JP2005210761A - Method of manufacturing stator winding of 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 which can prevent a coil end part from being widened in the radial direction. <P>SOLUTION: The method of manufacturing the stator winding of the rotary electric machine includes a first twisting step of twisting a turn part 33c by moving each of straight line parts 33a, 33b relatively mutually along a second direction B different from a first direction A, a second twisting step of twisting the turn part 33c by moving each of the straight line parts relatively to the opposite side of a circumferential direction to match the first direction A to the circumferential direction, and an inserting step of inserting each straight line part in each of two slots formed at different positions along the circumferential direction of a stator core. The second twisting step is performed by widening the radial direction distance of each of the straight line parts included in each of the segments after the first twisting step is finished. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a stator winding of a rotating electrical machine that manufactures a winding of a rotating electrical machine such as an automotive alternator mounted on an automobile or a truck.

2. Description of the Related Art Conventionally, a rotating electrical machine including a stator winding formed by sequentially joining a number of segment conductors inserted into slots of a stator core is known (see, for example, Patent Document 1). In this rotating electrical machine, each U-shaped segment constituting the stator winding was set on a twisting jig with each linear portion arranged in the radial direction before being inserted into the stator core. Thereafter, the straight portions are twisted in opposite directions in the circumferential direction. After each segment twisted in this way is inserted into the slot of the stator core, the end portion on the side opposite to the turn portion protruding from the end surface of the starter core is shaped in the circumferential direction and then joined to a predetermined winding specification. A stator winding having is completed. As a method for manufacturing a U-shaped segment before being inserted into the twisting jig described above, a technique is known in which a single wire is cut into a predetermined length and then bent into a U-shape (for example, Patent Document 2). reference.). In this method, when the wire is bent into a U-shape, an excessive bending prevention member is interposed in the bent portion to prevent excessive bending in the bent portion and damage to the insulating film formed around the wire. It is preventing.
Japanese Patent No. 3118837 (page 4-7, FIG. 1-15) JP 2001-45721 A (page 3-8, FIG. 1-12)

  By the way, when manufacturing a U-shaped segment using the method disclosed in Patent Document 2 described above, since the width in the vicinity of the turn portion of the segment is increased by an amount corresponding to the excessive bending prevention member, When the number of segments inserted into one slot increases, there is a problem that the coil end portion of the stator winding constituted by the turn portion spreads in the radial direction. For example, when considering a case where a stator winding is formed by arranging four sets of U-shaped large and small segments in the radial direction, each U-shaped segment has a turn portion rather than a radial dimension of the straight portion. When the space factor of the straight portion inserted into the slot is increased (when the straight portions are arranged in the radial direction so that there is almost no gap in the slot), the turn portion becomes larger. Projecting radially outward (or inward), it is difficult to reduce the size of the rotating electrical machine if it does not interfere with the frame (or the rotor disposed on the inner peripheral side) disposed on the outer peripheral side thereof. Moreover, when the respective turn portions are inclined toward the outer diameter side, it is necessary to add a process for the inclination, which is not preferable because the process becomes complicated. Further, it is conceivable to reduce the amount of protrusion in the radial direction by shifting the turn parts of the four sets of U-shaped segments in the axial direction. In this case, however, it is difficult to reduce the axial size. Since the segment length changes for each group and the resistance value varies, it is difficult to employ the segment. In addition, each segment is formed with a U-shaped turn part by bending the electric conductor with a small radius of curvature, and the turn part is then twisted and deformed, so the periphery of the turn part is bent or twisted. Easy to work harden. Each segment inserted in the slot has the minimum radial dimension (width) of the coil end when there is no gap between adjacent electrical conductors. However, when work hardening occurs, the shape after the twisting process is the target shape. And a gap is generated between adjacent electrical conductors, and the coil end portion is expanded in the radial direction.

  The present invention has been created in view of the above points, and an object of the present invention is to provide a method of manufacturing a stator winding of a rotating electrical machine that can prevent the radial expansion of a coil end portion. It is in.

  In order to solve the above-described problem, a method for manufacturing a stator winding of a rotating electrical machine according to the present invention is a method of manufacturing a U-shaped segment having two straight portions whose positions along a radial direction are shifted. Twist process by twisting each by moving to the opposite side in the circumferential direction, Inserting process to insert each straight part of segment twisted by twisting process into slot formed in stator core, Inserting into slot A bending step of bending the anti-turn portion side of the formed segment in the circumferential direction, and a joining step of joining the ends of adjacent segments bent by the folding step, arranged in the circumferential direction before the twisting step A preliminary process for shifting the radial position and the circumferential position of each linear part by moving each linear part of the segment formed relative to each other in the radial direction, the preliminary process comprising: Expanding the mutual radial distance of the straight portion included in the respective segments after completion implementing twisting process. As described above, the U-shaped segment used in the twisting process is projected along the circumferential direction because the radial position and the circumferential position of the two linear portions are shifted in the preliminary process performed before that. In addition, even when the positions of these two straight portions are approximated along the radial direction, there is no need to bend the segment with an extremely small radius in the turn portion, and a stator formed using such a segment. The radial expansion of the coil end portion of the winding can be prevented. In addition, since each segment is subjected to a twisting process after the preparatory process is completed, the straight portions are spread out to the opposite sides in the radial direction, so that the radial extent of each straight portion can be minimized.

  In addition, the first radial distance of each linear portion included in the segment after the preliminary process described above is shorter than the second radial distance when the twisting process is performed, and is accompanied by elastic deformation of the segment. It is desirable that the twisting process is performed by expanding each straight line portion. The straight portions of the segments arranged on the outer diameter side of the slot and the straight portions of the segments arranged on the inner diameter side attract each other by elastic force by elastically deforming and spreading each straight portion during the twisting process. The spread along the radial direction of the coil end portion can be minimized.

  In addition, the first radial distance of each straight line portion included in the segment after the preliminary process described above is shorter than the second radial distance when the twisting process is performed, and is accompanied by plastic deformation of the segment. It is desirable that the twisting process is performed by expanding each straight line portion. As a result, it is possible to reduce the amount of deformation in the preliminary process and reduce the degree of work hardening, thereby improving workability and preventing unnecessary spread along the radial direction of the coil end portion.

  In addition, the first radial distance of each linear portion included in the segment after the preliminary process is completed is shorter than the second radial distance when the twisting process is performed, and the elastic deformation and plasticity of the segment It is desirable that the twisting process is performed by expanding each straight line portion with deformation. The straight portions of the segments arranged on the outer diameter side of the slot and the straight portions of the segments arranged on the inner diameter side attract each other by elastic force by elastically deforming and spreading each straight portion during the twisting process. The spread along the radial direction of the coil end portion can be minimized.

  In addition, the radial distance of each linear portion of the segment after the above-described twisting process is reduced along with the restoration of the elastic deformation, and each linear part included in each segment after the twisting process is completed It is desirable to carry out the insertion process by increasing the radial distance. Thereby, it becomes possible to reduce reliably the radial expansion of the coil end part after being mounted on the stator core by elastic deformation.

  Moreover, the U-shaped segment mentioned above is manufactured by the bending shaping process which bends and shapes a linear wire material in a U shape, and a preliminary process may be performed for each of the segments manufactured by the bending shaping process. desirable. Thereby, since a preliminary | backup process can be implemented according to a bending shaping process, the delay time by adding a process can be suppressed to the minimum.

  Further, it is desirable that the amount of shifting each linear portion of the segment along the circumferential direction in the preliminary step described above is equal to or less than the adjacent pitch of the slots formed along the circumferential direction of the stator core. Thereby, the interference between the adjacent segments at the time of implementing a twist process can be prevented.

  Hereinafter, a method of manufacturing a stator winding of a rotating electrical machine according to an embodiment to which the present invention is applied will be described in detail with reference to the drawings.

  FIG. 1 is a cross-sectional view showing the overall configuration of a vehicular AC generator as a rotating electrical machine according to an embodiment. As shown in FIG. 1, the vehicle alternator 1 of this embodiment includes 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 includes a Landel pole core 7, a field coil 8, slip rings 9 and 10, a mixed flow fan 11, and a centrifugal fan 12. Yes. The shaft 6 is connected to a pulley 20 and is rotationally driven by a traveling engine (not shown) mounted on the vehicle.

  The housing 4 is composed of a front housing 4a and a rear housing 4b. A suction hole 41 is formed on the end surface in the axial direction, and a first coil end group 31a and a second coil end group of the stator 2 are formed on both outer peripheral shoulders. Cooling air discharge holes 42 are provided corresponding to the respective radial outer sides of 31b.

  The rectifier 5 performs a rectifying action for converting the alternating voltage output from the stator 2 into a direct current, and is provided at the end of the vehicle alternator 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, and shows an arrangement state of the segment conductors 33 in the slots 35 of the stator core 32. FIG. 3 is a perspective view showing a schematic shape of the segment conductor 33 attached to the stator 2.

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

  As shown in FIG. 2, the stator core 32 is formed with a plurality of slots 35 having openings on the inner diameter side. In the present embodiment, 96 slots 35 are arranged at equal intervals in order to accommodate the three-phase stator windings 31 corresponding to the number of magnetic poles of the rotor 3.

  The stator winding 31 provided in the slot 35 of the stator core 32 can be grasped as one electric conductor, and each of the plurality of slots 35 has an even number (four in this embodiment). ) Electrical conductors are accommodated. Further, the four electrical conductors in one slot 35 are arranged in a row in the order of the inner end layer, the inner middle layer, the outer middle layer, and the outer end layer from the inside in the radial direction of the stator core 32. These electric conductors are coated with a coating material such as polyamideimide as the insulating coating 37.

  The stator windings 31 are formed by connecting these electric conductors in a predetermined pattern. In the present embodiment, one end of the electrical conductor in the slot 35 is connected by arranging a continuous line on the first coil end group 31a side, and on the second coil end group 31b side, the electrical conductor in the slot 35 is joined. Is connected to the other end.

  One electrical conductor in each slot 35 is paired with one other electrical conductor in another slot 35 that is 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 other slots 35 apart from a predetermined magnetic pole pitch. Pairs with other layers of electrical conductors.

  For example, the electric conductor 331a in the inner end layer in one slot is paired with the electric conductor 331b in the outer end layer in another slot which is one magnetic pole pitch away in the clockwise direction of the stator core 32. . Similarly, the inner and middle layer electric conductors 332a in one slot are paired with the outer and middle layer electric conductors 332b in another slot spaced by one magnetic pole pitch in the clockwise direction of the stator core 32. The paired electrical conductors are connected via the turn portions 331c and 332c by using a continuous line 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 outer middle layer electric conductor and the inner middle layer electric conductor is connected to the outer end layer electric conductor and the inner end layer electric conductor. A continuous line will enclose. As described above, at one end of the stator core 32, the connecting portion of the pair of electric conductors is surrounded by the connecting portion of the other pair of electric conductors accommodated in the same slot. An intermediate layer coil end is formed by connecting the outer middle layer electric conductor and the inner middle layer electric conductor, and an end layer coil end is formed by connecting the outer end layer electric conductor and the inner end layer electric conductor.

  On the other hand, the inner middle layer electric conductor 332a in one slot 35 is also paired with the inner end layer electric conductor 331a 'in the other slot 35 which is one magnetic pole pitch away in the clockwise direction of the stator core 32. ing. Similarly, the outer end layer electric conductor 331b ′ in one slot 35 is paired with the outer middle layer electric conductor 332b in the other slot 35 which is separated by one magnetic pole pitch in the clockwise direction of the stator core 32. There is no. These electric conductors are connected by joining at the other end in the axial direction of the stator core 32.

  Therefore, at the other end portion of the stator core 32, a joint portion that connects the electric conductor of the outer end layer and the electric conductor of the outer middle layer, and the electric conductor of the inner end layer and the electric conductor of the inner middle layer are connected. The joint portion is aligned in the radial direction. The adjacent layer coil ends are formed by the connection between the outer end layer electrical conductor and the outer middle layer electrical conductor, and the inner end layer electrical conductor and the inner middle layer electrical conductor. In this way, at the other end of the stator core 32, the connecting portions of the paired electrical conductors are arranged side by side without overlapping.

  Further, the plurality of electric conductors are provided by U-shaped segment conductors formed by shaping an electric conductor having a substantially rectangular cross section (flat cross section) into a predetermined shape. As shown in FIG. 3, the electric conductors of the inner end layer and the outer end layer 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 forming a series of electric conductors in a substantially U shape. FIG. 4 is a diagram illustrating a state in which a segment set including the large segment 331 and the small segment 332 is inserted into the slot 35 of the stator core 32.

  Each of the large segment 331 and the small segment 332 forms a basic segment conductor 33. The segment conductors 33 are regularly arranged in the slots 35 to form a coil that makes two rounds around the stator core 32.

  Next, a manufacturing process of the stator winding 31 will be described.

(Bending and shaping process)
First, a U-shaped segment 33 before shaping is manufactured by cutting a continuous wire having a flat rectangular shape (rectangular shape) into a predetermined length and then bending it in the vicinity of the center. FIG. 5 is a front view of the U-shaped segment 33 manufactured by the bending and shaping process. FIG. 6 is a side view of the segment 33 shown in FIG. 5 and shows a state seen from the turn part side. FIG. 7 is a perspective view of the segment 33 shown in FIG. As shown in these drawings, the segment 33 shaped in a U shape has two straight portions 33a and 33b with a turn portion 33c interposed therebetween. 5 to 7 show a small segment 332 having two straight portions 332a and 332b arranged with the turn portion 332c interposed therebetween as a specific example of the segment 33. The diameter of the part 331c only becomes large and has basically the same shape.

(First twisting process)
Next, a first twisting process of twisting the turn portion 33c is performed on each of the segments 33 that have been shaped into a U shape by the bending shaping process. Assuming that the direction in which the two straight portions 33a and 33b are arranged as a first direction, in the first twisting step, each of the two straight portions 33a and 33b is along a second direction different from the first direction. The segments 33 in the vicinity of the turn portion 33c are twisted by moving the relative portions to each other.

  FIG. 8 and FIG. 9 are diagrams showing details of the first twisting process, and the state before and after the twist shaping using the twisting jig is shown for the small segment 332. As shown in FIGS. 8 and 9, the first twisting process is performed by a twisting jig in which the fixed clamper 200 and the movable clamper 210 are combined. The fixed clamper 200 includes a storage unit 202, a moving unit 204, and an adjusting unit 206. The storage unit 202 has a concave portion that stores one straight portion 332a of the small segment 332 in part. Two adjacent side surfaces of the linear portion 332a abut against the recess. The moving unit 204 rotatably accommodates a cylindrical adjustment unit 206 having a flat portion on a part of the side surface. By pressing the flat portion against the side surface of the linear portion 332a, the storage unit 202 and the moving unit 204 are moved. The one linear portion 332a is restrained by the above. By providing the rotatable adjusting portion 206, it is possible to adjust the flat portion formed in the adjusting portion 206 so as to be parallel to the side surface of the straight portion 332a, and to reliably restrain the straight portion 332a. be able to.

  The movable clamper 210 includes a storage unit 212, a moving unit 214, and an adjusting unit 216. The storage portion 212 has a recess for storing the other straight portion 332b of the small segment 332 in part. Two adjacent side surfaces of the linear portion 332b abut against the recess. The moving part 214 rotatably accommodates a cylindrical adjustment part 216 having a flat part on a part of the side surface, and presses the flat part against the side face of the linear part 332b, thereby allowing the storage part 212 and the moving part 214 to move. The other straight portion 332b is constrained by this. By providing the rotatable adjusting portion 216, it is possible to adjust the flat portion formed in the adjusting portion 216 so as to be parallel to the side surface of the straight portion 332b, and the straight portion 332b is reliably restrained. be able to.

  The movable clamper 210 is configured to be movable as a whole by a drive mechanism (not shown). As shown in FIG. 9, when the direction in which the two straight portions 332a and 332b of the small segment 332 before twist shaping are arranged as a first direction A as shown in FIG. 8, this first direction as shown in FIG. The movable clamper 210 moves along a second direction B substantially perpendicular to A. As a result, each of the two linear portions 332a and 332b constrained by the fixed clamper 200 and the movable clamper 210 moves relatively perpendicular to the first direction A, and the turn portion 332c is twisted. In the present embodiment, the two straight portions 332a and 332b are arranged along the first direction A at positions separated from each other by the adjacent pitch of the slot 35 in the first twisting process. Further, the amount by which the straight portions 332a and 332b of the small segment 332 are displaced along the radial direction in the first twisting step is set to a value smaller than the width along the radial direction of the small segment 332.

  Similarly, FIG. 10 and FIG. 11 are diagrams showing details of the first twisting process, and the state before and after the twist shaping using the twisting jig is shown for the large segment 331. As shown in FIGS. 8 and 9, the first twisting process is performed by a twisting jig in which the fixed clamper 200 and the movable clamper 210 are combined. The fixed clamper 200 includes a storage unit 202, a moving unit 204, and an adjusting unit 206. The storage unit 202 has a concave part that stores one straight portion 331a of the large segment 331 in part. Two adjacent side surfaces of the linear portion 331a abut against the recess. The moving unit 204 rotatably accommodates a cylindrical adjustment unit 206 having a flat part on a part of the side surface. By pressing the flat part against the side surface of the linear part 331a, the storing unit 202 and the moving part 204 are stored. The one linear portion 331a is constrained by. By providing the rotatable adjustment portion 206, it is possible to adjust the flat portion formed in the adjustment portion 206 so as to be parallel to the side surface of the straight portion 331a, and to reliably restrain the straight portion 331a. be able to.

  The movable clamper 210 includes a storage unit 212, a moving unit 214, and an adjusting unit 216. The storage portion 212 has a recess for storing the other straight portion 331b of the large segment 331 in part. Two adjacent side surfaces of the linear portion 331b abut against the recess. The moving part 214 rotatably accommodates a cylindrical adjustment part 216 having a flat part on a part of the side surface. By pressing the flat part against the side surface of the linear part 331b, the storage part 212 and the moving part 214 are moved. The other straight portion 331b is restrained by the above. By providing the rotatable adjusting portion 216, it is possible to adjust the flat portion formed in the adjusting portion 216 so as to be parallel to the side surface of the straight portion 331b, and the straight portion 331b is reliably restrained. be able to.

  The movable clamper 210 is configured to be movable as a whole by a drive mechanism (not shown). As shown in FIG. 9, when the direction in which the two straight portions 331a and 331b of the large segment 331 before twist shaping are arranged as a first direction A as shown in FIG. 10, the first direction as shown in FIG. The movable clamper 210 moves along a second direction B substantially perpendicular to A. As a result, each of the two linear portions 331a and 331b constrained by the fixed clamper 200 and the movable clamper 210 moves relatively perpendicular to the first direction A, and the turn portion 331c is twisted. In the present embodiment, the two straight portions 331a and 331b are arranged along the first direction A at positions separated from each other by the adjacent pitch of the slot 35 in the first twisting process. In addition, when the linear segments 331a and 331b of the large segment 331 are displaced along the radial direction in the first twisting step, the widths of the small segment 332 and the large segment 331 along the radial direction are equal. It is set to a value smaller than three times the width along the radial direction of 331.

  FIG. 12 is a perspective view showing the small segment 332 after the twist shaping is performed by the first twisting process. In the small segment 332 shown in FIG. 12, one straight portion 332b moves in a direction different from the first direction A with respect to the small segment 332 before twist shaping shown in FIG. 7, and the turn portion 332c is twisted. I understand that.

(Second twisting process)
Next, a second twisting step of twisting the turn portion 33c by moving the straight portions 33a and 33c of the segment 33 relative to the opposite side in the circumferential direction with the first direction A described above aligned with the circumferential direction. Is done.

  FIG. 13 is a cross-sectional view of a twisting jig used in the second twisting step. FIG. 14 is a perspective view showing a main part of the twisting jig shown in FIG. As shown in FIG. 13, the twisting jig 300 includes an inner twisted portion 311 and an outer twisted portion 312, rotational drive mechanisms 313 and 314 that rotationally drive the inner twisted portion 311 and the outer twisted portion 312, respectively, a controller 315, A segment presser 316, a segment push-up jig 317, a lift drive mechanism 318, and the like are provided.

  The inner twisted portion 311 is provided with segment insertion holes 321 and 322 adjacent to each other in the radial direction in which the slot conductor portions 331a and 332a (linear portions 33a) of the large segment 331 and the small segment 332 are inserted and held. Yes. The segment insertion holes 321 and 322 are formed side by side in the circumferential direction at equal intervals corresponding to the number of slots 35 of the stator core 32. That is, in this embodiment, a large number of segment insertion holes 321 and 322 arranged in the circumferential direction at equal intervals are formed on concentric circles. The same applies to the outer twisted portion 312, and a large number of segment insertion holes 323 and 324 arranged in the circumferential direction at equal intervals are formed concentrically. As a result, four segment insertion holes 321, 322, 323, and 324 are formed side by side in the inner twisted portion 311 and the outer twisted portion 312.

  As shown in FIG. 14, the slot conductor portions 331b and 332b as one straight portion 33b of one set of the large segment 331 and the small segment 332 are inserted into the segment insertion holes 324 and 323 of the outer twisted portion 312, and the other The slot conductor portions 331a and 332a as the straight portions 33a are inserted into the segment insertion holes 321 and 322 which are shifted by one slot pitch of the inner twisted portion 311.

  By the way, as described with reference to FIG. 9, the small segment 332 before the second twisting step is performed has two linear portions 332 a along the direction (radial direction) perpendicular to the circumferential direction (direction A). The amount of shifting 332b is set to a value smaller than the width of the straight line portion 332a or the like. In such a setting state, the straight portion 332a of one small segment 332 accommodated in one slot 35 and the straight portion 332b of another small segment 332 interfere with each other. In the present embodiment, when each small segment 332 is inserted into the two slots 35, the two straight portions 332 a and 332 b are expanded in the radial direction to elastically deform the vicinity of the turn portion 332 c. The straight portion 332a of the one small segment 332 and the straight portion 332b of the other small segment 332 ensure a shift amount substantially corresponding to the width of the straight portion 332a and the like to avoid the above-described interference.

  Similarly, as described with reference to FIG. 11, the two straight portions 331 a and 331 b are displaced along the direction (radial direction) perpendicular to the circumferential direction of the large segment 331 before the second twisting process is performed. The amount is set to a value smaller than three times the width of the straight line portion 331a and the like. In such a setting state, the straight portion 331a of the small segment 332 sandwiched between the straight portion 331a of one large segment 331 and the straight portion 331b of the other large segment 331 accommodated in one slot 35, It interferes with 332b. In the present embodiment, when each large segment 331 is inserted into the two slots 35, the two straight portions 331a and 331b are radially expanded from each other and elastically deformed in the vicinity of the turn portion 331c. The straight portion 331a of the one large segment 331 and the straight portion 331b of the other large segment 331 have a shift amount corresponding to approximately three times the width of the straight portion 331a and the like to avoid the interference described above. is doing.

  After the large segment 331 and the small segment 332 are inserted into all the segment insertion holes 321, 322, 323, and 324, the annular segment pressing portion 316 is lowered from above the inner twisted portion 311 and the outer twisted portion 312 to increase the size. It contacts the turn part 331c of the segment 331. Thereby, it is possible to prevent the large segment 331 and the small segment 332 from floating from the segment insertion holes 321, 322, 323, and 324 in the twisting process.

  Each of the inner twisted portion 311 and the outer twisted portion 312 is rotationally driven by rotational drive mechanisms 313 and 314 controlled by the controller 315. In the present embodiment, as viewed from above the twisting jig 300, the inner twisted portion 311 is rotated counterclockwise and the outer twisted portion 312 is rotated by a predetermined amount, respectively, but the second twisting step is performed. In the previous state, the straight portions 33a and 33b of each segment 33 are already arranged with a one-slot pitch shift in the circumferential direction, so the outer twisted portion 312 and the inner twisted portion are taken into account in consideration of this one-slot pitch shift. A rotational drive amount 311 is set.

  The first twisting process described above corresponds to the “preliminary process” in claim 1, and the second twisting process corresponds to the “twisting process” in claim 1.

(Insertion process)
Next, each segment 33 after being twisted by the second twisting process is inserted into each slot 35 of the stator core 32 from one end face side along the axial direction. At this time, as shown in FIG. 4, the insertion is performed with the small segment 332 aligned so that the large segment 331 surrounds.

  In addition, when taking out each segment 33 after the twist shaping is performed by the second twisting process, the two straight portions 332a and 332b of the small segment 332 and the two straight portions 331a and 331b of the large segment 331 are: In order to return to the original state from the elastically deformed state, they are again deformed so as to approach each other along the radial direction. Therefore, when the insertion step is performed, the two straight portions 331a and 332a serving as the electrical conductors of the inner end layer and the inner and middle layers and the two straight portions 331b and 332b serving as the electrical conductors of the outer end layer and the outer and middle layers again have a diameter. It is necessary to push away in the direction along the direction and elastically deform the vicinity of the turn portions 331c and 332c and insert it into the slot 35.

(Bending process)
After inserting each segment 33, straight portions 33 a and 33 b that are opposite to the turn portion 33 c and project from the end face of the stator core 32 are bent in the circumferential direction according to the winding specifications of the stator winding 31.

(Joining process)
The ends of the straight portions 33a and 33b of the adjacent segments 33 bent by the bending step are joined so as to obtain electrical conduction by means such as welding, ultrasonic welding, arc welding, brazing, etc. A stator winding 31 having a cross section shown in FIG.

  As described above, in the stator winding 31 used in the vehicle alternator 1 of the present embodiment, the U-shaped segment 3 used in the second twisting process is the first performed before that. Since the radial position and the circumferential position of the two straight portions 33a and 33b are shifted in the twisting process, the positions of the two straight portions 33a and 33b projected along the circumferential direction are approached along the radial direction. Even in this case, it is not necessary to bend the segment 33 with an extremely small radius in the turn portion 33c, and the coil end portion 31 of the turn portion side coil end portion 31 of the stator winding 31 formed using such a segment 33 can be used. Radial spread can be prevented. Moreover, since each segment 33 is subjected to the second twisting process after the first twisting process is completed, the straight line parts are pushed to the opposite side in the radial direction, so that the radial spread of each straight line part is minimized. can do.

  In particular, the U-shaped segment 33 is formed by bending a linear wire into a U-shape in the bending and shaping process, and the next first twisting process is performed for each of the segments 33 manufactured by the bending and shaping process. Therefore, the first twisting process can be performed in accordance with the bending shaping process, and the delay time due to the addition of the process can be minimized.

  Further, in the first twisting step, the amount by which the straight portions 33a and 33b of the segment 33 (particularly the small segment 332) are displaced along the radial direction is set to be substantially equal to the width of the segment 33 along the radial direction. Therefore, the spread of the turn part side coil end part 31 in the radial direction can be minimized.

  In addition, by elastically deforming and expanding each linear portion during the second twisting step, the linear portion of the segment 33 disposed on the outer diameter side of the slot 35 and the linear portion of the segment 33 disposed on the inner diameter side Are attracted to each other by the elastic force, so that the spread of the coil end portion 31 along the radial direction can be minimized.

  In particular, the radial distance of each linear portion of the segment 33 after the second twisting process is finished decreases with the restoration of the elastic deformation, and is included in each segment 33 after the first twisting process is finished. Since the second twisting process is carried out by increasing the radial distance between the straight portions, it is possible to reliably reduce the radial extension of the coil end portion 31 by elastic deformation.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. For example, in the above-described embodiment, the linear portions 33a and 33b of the segment 33 are elastically deformed when they are spread to the opposite side along the radial direction after the first twisting process is finished. It may be. Further, plastic deformation may be accompanied after the first elastic deformation.

It is sectional drawing which shows the whole structure of the alternating current generator for vehicles as a rotary electric machine of one Embodiment. It is a fragmentary sectional view of a stator. It is a perspective view which shows the typical shape of the segment conductor with which a stator is mounted | worn. It is a figure which shows the state which inserts the segment set which consists of a large segment and a small segment in the slot of a stator core. It is a front view of the U-shaped segment manufactured by the bending shaping process. It is a side view of the segment shown in FIG. It is a perspective view of the segment shown in FIG. It is a figure which shows the detail of a 1st twist process. It is a figure which shows the detail of a 1st twist process. It is a figure which shows the detail of a 1st twist process. It is a figure which shows the detail of a 1st twist process. It is a perspective view which shows the small segment after twist shaping was performed by the 1st twist process. It is sectional drawing of the twist jig | tool used at a 2nd twist process. It is a perspective view which shows the principal part of the twist jig | tool shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Vehicle alternator 2 Stator 3 Rotor 4 Housing 5 Rectifier 32 Stator core 33 Segment conductor 35 Slot 36 Insulation sheet 300 Twist jig 311 Inner twist part 312 Outer twist part 313, 114 Rotation drive mechanism 315 Controller 316 Segment Presser 317 Segment push-up jig 318 Lift drive mechanism

Claims (7)

A twisting step of twisting a U-shaped segment having two straight portions whose positions along the radial direction are shifted by relatively moving each of the straight portions to the opposite side in the circumferential direction;
An insertion step of inserting each straight portion of the segment twisted by the twisting step into a slot formed in the stator core;
A bending step of bending the anti-turn portion side of the segment inserted into the slot in the circumferential direction;
A joining step of joining ends of adjacent segments folded by the folding step;
In the method of manufacturing a stator winding of a rotating electrical machine having
Prior to the twisting step, a preliminary step of shifting the radial position and the circumferential position of each linear portion by moving each linear portion of the segments arranged in the circumferential direction relative to each other in the opposite radial direction. With
A method of manufacturing a stator winding of a rotating electrical machine, wherein the twisting step is performed by increasing the radial distance between the straight portions included in each of the segments after the preliminary step is completed. In claim 1,
The first radial distance of each linear portion included in the segment after the preliminary process is finished is shorter than the second radial distance when the twisting process is performed, and the segment is elastically deformed. A method of manufacturing a stator winding of a rotating electrical machine, wherein the twisting step is performed by expanding each straight line portion. In claim 1,
The first radial distance of each linear portion included in the segment after the preliminary process is finished is shorter than the second radial distance when the twisting process is performed, and is accompanied by plastic deformation of the segment. A method of manufacturing a stator winding of a rotating electrical machine, wherein the twisting step is performed by expanding each straight line portion. In claim 1 or 2,
The first radial distance of each linear portion included in the segment after the preliminary process is finished is shorter than the second radial distance when the twisting process is performed, and the elastic deformation and plasticity of the segment A method of manufacturing a stator winding of a rotating electrical machine, wherein the twisting step is performed by expanding each straight portion with deformation. In claim 2 or 4,
The radial distance of each linear part of the segment after the twisting process is finished decreases with the restoration of the elastic deformation,
A method of manufacturing a stator winding of a rotating electrical machine, wherein the inserting step is performed by widening the radial distance between the straight portions included in each of the segments after the twisting step is completed. In any one of Claims 1-5,
The U-shaped segment is manufactured by a bending and shaping process in which a linear wire is bent and shaped into a U shape,
The said preliminary process is performed for each of the said segments manufactured by the said bending shaping process, The manufacturing method of the stator winding | coil of a rotary electric machine characterized by the above-mentioned. In any one of Claims 1-6,
The amount of shifting each linear portion of the segment along the circumferential direction in the preliminary step is equal to or less than the adjacent pitch of the slots formed along the circumferential direction of the stator core. Method of manufacturing the child winding.

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