JP2006157993A - Segment type stator and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a segment type stator where the dimensions of a coil end are made small while securing the insulation between the fellow conductor segments, and its manufacturing method. <P>SOLUTION: This segment type stator 1 is one where for a plurality of conductor segments 20 inserted into a slot 42 of a stator core 40, the ends projected from the slot 42 are bent and twisted in in its circumferential direction and the junctions 21 at the tips are joined with the junctions 21 of conductor segments 20 inserted into another slot 42, and the conductor segments 20 being bent and twisted in its circumferential direction have insulating members 26 between itself and another conductor segment 20 positioned in the axial direction of the stator core 40, and the fellow segments 20 are laid on top of the other in insulated state, with the insulating member 26 between. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  A coil formed by inserting a plurality of conductor segments into slots of the stator core, bending the conductor segments at the axial end portions of the stator core, adding twist, and joining the conductor segments inserted in other slots by welding or the like BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a segment type stator having end portions and a method for manufacturing the same, and to a segment type stator in which an axial dimension of the coil end portion is reduced and a method for manufacturing the same.

  Conventionally, a plurality of conductor segments are used instead of coil windings for the stator constituting the electric motor, and after inserting the conductor segments into the slots of the stator core, there are various segment-type stators whose ends are joined to each other. Proposed. The following Patent Document 1 also describes such a generator. FIG. 10 is a perspective view showing a coil end portion of the stator constituting the AC generator described in the same document. FIG. 11 is a perspective view showing conductor segments constituting the stator.

  A conductor segment 110 shown in FIG. 11 is a wire formed by covering an electric conductor such as copper having a rectangular rectangular cross section with an insulating film. As shown in the figure, the conductor segment 110 has a substantially U shape, and a joint 112 from which the insulating coating 41 is removed is provided at both ends. In the stator 100, such a conductor segment 110 is inserted from one side into the slot 122 of the stator core 120 as shown in FIG. 10, and both end portions protrude from the other end.

A plurality of conductor segments 110 are inserted into one slot 122 and arranged as shown in FIG. 10, and the height of the turn portion 114 is aligned on one side of the stator core 120. At the other end of the stator core 120, the conductor segment 110 protruding from the slot 122 is bent and twisted along the circumferential direction, and, for example, an arc is formed between the conductor segment 110 inserted into the other slot 122. Joined by TIG welding using
JP 2001-238385 A (page 5-7, FIG. 7, FIG. 14) JP 2003-116242 A (page 3, FIG. 6)

  By the way, in the conventional segment type stator 100, a conductor segment 110 provided with an insulating film as shown in FIG. 11 is used. This conductor segment 110 is a straight wire having a rectangular shape and a linear rectangular shape. Are prepared and cut at the positions of the joints 112 formed at a predetermined interval, and a conductor segment 110 having a predetermined length is obtained. Further, a U-shaped deformation is added to each. However, in the conventional segment type stator, since the number of conductor segments 110 such as 200 to 300 is used for one generator, the labor of processing the segment itself and the trouble of inserting each one into the slot 122 are reduced. The production efficiency was not good.

On the other hand, as shown in FIG. 10, when the conductor segments 110 are inserted and connected to each other, the whole is fixed by molding. Therefore, if the conductor segments 110 are not in contact with each other at the coil end portion protruding from the slot 122, insulation is performed. No film is required. Therefore, the material cost can be reduced as compared with the case where the above-described insulating film is coated, and the processing of the joining portion 112 is not necessary. Therefore, the production efficiency is high and the manufacturing cost is advantageous because the number of processing steps is small.
However, it is necessary to ensure the separation between the conductor segments 110, the dimensions of the coil end portion are increased, and the stator 100 itself and the generator are increased in size.

By the way, when the U-shaped conductor segment 110 is used as shown in FIG. 11, the difficulty of inserting the U-shaped conductor segment 110 into the two slots 122 leads to an increase in the lead time and an increase in the defect rate. Therefore, a conductor segment 130 as shown in FIG. 13 described in Patent Document 2 is effective for such a problem. As can be seen from the figure, the deformed shape is simpler than that of FIG. 11, and since this is deformed after being placed in the slot 122, the machining process is simplified, and into the slot 122. Is easy to insert.
However, while having such an advantage, since the conductor segments are joined at both ends of the stator core 120, the above-described problem of expanding the coil end size occurs at both ends, and further increases the dimensions of the stator and the generator.

  Accordingly, an object of the present invention is to provide a segmented stator in which the dimensions of the coil ends are reduced while ensuring insulation between the conductor segments and a method for manufacturing the same.

  In the segment type stator according to the present invention, the plurality of conductor segments inserted into the slots of the stator core are twisted in the circumferential direction by bending the ends protruding from the slots, and the joints at the ends are inserted into the other slots. The conductor segment, which is joined to the joined portion of the conductor segment, is bent and twisted in the circumferential direction, and is interposed between the other conductor segments located in the axial direction of the stator core. It has an insulating member, and the conductor segments are overlapped in an insulating state with the insulating member interposed therebetween.

In the segment type stator according to the present invention, the conductor segment has a rectangular rectangular cross section, and when inserted into the slot, an insulating member is attached to one circumferential surface. Preferably there is.
Further, in the segment type stator according to the present invention, the conductor segment has a linear rectangular shape with a rectangular cross section, and when inserted into the slot, an insulating member is attached to each surface in the circumferential direction and the radial direction. It is preferable that
In addition, the segment type stator according to the present invention has a segment unit in which the conductor segment is inserted into an insulating insulator having a plurality of insertion holes arranged in a line, and the segment unit is mounted in a slot of the stator core. It is preferable that they are as described above.

  On the other hand, in the manufacturing method of the segment type stator according to the present invention, the plurality of conductor segments inserted into the slots of the stator core are twisted in the circumferential direction by bending the ends protruding from the slots, and the joint portion at the tip is A conductor segment which is joined to a joint portion of a conductor segment inserted into another slot and which has a rectangular rectangular cross section and has an insulating member attached to at least one surface thereof is inserted into the slot, and the conductor The segment is bent and twisted, and further, the conductor segment is pressed against the stator core side so as to overlap with the other conductor segment located in the axial direction of the stator core in an insulating state via the insulating member. To do.

In the method of manufacturing a segment type stator according to the present invention, it is preferable that the conductor segment is formed by bonding an insulating plate of the same size to a rectangular conductor plate and cutting it with a predetermined width.
Further, in the method of manufacturing a segment type stator according to the present invention, the conductor segments are formed by bonding an insulating plate of the same size to a rectangular conductor plate, cutting with a predetermined width, and arranging them side by side. It is preferable to apply an insulating member to the two surfaces by cutting after bonding the insulating plate.
In the method for manufacturing a segment type stator according to the present invention, a segment unit is formed by inserting the conductor segment into an insulating insulator having a plurality of insertion holes arranged in a line, and the segment unit is placed in a slot of the stator core. It is preferable to be mounted.

  Therefore, according to the segment type stator and the manufacturing method thereof of the present invention, for example, an insulating member is attached to one surface of a conductor segment, thereby ensuring an insulating state by interposing an insulating member between other conductor segments. Since the conductor segments can be overlapped with each other, the dimension of the coil end portion can be suppressed by eliminating an extra gap between the conductor segments. Further, in the present invention, the conductor segment can be manufactured by a simple process in which an insulating plate is attached to a conductor plate and cut. Furthermore, since the plurality of conductor segments are integrated by the insulating insulator, handling in the manufacture of the stator is convenient.

  Next, the segment type stator and the manufacturing method thereof according to the present invention will be described below with reference to the drawings. Here, FIG. 1 is a front view in which the conductor segment is set in the insulating insulator, and FIG. 2 is a perspective view showing the state in which the conductor segment is inserted into the insulating insulator and set.

  The insulating insulator 10 has a plurality of through-holes (insertion holes) 11 aligned with the cross-sectional shape of the linear flat rectangular conductor segment 20 having a rectangular cross section. The conductor segments 20 are inserted into the insertion holes 11 one by one, and are formed of polyphenylene sulfide (PPS) so as to ensure insulation between adjacent conductor segments 20. Further, as will be described later, when mounted in the slot of the stator core, a protrusion 12 that functions as a retaining member is formed by rubbing against the wall of the slot so that the insulating insulator 10 is held.

The conductor segment 20 has tapered surfaces at both ends or one end for the purpose of facilitating insertion into the insulating insulator 10. Such a conductor segment 20 is inserted into the insulating insulator 10 as shown in FIG. At that time, the conductor segments 20 having different lengths are inserted in order from the end of the insulating insulator 10, and the conductor segments 20 protrude from the both sides of the insulating insulator 10 by the same length. The conductor segment 20 is inserted into the insertion hole 11 so as to receive a frictional resistance, and is held at that position after insertion.
In addition to this, a method is also conceivable in which the segment unit 30 is manufactured by holding the conductor segments 20 in a state of being arranged at a predetermined interval and molding the insulating insulator 10 by insert molding.

  By the way, in this embodiment, the insulating member is pasted on the conductor segment 20 in advance. FIG. 3 is a diagram showing a process of manufacturing the conductor segment 20 and the segment unit 30. The conductor segment 20 is first prepared with a conductor member 25 and an insulating member 26 having a square shape and a predetermined size (a), which are overlapped and attached to two layers by an adhesive or baking (b). For example, a copper plate is used for the conductor member 25 and a PPS plate is used for the insulating member 26. The plate thickness of the insulating member 26 is determined by the magnitude of the voltage applied to the conductor segment 20 when the electric motor is configured. Next, a two-layer plate composed of the conductor member 25 and the insulating member 26 is cut with a predetermined width indicated by a wavy line (c), and the conductor segment 20 having the insulating member 26 on one surface thereof having a linear rectangular shape is formed. Formed (d). The conductor segment 20 thus formed is inserted with the insulating member 26 aligned in the same direction in the insertion hole 11 of the insulating insulator 10 (e).

  In FIG. 3 (e), all the conductor segments 20 are shown with the same length. However, when the length is changed as shown in FIG. The insulating segments 26 are used to form the conductor segments 20 having the respective lengths.

  Next, FIG. 4 is a view showing a state in which the segment unit 30 is mounted in the slot 42 of the stator core 40. The segment unit 30 is inserted into a slot 42 cut out on the inner peripheral side of the stator core 40. Although the length of the conductor segment 20 is different, the segment unit 30 is mounted in a direction in which the length increases from the center portion of the stator core 40 to the outside. Since the length of the insulating insulator 10 is substantially the same as the axial dimension of the stator core 40, the insulating insulator 10 is accommodated without exiting from the slot 42. Therefore, in this state, the plurality of conductor segments 20 protrude in the axial direction from the slots 42 of the stator core 40.

Next, the segment unit 30 thus attached to the stator core 40 is bent at both ends of the conductor segment 20 coming out of the slot 42 as shown in FIG. FIG. 5 is a perspective view showing one of the segment units 30 constituting the stator.
That is, the conductor segment 20 is bent obliquely when it exits from the slot 42 using a jig, and is further bent at the front end portion toward the axial direction of the stator core 40 (hereinafter, the same direction is referred to as the vertical direction). The plurality of conductor segments 20 provided in one slot 42 are alternately bent in opposite directions except for both ends. The conductor segments 20 are further twisted so as to be bent along the circumferential direction of the stator core 40.

  Here, FIG. 6 is a perspective view showing a coil end portion of the stator in which the conductor segments 20 are joined together. The conductor segment 20 is formed with a joint portion 21 that is bent so as to protrude in the vertical direction at the tip thereof, and is the conductor segment 20 of the slot 42 that is separated from each other by eight, and the same circumference that is bent in the opposite direction. The joints 21 of the upper ones are joined together. TIG welding or an adhesive is used for joining of the joining portion 21, and the conductor members 25 are connected to each other. In the present embodiment, the inclined portion 22 is pressed using a jig prior to the joining of the joining portion 21 in this way. Conventionally, in the case of a conductor segment composed only of a conductor member, as shown in FIG. 6, the inclined portions with other conductor segments positioned above and below are separated in the vertical direction in order to prevent short circuit due to contact. It was. However, in this embodiment, since the insulating member 26 is present on one of the upper and lower surfaces of the inclined portion 22 of each conductor segment 20, the conductor segments 20 of the different slots 42 that overlap vertically are overlapped with each other. .

  The conductor segment 20 attached to the stator core 40 and subjected to bending and twisting has a coil end portion above the stator core 40 shown in FIGS. There is an insulating member 26 on the lower surface side of all those inclined to the right side of the drawing. Therefore, even if the conductor segments 20 are pressed against the stator core 40 side from the state shown in FIG. 6 and overlapped as shown in FIG. 7, one conductor member 25 is always in contact with the other insulating member 26. And the insulation state is maintained.

When viewed in the stator axial direction in which the mounting of the conductor segments 20 to the stator core 40 is completed in this way, as shown in FIG. 8, the joint portions 21 at the tips of the twisted conductor segments 20 are aligned radially.
Since the conductor segments 20 constituting the segment unit 30 have different lengths as shown in FIGS. 1 and 2, the heights of the connecting portions are aligned. In the present embodiment, only the coil end portion on the upper end side of the stator core 40 is specifically shown in FIGS. 6 and 7, but the conductor segment 20 is bent and twisted both vertically and further pressed to the stator core 40 side. Thereafter, joining is performed by welding the joining portion 21 at the tip.

  Therefore, according to the segment type stator 1 and the manufacturing method thereof of the present embodiment, since the insulating member 26 is attached to one surface of the conductor segment 20, insulation between the conductor segments 20 stacked in the vertical direction is ensured and short-circuited. There is no end to it. Accordingly, since the conductor segments 20 can be pressed and overlapped in the vertical direction, the extra space between the conductor segments can be eliminated to reduce the size of the coil end portion. The whole electric motor using 1 can be made compact. In particular, in the case of the present embodiment in which the conductor segments are connected at both ends of the stator core, the coil ends can be formed at two upper and lower portions. Therefore, suppressing the height of this portion greatly contributes to the downsizing of the electric motor.

  Further, since the conductor segment 20 is simple as long as the insulating member 26 is attached to the conductor member 25, the cost can be reduced as compared with the conductor segment 110 coated with a conventional insulating film. In addition, as shown in FIG. 7, the cost can be reduced in that a plurality of pieces can be easily manufactured at a time. Furthermore, since the plurality of conductor segments 20 are integrated by the insulating insulator 10, the handling in the manufacture of the stator is convenient.

  By the way, in this embodiment, since the insulating member 26 exists in the up-down direction in the inclined portion 22 of the conductor segment 20, there is a risk that the conductor members 25 come into contact with each other when viewed in the radial direction of the stator core 40. Therefore, in order to prevent radial contact, an insulating ring 45 is used as shown in FIG. Although only one insulating ring 45 is shown in the drawing, a plurality of insulating rings 45 having different diameters are provided so as to be divided for each conductor segment 20 on each circumference arranged in the radial direction. A plurality of insulating rings 45 are inserted between the conductor segments 20 adjacent in the radial direction, and an insulating state is ensured. Therefore, even when the conductor segment 20 in the coil end portion is bent and twisted in this state, a short circuit due to contact between adjacent ones in the radial direction can be prevented.

On the other hand, a segment type stator for preventing a short circuit due to a radial contact with a conductor segment is proposed as a second embodiment. That is, the configuration is such that the insulating ring is eliminated. In addition, about the structure which is common in the said embodiment, the same code | symbol is attached | subjected and demonstrated. Here, FIG. 9 is a diagram showing the conductor segment (a) and the segment unit (b) of the present embodiment.
As shown in FIG. 3, the conductor segment 50 of the present embodiment is provided with an insulating member 26 having the same area as the conductor member 25 having a predetermined size as shown in FIG. (B) or by baking or the like. Also in this embodiment, a copper plate is used for the conductor member 25, and a PPS plate is used for the insulating member 26, for example. The plate thickness of the insulating member 26 is determined by the magnitude of the voltage applied to the conductor segment 20. Next, a two-layer plate composed of the conductor member 25 and the insulating member 26 is cut with a predetermined width (c), and the conductor segment 20 including the insulating member 26 is formed on one surface thereof which has a linear rectangular shape. (D).

  Thereafter, in the present embodiment, as shown in FIG. 9A, the insulating member 27 is attached to the conductor member 25 on a surface orthogonal to the insulating member 26. This is because the conductor segments 20 formed according to FIG. 3D are arranged in the same direction, and a single insulating member 27 similar to the insulating member 26 shown in FIG. The insulating member 27 is cut for each segment 20. The resulting conductor segment 50 in FIG. 9A is inserted into the insertion hole 11 of the insulating insulator 10 with the orientation of the insulating members 26 and 27 aligned as shown in FIG. 9B.

  Although not shown in detail, the segment unit 31 formed in this way is inserted into the slot 42 cut out on the inner peripheral side of the stator core 40 as in the above embodiment, and both ends of the conductor segment 50 protruding in the axial direction from the slot 42. However, it is bent and twisted as shown in FIG. 4 using a jig and further pressed against the stator core 40 side. Then, the joint portion 21 at the tip of the conductor segment 50 is joined to the joint portion 21 of another conductor segment 50.

Therefore, according to the segment type stator of this embodiment and the manufacturing method thereof, since the insulating members 26 and 27 are attached to the conductor segment 50, insulation between the conductor segments 50 stacked in the vertical direction is ensured and short-circuited. There is no end to it. Furthermore, insulation with the conductor member 25 of the conductor segment 50 adjacent in the radial direction is secured by the insulating member 27, and it is not necessary to provide the insulating ring 45, thereby preventing a short circuit.
Since the conductor segments 50 can be pressed and overlapped in the vertical direction, the extra space between the conductor segments can be eliminated to reduce the size of the coil end portion. It becomes possible to make the whole electric motor compact. In particular, in the case of the present embodiment in which the conductor segments are connected at both ends of the stator core, the coil ends can be formed at two upper and lower portions. Therefore, suppressing the height of this portion greatly contributes to the downsizing of the electric motor.

  Further, since the conductor segment 50 is simple as long as the insulating members 26 and 27 are attached to the conductor member 25, the cost can be reduced as compared with the conductor segment 110 or the like coated with a conventional insulating film. Moreover, as shown in FIGS. 3 and 9, the cost can also be reduced in that a plurality of pieces can be easily manufactured at a time. Furthermore, since the plurality of conductor segments 50 are integrated by the insulating insulator 10, handling in the manufacture of the stator is convenient.

As mentioned above, although one embodiment was described about the segment type stator which concerns on this invention, and its manufacturing method, this invention is not limited to this, A various change is possible in the range which does not deviate from the meaning.
For example, in the above-described embodiment, the stator core 40 has coil ends on the upper and lower sides. However, the U-shaped conductor segment shown in FIGS. 10 and 11 is formed by pressing the coil end portion toward the stator core. It may be a segmented stator made compact.

It is the front view which showed the state by which the conductor segment was set to the insulation insulator. It is the perspective view shown so that the state which inserts a conductor segment in an insulation insulator and can set may be understood. It is the figure which showed the process of manufacturing a conductor segment and a segment unit. It is the figure which showed the state which mounted | wore the slot of the stator unit with the segment unit. It is the perspective view which showed one of the segment units which comprise a stator. It is the perspective view which showed the coil end part of the stator which joined conductor segments. It is the perspective view which showed the coil end part of the stator of the state which pressed the conductor segment on the stator core side. It is the figure which looked at the segment type stator in the axial direction. It is the figure which showed the conductor segment (a) and segment unit (b) of 2nd Embodiment. It is the perspective view which showed the coil end part about the conventional stator which comprises an alternating current generator. It is the perspective view which showed the conductor segment which comprises the conventional stator. It is the perspective view which showed the conductor segment which comprises the conventional stator.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Segment type stator 10 Insulation insulator 20 Conductor segment 21 Joint part 22 Inclination part 25 Conductive member 26 Insulation member 30 Segment unit 40 Stator core 42 Slot

Claims (8)

A plurality of conductor segments inserted into the slots of the stator core are twisted in the circumferential direction by bending the ends protruding from the slots, and the joints at the tips are joined to the joints of the conductor segments inserted into other slots. In the segmented stator,
The conductor segment that is bent and twisted in the circumferential direction has an insulating member between other conductor segments positioned in the axial direction of the stator core, and the conductor segments sandwich the insulating member between them. A segmented stator characterized by being superposed in a state. In the segment type stator according to claim 1,
The segment type stator, wherein the conductor segment has a rectangular shape with a rectangular cross section, and when inserted into the slot, an insulating member is attached to one surface in the circumferential direction. In the segment type stator according to claim 1,
The conductor segment is a linear rectangular shape having a rectangular cross section, and when inserted into the slot, an insulating member is attached to each surface in the circumferential direction and the radial direction. Type stator. In the segment type stator according to any one of claims 1 to 3,
An insulating insulator having a plurality of insertion holes arranged in a line has a segment unit in which the conductor segment is inserted, and the segment unit is mounted in a slot of the stator core. Segment type stator. A plurality of conductor segments inserted into the slots of the stator core are twisted in the circumferential direction by bending the ends protruding from the slots, and the joints at the tips are joined to the joints of the conductor segments inserted into other slots. In the method of manufacturing a segmented stator,
A conductor segment having an insulating member attached to at least one surface thereof having a rectangular rectangular cross section is inserted into the slot, the conductor segment is bent and twisted, and another conductor segment positioned in the axial direction of the stator core; and A method of manufacturing a segment type stator, wherein a conductor segment is pressed against the stator core side so as to overlap in an insulated state via the insulating member. In the manufacturing method of the segment type stator according to claim 5,
The method of manufacturing a segment type stator, wherein the conductor segment is formed by bonding an insulating plate of the same size to a rectangular conductor plate and cutting with a predetermined width. In the manufacturing method of the segment type stator according to claim 5,
The conductor segment is bonded to a rectangular conductor plate by bonding an insulating plate of the same size, cutting with a predetermined width, and arranging them side by side and then bonding another insulating plate, then cutting the two sides. A method of manufacturing a segment type stator, wherein an insulating member is provided. In the manufacturing method of the segment type stator according to any one of claims 5 to 7,
A segmented stator comprising: a segment unit in which the conductor segment is inserted into an insulating insulator having a plurality of insertion holes arranged in a line; and the segment unit is mounted in a slot of the stator core. Production method.

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