electric conductor than the end face side intersection C.
[0058]
As described above, in the constrained portions other than the end face side intersection C, the two types of electric conductors having different inclination directions are separately constrained by using the constrained portions 112d and 112e having an arbitrary cross section (a circular shape in FIG. 15). By doing so, the respective electric conductors are constrained in these constrained portions, so that the radially, circumferentially and axially positioning of the joint between the two electric conductor tips to be joined can be reliably performed. It is possible to prevent the occurrence of poor bonding. In addition, since the electric conductors are constrained and joined at a position closer to the end face of the stator core 32 than the joint, rather than near the joint, the coil end height required for the constraint at the joint at the tip is reduced. This is unnecessary, and the coil end can be reduced.
[0059]
Further, in the example shown in FIG. 15, a restricting portion is set on the distal end side of the electric conductor with respect to the end surface side intersection C, and the upper surface of the electric conductor to be restricted (the surface on the opposite side to the end surface of the stator core 32). Although the restricting members 112d and the like are brought into contact, the lower surface of the electric conductor (the surface close to the end face of the stator core 32) is brought into contact with the restricting members 112f and 112h as shown in FIG. The restricting portion may be set at a position closer to the end face of the stator core 32 than the end face side intersection C, such as 112 g. The position of each constraining member may be determined in consideration of various layout constraints, such as the degree of interference with the joint and the degree of interference with electrical conductors other than those to be restricted. Further, it is not always necessary to restrain two types of electric conductors having different inclinations with the restraining member, and only one of them may be restrained.
[0060]
Note that the present invention is not limited to the above embodiment, and various modifications can be made within the scope of the present invention. For example, in the segment 33 of the above-described embodiment, the adjacent electric conductors intersect with each other at an angle larger than 0 °, and welding or the like is performed in a state where the side surfaces of the tip end portions are in contact with each other at the intersection. Although the bonding portion is formed by performing the bonding, as shown in FIG. 16, the present invention can be applied to a case where the tips of the adjacent electric conductors are arranged in parallel to form the bonding portion.
[0061]
When a plurality of electric conductors are arranged in the radial direction, a plurality of restraining members may be arranged in a line in the radial direction to restrain each electric conductor.
The number of radial layers of the electric conductors constituting the stator winding of the rotating electric machine is not limited to eight, but may be four, twelve, or another number.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an overall configuration of a vehicular AC generator as a rotating electric machine according to a first embodiment.
FIG. 2 is a partial 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 side view of a stator winding.
FIG. 5 is a view of a stator winding viewed from a tip end side of a segment.
FIG. 6 is a diagram showing an appearance and a configuration of a winding joining apparatus of the present embodiment used in a joining step.
FIG. 7 is a plan view showing various restraining members used in the restraining device shown in FIG.
FIG. 8 is a side view showing details of a skewer-shaped restraining member in the restraining member shown in FIG. 7;
FIG. 9 is a view of the skewer-shaped restraining member shown in FIG.
FIG. 10 is a view of the skewer-shaped restraining member shown in FIG.
FIG. 11 is a perspective view showing a state in which a skewered restraining member is attached to a segment to restrain each electric conductor.
FIG. 12 is a diagram showing a configuration and an operation procedure relating to a mounting and releasing mechanism of a skewer-shaped restraining member included in the restraining device.
FIG. 13 is a diagram showing a configuration and an operation procedure relating to a mounting and releasing mechanism of a skewer-shaped restraining member included in the restraining device.
FIG. 14 is a view showing a state in which a skewer-shaped restraining member is inserted into a skewer pushing-down member.
FIG. 15 is a view showing a constraint member according to a second embodiment in which a cross-sectional shape, a constraint position, and the like are changed.
FIG. 16 is a partial perspective view showing a structure of a stator to which a conventional joining method is applied.
FIG. 17 is a plan view showing an arrangement of joining portions of the stator winding shown in FIG. 16;
FIG. 18 is a view showing a main part of a conventional bonding apparatus.
[Explanation of symbols]
2 Stator
31 Stator winding
32 Stator core
33 segments
100 Winding joining device
112 restraint
112a Inner circumference restraining member
112b Outer circumference side restraining member
112c Skewer restraint
210 recess
212 protrusion
214 side view

Claims (11)

A stator core having a plurality of slots formed in a circumferential direction,
A stator winding provided with a plurality of electric conductors, a part of which is accommodated in each of the slots and the rest is exposed to the outside of the slots,
The electric conductor includes a first electric conductor having an exposed portion inclined from the slot in one circumferential direction and an exposed portion having a position different from the slot in which the first electric conductor is accommodated in the circumferential direction. A second electric conductor extending from the slot to the other in the circumferential direction and having a distal end joined to the distal end of the first electric conductor; and the first and second electric conductors being accommodated therein. The first electric conductor extends from the slot different from the slot at an end face side intersection closer to the end face of the stator core than the joining position of the first and second electric conductors, while being inclined in the other circumferential direction. A method for manufacturing a stator of a rotating electric machine having a third electric conductor crossing a conductor,
The first electric conductor and the third electric conductor are constrained by a constraining portion closer to the end face of the stator core than the joint position between the first and second electric conductors, and the first electric conductor A method for manufacturing a stator of a rotating electrical machine, wherein a tip of the second electric conductor is joined to a tip of the second electric conductor. In claim 1,
The method for manufacturing a stator of a rotating electric machine, wherein the restraining portion is the end surface side intersection. In claim 2,
A plurality of sets of conductors each including the first electric conductor and the second electric conductor whose ends are joined are provided in the radial direction to form the stator winding, and
A stator for a rotating electric machine, wherein a restraining member provided with a protrusion projecting into a space between the conductor sets arranged in a radial direction restrains the first electric conductor and the third electric conductor. Manufacturing method. In claim 3,
The restraining member has a concave portion disposed adjacent to the protrusion, and the concave portion accommodates the first electric conductor and the third electric conductor to restrict these electric conductors. A method for manufacturing a stator of a rotating electric machine, which is characterized in that: In claim 4,
The method for manufacturing a stator of a rotating electrical machine, wherein the recess has a side surface on which a side on which the first electric conductor and the third electric conductor are arranged is widened. In claim 5,
A method of manufacturing a stator for a rotating electric machine, wherein a bottom surface of the recess has a width equal to a conductor width of the first electric conductor and the third electric conductor. A stator core having a plurality of slots formed in a circumferential direction,
A stator winding provided with a plurality of electric conductors, a part of which is accommodated in each of the slots and the rest is exposed to the outside of the slots,
The electric conductor includes a first electric conductor having an exposed portion inclined from the slot in one circumferential direction and an exposed portion having a position different from the slot in which the first electric conductor is accommodated in the circumferential direction. A second electric conductor extending from the slot to the other in the circumferential direction and having a distal end joined to the distal end of the first electric conductor; and the first and second electric conductors being accommodated therein. The first electric conductor extends from the slot different from the slot at an end face side intersection closer to the end face of the stator core than the joining position of the first and second electric conductors, while being inclined in the other circumferential direction. A method for manufacturing a stator of a rotating electric machine having a third electric conductor crossing a conductor,
The front end of the first electric conductor and the front end of the second electric conductor are joined while the first electric conductor and the third electric conductor are constrained radially by a constraining member. Manufacturing method of a rotating electric machine stator. In claim 7,
The first electric conductor, the second electric conductor, and the third electric conductor are provided in the slot in a plurality in a radial direction, respectively.
The method of manufacturing a stator for a rotating electrical machine, wherein the restraining member extends in a radial direction and restrains a plurality of the first electrical conductors and a plurality of the third electrical conductors simultaneously in a radial direction. In claim 7,
The rotating electric machine, wherein the restraining member restrains the first and third electric conductors at a position closer to an end face of the stator core than a joint position between the first and second electric conductors. Stator manufacturing method. In claim 9,
The method of manufacturing a stator for a rotating electric machine, wherein the restraining member restrains the first and third electric conductors at the end face side intersection. In claim 7,
The restraining member has a skewer shape in which a recess is partially formed, and the recess is located at a position slightly apart in the axial direction from a radial restraint position between the first electrical conductor and the third electrical conductor. An insertion step of inserting the restraining member in the radial direction so as to
A restraining step of moving the restraining member in the axial direction and restraining the first electrical conductor and the third electrical conductor in the recess;
A joining step of joining the first electric conductor and the second electric conductor,
A constraint release step of moving the constraint member in the axial direction to release the constraint in the radial direction,
A removing step of moving the restraining member in a radial direction and removing the restraining member,
A method for manufacturing a stator of a rotating electric machine, comprising:

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