JP2011234503A - Method for manufacturing stator of motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a stator of a motor, the method reducing quantity of coil, preventing coil resistance and copper loss to improve motor efficiency, reducing a weight of the motor, downsizing a physical size of the motor, and eliminating or simplifying a coil fixing process such as a lacing process or a varnish treatment.SOLUTION: In the method for manufacturing a stator of a motor, a wire 20 is wound around a slot 16 via an insulation member 12 by distributed winding, in a state that a tension force is applied, to form a U-phase coil 13u, a V-phase coil 13v, and a W-phase coil 13w, and coil ends 17u, 17v and 17w of the coils 13u, 13v and 13w are arranged on a stator core 11 alternately in increments of number of windings of each phase.

Description

  The present invention relates to a method for manufacturing a stator of a motor in which wire wires are distributedly wound, which is mainly used as a drive source for an electric vehicle or a hybrid vehicle.

  Conventionally, a stator of a distributed winding motor has a direct winding method in which a wire is wound around a stator core to form a coil, or an inserter method in which a coil formed by winding a wire wire in advance is inserted into a slot of the stator core. It is manufactured by.

  In the direct winding method, the former attachment / detachment / exchange part, winding arm drive part, inspection part, and interphase insulator assembly part are sequentially arranged around the stator core held by the holder, and the stator core is rotated by a predetermined angle. However, a winding method and a winding device for a stator core are disclosed in which a wire nozzle is moved in the axial direction of the stator and around the axis so that wire work is performed by a single facility (for example, refer to Patent Document 1). ). With this stator core winding method and winding device, as shown in FIG. 12, U, V, and W phase coils 112, 113, and 114 are wound around the slots 111 of the stator core 110.

  Further, as shown in FIG. 13, a nozzle 121 that moves relative to the stator core 110 in the three-dimensional direction and feeds the wire 115 and guides 122 and 123 that can move relative to the stator core 110 in the radial direction are provided. A winding method and a winding device are known in which the wire rod 115 inserted into the slot 111 is wound by relatively moving the guides 122 and 123 to increase the wire material space factor of the coils 112, 113, and 114. (For example, refer to Patent Document 2).

  As an inserter system, as shown in FIG. 14, for example, a blade 125 inserted into the stator core 110, a coil insertion jig 126 for pushing the coil 112 hung on the blade 125 into the stator core 110, and a wedge 127 are guided. Outer core provided with a wedge guide 128, a wedge insertion jig 129 for pushing the wedge 127 toward the slot, and a load cell 131 for measuring the wedge insertion force, so that an abnormal insertion of the wedge 127 can be detected in the stator core assembly process An assembling apparatus 130 has been proposed (see, for example, Patent Document 3).

JP 2007-6777 A Japanese Patent No. 3669966 JP 2006-166675 A

  However, in the case of the stator of the motor manufactured by the stator core winding method and winding device described in Patent Document 1, other phase slots (for example, V-phase slots, W-phases) are provided between the in-phase slots (for example, U-phase slots). Therefore, when a wire is inserted from the U-phase slot into the next U-phase slot, the coil end straddles the other-phase slot, and when the wire is linearly inserted into the U-phase slot, the other-phase slot (V-phase slot, W-phase slot) is covered with the coil end portion. In this case, many wires cannot be inserted into the other-phase slot, and the wire space factor decreases. For this reason, as shown in FIG. 12, in order to insert the V-phase coil 113 into the slot 111 without lowering the wire space factor, the coil end portion 112a of the U-phase coil 112 that has been previously inserted is previously connected to the stator core. 110, it is necessary to ensure a space for inserting the V-phase coil 113, and to insert the W-phase coil 114 into the slot 111, the V-phase coil 113 previously inserted must be inserted. The coil end portion 113a also needs to be largely released to the outer peripheral side of the stator core 110 in advance to secure an insertion space for the W-phase coil 114.

  As a result, the coil end portions 112a, 113a, and 114a that do not directly contribute to the improvement in motor performance are increased, and the physique of the motor is increased. Further, since the amount of coils increases, the motor weight increases and the coil resistance increases, resulting in a problem that the copper loss increases and the efficiency of the motor decreases. Further, in order to fix the coils 112, 113, and 114 of each phase, a lacing process, a varnish process, and the like are required after winding the wire 115.

  Further, according to the winding method and winding device of Patent Document 2, the wire 112 is wound by the guides 122 and 123 toward the outside in the radial direction of the slot 111 and the wire 115 is wound while being temporarily positioned. , 113 and 114 can be increased to some extent. However, the coils 112, 113, 114 are not fixed to the stator core 110, and after winding the wire 115, a lacing process or a varnish process is necessary, and a lot of man-hours are required for stator production, There was a problem that the cost increased.

  Further, according to the outer core assembly device 130 of Patent Document 3, the wire 115 is formed into the coil 112 in advance, and the coil 112 is pushed into the slot of the stator core 110 with the coil insertion jig 126 while being inclined with respect to the stator core 110. Therefore, the length of the wire 115 longer than that required for the product is required. As a result, there is a problem that the amount of useless coils increases, the motor weight and coil resistance increase, and the motor efficiency decreases as the copper loss increases. In addition, there is a problem that the physique of the motor becomes large, and there is room for improvement. Further, according to Patent Document 3, there is a problem that a racing process or a varnish process is required after the coil 112 is pushed into the slot.

  The present invention has been made in view of the above-described problems, and its purpose is to reduce the coil amount, suppress coil resistance and copper loss, improve motor efficiency, reduce motor weight, and improve the motor physique. Another object of the present invention is to provide a method of manufacturing a motor stator which can be miniaturized and can eliminate or simplify coil fixing processing such as racing processing and varnish processing.

In order to achieve the above-described object, the invention according to claim 1 is configured such that a wire line (for example, a wire line 20 in an embodiment to be described later) composed of a plurality of strands (for example, an element wire 20 ′ in an embodiment to be described later). A plurality of coils (e.g., a plurality of coils (e.g., a plurality of slots) (e.g., a stator core 11 in an embodiment described later) are distributedly wound in a plurality of slots (e.g., slot 16 in an embodiment described later) with a predetermined number of slots. A method of manufacturing a stator of a motor (for example, a stator 10 of a motor in an embodiment described later), which respectively forms a U-phase coil 13u, a V-phase coil 13v, and a W-phase coil 13w in an embodiment described later. ,
Disposing an insulating member (for example, an insulating member 12 in an embodiment described later) for electrically insulating the stator core and the wire wire in the plurality of slots;
A step of distributedly winding the wire wires around the plurality of slots while applying tension to the wire wires so as to physically fix the stator core, the insulating member, and the coil. And

  In addition to the configuration of claim 1, the invention according to claim 2 includes coil end portions (for example, a U-phase coil end portion 17u, a V-phase coil end portion 17v, and a W-phase in an embodiment described later) of the plurality of phase coils. The coil end portions 17w) are alternately arranged on the stator core in units of the number of windings of each phase.

  According to a third aspect of the invention, in addition to the configuration of the first or second aspect, the insulating member is an elastic resin member (for example, an insulating member 12 in an embodiment described later). .

  According to a fourth aspect of the present invention, in addition to the structure of any one of the first to third aspects, the tension of the wire line is equal to or less than an elastic allowable stress of the wire line and / or an allowable compressive strength of the insulating member. It is characterized by the following.

  According to a fifth aspect of the present invention, in addition to the structure of any one of the first to fourth aspects, the slot has an opening (for example, an opening 18 in an embodiment described later) having an inner diameter surface (for example, an inner surface of the stator core). An opening is formed in an inner peripheral surface 19) in an embodiment described later.

According to a sixth aspect of the present invention, in addition to the configuration of any of the first to fifth aspects, the plurality of phase coils comprises a U-phase, a V-phase, and a W-phase coil.
The three-phase coil is formed by wrapping the wire wire around the plurality of slots so that coil end portions of the two-phase coil are aligned in the radial direction.

In the invention according to claim 7, in addition to the configuration of claim 1, the distributed winding step includes:
Inserting the wire into the insulating member of a first slot (for example, a first slot 16a in an embodiment described later) from one axial end to the other end of the stator core;
Holding the wire wire drawn out from the first slot on the other end side in the axial direction of the stator core outside the first slot in a state where tension is applied to the wire wire; and
Rotating the stator core together with the wire wire by a predetermined angle to a second slot (for example, a second slot 16b in an embodiment described later) through which the wire wire is next inserted;
Holding the wire wire radially outward of the second slot at the other axial end of the stator core;
Inserting the wire into the insulating member of the second slot from the other axial end of the stator core toward one end;
Holding the wire wire drawn out from the second slot on one end side in the axial direction of the stator core outside the second slot in a state of applying tension to the wire wire; and
Rotating the stator core together with the wire wire by a predetermined angle to a third slot position where the wire wire is next inserted;
Holding the wire wire radially outward of the third slot at one axial end of the stator core; and
And repeating these steps.

  According to the invention of claim 1, coil fixing processing such as racing processing and varnish processing can be abolished or simplified, the manufacturing process can be simplified, and the manufacturing cost of the stator of the motor is suppressed.

  According to the invention of claim 2, the amount of coils can be reduced, and the motor efficiency can be improved by suppressing coil resistance and copper loss. Further, the motor weight can be reduced and the motor size can be reduced.

  According to the invention of claim 3, when forming a coil of a plurality of phases, even if the wire wire is distributedly wound around the insulating member in a state where tension is applied, there is no possibility of damaging the wire wire, and a predetermined motor performance is maintained. Is done.

  According to the invention of claim 4, when forming a coil of a plurality of phases, even if the wire wire is distributedly wound around the insulating member in a state where tension is applied, the wire wire and the insulating member are not plastically deformed and are predetermined. Motor performance is maintained.

  According to the invention of claim 5, it can be suitably used as a stator of an inner rotor type motor.

  According to the invention of claim 6, it is possible to reduce the coil amount, and it is possible to improve the motor efficiency by suppressing the coil resistance and the copper loss. In addition, the motor weight can be reduced and the motor size can be reduced.

  According to the invention of claim 7, while applying tension to the wire, the coil end portions of the two-phase coil can be arranged in the radial direction so as to be wound in a plurality of slots, thereby fixing the coil. The manufacturing process can be simplified by eliminating or simplifying the process, and the motor efficiency can be improved by suppressing coil resistance and copper loss. Further, the motor weight can be reduced and the motor size can be reduced.

It is a principal part expansion perspective view which shows the state by which the wire wire was distributedly wound by the stator of the motor which concerns on this invention. It is a schematic diagram which shows the winding state of the wire wire shown in FIG. It is the elements on larger scale of the stator seen from the inner diameter side. It is a principal part expansion perspective view which shows the winding state of the wire wire for 1 phase. It is sectional drawing which shows the state of the wire wire inserted in the slot. (A) And (b) is a figure for demonstrating a space factor. (A) is a manufacturing-process figure of the stator of the motor which concerns on this invention, (b) is a conventional manufacturing-process figure. It is a principal part enlarged view of the manufacturing apparatus of the stator of a motor. It is a plane conceptual diagram of the manufacturing apparatus shown in FIG. It is a principal part perspective view which shows the procedure in which a wire wire is wound around a stator core by the manufacturing apparatus shown in FIG. 8 in steps. It is a side view which shows the state in which tension | tensile_strength is provided to a wire wire with the hook of a manufacturing apparatus. It is a principal part enlarged view of the stator of the conventional motor. It is a principal part expansion perspective view which shows the state by which a wire wire is directly wound around the stator of another conventional motor. It is a conceptual diagram of the other conventional manufacturing apparatus which inserts the coil formed of the wire wire into the slot of a stator core.

  Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  As shown in FIG. 1, the stator 10 of the motor of this embodiment is a three-phase eight-pole distributed winding stator, and includes a stator core 11, an insulating member 12, and a coil 13 (U-phase coil 13u, V-phase coil). 13v and W-phase coil 13w). The stator core 11 is configured by, for example, laminating a plurality of pressed silicon steel plates, and includes 48 teeth 15 and 48 slots 16 formed between adjacent teeth 15 and 15. Further, the motor is an inner rotor type, and the opening 18 of the slot 16 opens to the inner peripheral surface 19 of the stator core 11.

  Each slot 16 is formed by injection molding of a resin material, and a plurality of insulating members 12 having electrical insulation characteristics and appropriate elasticity are inserted from both axial sides of the stator core 11 so as to cover the inner surface of the slot 16. Has been. The insulating member 12 electrically insulates between the stator core 11 and each phase coil 13u, 13v, 13w. Examples of the resin material to be injection-molded include polyamide, polyethylene terephthalate, polybutylene terephthalate, polyether ether ketone, and polyphenylene sulfide.

  The insulating member 12 is not limited to a resin molded product, as long as the insulating member 12 can be wound while applying tension to the wire wire 20 without fear of damaging the wire wire 20 and can ensure insulation performance. An aramid paper having an appropriate thickness and elasticity can also be used. Alternatively, the insulating member 12 may be formed by outsert molding of the stator core 11 with resin. Furthermore, when the voltage applied to the coil 13 is high (for example, 650 V or more), interphase insulating paper or the like may be disposed between the phases according to the voltage.

  The U-phase coil 13u, the V-phase coil 13v, and the W-phase coil 13w bundle a plurality (11 in this embodiment) of strands 20 ′ (see FIG. 5) such as a small-diameter polyamide-imide enameled copper wire. The wire 20 is inserted into a predetermined slot 16 and wound around the stator core 11 by wave winding.

  The coil end portions 17u, 17v, 17w of the respective phase coils 13u, 13v, 13w are two-phase coils (13u and 13v, 13v and 13w, or 13w and 13u) among the three-phase coils 13u, 13v, and 13w. The coil end portions (17u and 17v, 17v and 17w, or 17w and 17u) are alternately arranged in the radial direction of the stator core 11 in units of the number of windings of the phase coils 13u, 13v, and 13w. .

  As shown in FIGS. 2 to 4, the stator 10 of this embodiment is a double slot type stator, and two sets of wire wires 20 for each phase are connected to adjacent slots 16 (U-phase slots) of the stator core 11. 16u, V-phase slot 16v, and W-phase slot 16w) are distributed by wave winding. The slots 16 are repeatedly arranged in the circumferential direction of the stator core 11 in the order of the U-phase slot 16u, the V-phase slot 16v, and the W-phase slot 16w.

  Specifically, first, two sets of wire wires 20 constituting the U-phase coil 13u are respectively connected to two U-phase slots 16u from one axial end side (lower end in FIG. 2) to the other end side (FIG. 2). The insulating member 12 is inserted through the insulating member 12 toward the upper end of each of the two, and jumps over the two V-phase slots 16v and the W-phase slot 16w to the next two U-phase slots 16u from the other axial end to the one end. 12 is inserted. Thereafter, similarly, the wire 20 is inserted into the U-phase slot 16u by wave winding so as to go around the stator core 11, and the first turn 13u1 of the U-phase coil 13u is formed.

  Next, the two sets of wire wires 20 constituting the V-phase coil 13v are directed to the two V-phase slots 16v between the two U-phase slots 16u from the other axial end of the stator 10 toward one end. Inserted through the insulating member 12 and jumps over each of the two W-phase slots 16w and the U-phase slot 16u into the next two V-phase slots 16v from the one end side in the axial direction to the other end side through the insulating member 12. Thereafter, similarly, the first turn 13v1 of the V-phase coil 13v is formed by being wound around the V-phase slot 16v so as to go around the stator core 11.

  Similarly, two sets of wire wires 20 constituting the W-phase coil 13w are respectively connected to the two W-phase slots 16w between the two U-phase slots 16u from one end side in the axial direction of the stator 10 to the other end side. Inserted through the insulating member 12 and jumps over the two U-phase slots 16u and V-phase slots 16v to the next two W-phase slots 16w via the insulating member 12 from the other axial end to the one end. Inserted. As a result, the other end in the axial direction or the one end in the axial direction opposite to the one end in the axial direction or the other end in the axial direction where the coil end portions 17u and 17w of the U-phase coil 13u and the W-phase coil 13w intersect each other is set as the V-phase coil 13v. The coil end portion 17v passes through. Thereafter, similarly, the first turn 13w1 of the W-phase coil 13w is formed by being wound around the W-phase slot 16w so as to go around the stator core 11.

  Similarly, the second turn 13u2 of the U-phase coil 13u, the second turn 13v2 of the V-phase coil 13v, the second turn 13w2 of the W-phase coil 13w, the third turn 13u3 of the U-phase coil 13u,. It is wound around the stator core 11 in this order.

  Thus, by alternately arranging the U-phase coil 13u, the V-phase coil 13v, and the W-phase coil 13w for each turn, as shown in FIG. 1, the U-phase coil 13u, the V-phase coil 13v, and Of the W-phase coil 13w, coil end portions (17u and 17w, 17v and 17w) of two-phase coils (13u and 13w, 13v and 13w) are arranged so as to be aligned in the radial direction, and the wire 20 is Waves are wound around the plurality of slots 16. By arranging the U-phase coil 13u, the V-phase coil 13v, and the W-phase coil 13w alternately in units of the number of turns of each phase, the volume of the coil end portions 17u, 17v, 17w is smaller than that of the conventional coil. As a result, the coil amount is reduced.

  FIG. 4 is a diagram showing only the U-phase coil 13u for easy understanding, and the coil end portions 17u, 17v, and 17w of each phase are provided between the first turn 13u1 and the second turn 13u2. The first turn 13w1 of the W-phase coil 13w and the first turn 13v1 of the V-phase coil 13v are inserted into the radial gap. For this reason, the coil end portion 17u is formed to be displaced radially outward little by little every turn. The amount of displacement gradually decreases from the outer diameter side of the stator core 11 toward the inner diameter side. Further, the amount of displacement of the coil end portion 17u is such that the coil end portion 17u disposed radially outward from the substantially central portion of the thickness of the stator core 11 in the radial direction is displaced outward in the radial direction, and the diameter from the substantially central portion is increased. You may make it displace the coil end part 17u arrange | positioned inside a direction toward radial inside. The same applies to the V-phase coil end portion 17v and the W-phase coil end portion 17w.

  As shown in FIG. 3, the wire wires 20 constituting the phase coils 13 u, 13 v, and 13 w are bent along the shape of the insulating member 12, and each phase slot 16 u, 16 v, and 16w is waved as described above. As a result, the stator core 11, the insulating member 12, and the phase coils 13 u, 13 v, 13 w are physically fixed by the tension of the wire wire 20. Therefore, it is possible to eliminate or simplify the coil fixing process such as the lacing process and the varnish process that have been performed with the conventional stator.

  The tension of the wire 20 is preferably equal to or less than the elastic allowable stress of the wire 20 or the stress acting on the insulating member 12 due to the tension of the wire 20 is equal to or less than the allowable compressive strength, and more preferably satisfies both. Thereby, the malfunction by the tension | tensile_strength of the wire wire 20, such as the plastic deformation and fracture | rupture of the wound wire wire 20, and the plastic deformation of the insulating member 12, does not arise.

  As shown in FIG. 5, the wire 20 is disposed in each slot 16 via the insulating member 12, and the U, V, W phase coil end portions 17u, 17v, 17w Since they are alternately arranged in the radial direction, when the coil of the other phase is wound, the coil of the already wound phase does not get in the way and the space factor S of the coil 13 is increased. The space factor S of the stator 10 of this embodiment can be 40% or more. Here, as shown in FIG. 6, the space factor S is obtained by integrating the cross-sectional area S1 of the electric conductor portion 20b excluding the insulating coating 20a by the number of portions of the strand 20 'passing through the slot 16. And the ratio of the cross-sectional area S2 of the slot 16 to that of the slot 16.

  Next, a method for manufacturing the motor stator 10 will be described with reference to FIGS. FIG. 7A is a manufacturing process diagram of the stator of the motor according to the present invention, and FIG. 7B is a conventional manufacturing process diagram. As shown in FIG. 7B, according to the conventional manufacturing method, after assembling an insulating member in each slot of the stator core (step S1), a wire wire is wound around the stator core via the insulating member (step S2). Then, intermediate forming is performed by bending the coil end portion protruding outward in the axial direction outward in the radial direction (step S3), and then finish forming for adjusting the shape of the coil end portion is performed (step S4). Then, the stator core, the insulating member, and the coil are fixed by performing a lacing process (step S5) for binding the coils with the lacing string and a varnish process for impregnating and hardening the varnish (step S6). Thus, according to the conventional manufacturing method, the stator of the motor is manufactured through a six-step process.

  On the other hand, in the method for manufacturing the stator of the motor according to the present invention, as shown in FIG. 7A, the step of assembling the insulating member 12 in each slot 16 of the stator core 11 (step S11), and the insulating member 12 Can be shortened to a two-step process including the step of winding the wire 20 around the stator core 11 (step S12), and the production time can be greatly shortened along with the reduction of materials, thereby suppressing the production cost. can do. In addition, when the wire 20 is a self-bonding wire or the like on which a resin that can be bonded by heat treatment is applied, the wire wire 20 can be simply fixed by the heat treatment step (step S13). Coil fixation can be simplified.

  As shown in FIGS. 8 and 9, three nozzles 31 for U, V, and W phases that discharge two sets of wire wires 20 to the horizontally arranged stator core 11, and wire wires at predetermined positions, respectively. The wire wire 20 is wound around the stator core 11 by a plurality of hooks 32 that hold 20.

  The nozzle 31 includes a U-phase nozzle 31u that discharges two sets of wire wires 20 that form a U-phase coil 13u, a V-phase nozzle 31v that discharges two sets of wire wires 20 that form a V-phase coil, and a W-phase coil. W-phase nozzle 31w that discharges two sets of wire wires 20 constituting 13w, and is arranged on the inner diameter side of stator core 11. Each phase nozzle 31u, 31v, 31w is guided by the nozzle guide rail 30 while discharging two sets of wire wires 20, and is movable in the vertical direction and radial direction of the stator core 11.

  Twenty-four hooks 32 are arranged on each side of the stator core 11 in the axial direction, for a total of 24 hooks, and the wire wires 20 discharged from the phase nozzles 31u, 31v, 31w are locked at predetermined positions, The stator core 11 is held outside in the radial direction.

  As shown in FIG. 10A, a specific process of winding the wire 20 around the stator core 11 (wave winding) is as follows. As shown in FIG. 10A, two sets of wire 20 are connected from one axial end of the stator core 11 (lower end in the figure). The pair of first slots 16a are inserted through the insulating member 12 toward the other end side (upper end in the figure). Then, the wire wire 20 drawn out from the first slot 16a is locked by the hook 32 moved inward in the radial direction (FIG. 10B), and the hook 32 is released outward in the radial direction, whereby the wire wire 20 is tensioned. Is held outside in the radial direction of the first slot 16a (FIG. 10C).

  When tension is applied to the wire 20, if the wire 20 is locked to the hook 32 and pulled outward in the radial direction, the wire 20 inserted through the slot 16 swells inward in the radial direction and the space factor is increased. May decrease. In this case, a wire wire pressing mechanism is provided so that the wire wire 20 is wound while the wire wire 20 in the slot 16 bulging radially inward is pressed radially outward to correct the swelling. Also good.

  Next, the stator core 11 is rotated together with the hook 32 by a predetermined angle to the position of the second slot 16b where the wire wire 20 is to be inserted next while the wire wire 20 is locked to the hook 32. Thereby, the wire 20 discharged from the nozzle 31 is arrange | positioned along the outer peripheral side of the stator core 11 (FIG.10 (d)). Here, the wire wire 20 is held on the radially outer side of the second slot 16b by another adjacent hook 32 (FIG. 10 (e)), and the wire wire 20 is held on the other axial end side (upper side) of the stator core 11. ) Through the second slot 16b through the insulating member 12 from one end side (lower side) (FIG. 10 (f)).

  Thereafter, similarly, as shown in FIG. 11, on one end side (lower end side) of the stator core 11 in the axial direction, the wire wire 20 drawn from the second slot 16 b is locked to the hook 32 and tension is applied to the wire wire 20. The stator core 11 is rotated together with the hook 32 by a predetermined angle until the position of the third slot 16 where the wire wire 20 is next inserted is held. Thereby, the wire 20 discharged from the nozzle 31 and arranged along the outer peripheral side of the stator core 11 is held outside in the radial direction of the third slot 16. By repeating the above process, the one-phase coil 13 (for example, the U-phase coil 13u) is wound around the stator core 11.

  By performing the above-described operation simultaneously with the three nozzles 31 of the U-phase nozzle 31u, the V-phase nozzle 31v, and the W-phase nozzle 31w, the stator core 11 has the U-phase coil 13u, the V-phase coil 13v, and the W-phase coil 13w. Three coils 13 are alternately formed in units of the number of windings.

  As described above, according to the method for manufacturing the stator 10 of the motor according to the present embodiment, after the insulating member 12 that electrically insulates the stator core 11 and the wire 20 is disposed in the plurality of slots 16, the wire Since the wire wire 20 is distributedly wound around the plurality of slots 16 while applying tension to the wire 20, and the stator core 11, the insulating member 12, and the coil 13 are each physically fixed, the racing process and the varnish process are performed. Etc. can be abolished or simplified, the manufacturing process can be simplified, and the manufacturing cost of the stator 10 of the motor is suppressed. Here, the stator core 11, the insulating member 12, and the coil 13 are physically fixed when the relative positional relationship between the stator core 11, the insulating member 12, and the coil 13 is hardly changed by the tension of the wire 20. Say that.

  Further, the coil end portions 17u, 17v, and 17w of the coils 13u, 13v, and 13w of the plurality of phases are alternately arranged on the stator core 11 in units of the number of windings of each phase, so that the coil amount is reduced and the coil resistance and copper are reduced. Loss can be suppressed and motor efficiency can be improved. Further, the motor weight can be reduced and the motor size can be reduced.

  Furthermore, since the insulating member 12 is a resin member having elasticity, when forming the multi-phase coils 13u, 13v, and 13w, even if the wire wire 20 is distributedly wound around the insulating member 12 with tension applied. There is no risk of damaging the wire 20, and the predetermined motor performance is maintained.

  In addition, since the tension applied to the wire 20 is equal to or less than the elastic allowable stress of the wire 20 and / or the allowable compressive strength of the insulating member 12, the multiphase coils 13u, 13v, and 13w are formed. Even if the wire wire 20 is distributedly wound around the insulating member 12 in a state where tension is applied, the wire wire 20 and the insulating member 12 are not plastically deformed, and a predetermined motor performance is maintained.

  Furthermore, since the opening 18 opens in the inner peripheral surface 19 of the stator core 11, the slot 16 can be suitably used as a stator of an inner rotor type motor.

  The multi-phase coil 13 includes U-phase, V-phase, and W-phase three-phase coils 13u, 13v, and 13w. In the three-phase coil, the coil end portion 17 of the two-phase coil 13 is arranged in the radial direction. Since the wire wires 20 are wound around the plurality of slots 16 so as to be lined up, the amount of coils can be reduced, and coil efficiency and copper loss can be suppressed to improve motor efficiency. In addition, the motor weight can be reduced and the motor size can be reduced.

  Further, the wire wire 20 is inserted into the first slot 16a from one end side in the axial direction of the stator core 11 to the other end side, and the wire wire 20 drawn from the first slot 16a is tensioned in the first state. Then, the stator core 11 is rotated to the position of the second slot 16b through which the wire 20 is next inserted, and is held radially outward of the second slot 16b. Next, the wire wire 20 is inserted into the second slot 16b in the direction opposite to the previous direction and held in the radially outward direction of the second slot 16b in a state where tension is applied, and then the stator core 11 and the wire wire 20 are Next, it is rotated to the position of the third slot 16 to be inserted and held outside in the radial direction of the third slot 16. Since the above process is repeated, the coil ends 17 of the two-phase coil 13 can be wound in a plurality of slots 16 so that the wire ends 20 are arranged in the radial direction while applying tension to the wire 20. Thus, the racing process, the varnish process, and the like can be eliminated or simplified to simplify the manufacturing process, and the coil resistance and copper loss can be suppressed to improve the motor efficiency. Further, the motor weight can be reduced and the motor size can be reduced.

  Table 1 shows a comparison between the stator of the motor according to the present invention manufactured by the method shown in FIG. 7A and the stator of the motor manufactured by the conventional method shown in FIG. Each item is expressed as a ratio when the value of the conventional stator is 100.

  As shown in Table 1, in the motor stator according to the present invention, the wire weight is reduced to 87% and the copper loss is reduced to 94% as compared with the conventional stator. Thereby, the total weight of the motor is reduced and the motor efficiency is improved. Moreover, since the cross-sectional area of the coil end portion was 85% and the height of the coil end portion was low, the motor size was also small, and the space factor was 45%. Furthermore, since the wire wire is disposed in the resin insulating member in a state where tension is applied, the coil is sufficiently fixed without performing a lacing process or a varnish process.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, in the above-described embodiment, the stator of the motor in which the wire wire is distributedly wound by wave winding has been described. However, the present invention is not limited to this, and for example, the stator of the motor to be wound in layers is used. Can also be applied.
In the above embodiment, the wire wire is wound with each of the two slots arranged in the circumferential direction straddling the four slots as a slot for the in-phase coil, but in the circumferential direction across the slots for the other phases. Any wire can be wound as long as a predetermined number of the slots are wound around the slots for the in-phase coil. For example, each slot across two slots is wound around the slots for the in-phase coil. You may turn.

10 Motor Stator 11 Stator Core 12 Insulating Member (Resin Member)
13 coil 13u U-phase coil 13v V-phase coil 13w W-phase coil 16 slot 16a first slot 16b second slot 17 coil end part 17u U-phase coil end part 17v V-phase coil end part 17w W-phase coil end part 18 opening Part 19 Inner peripheral surface 20 of stator core Wire wire

Claims (7)

A method for manufacturing a stator of a motor, wherein a plurality of coils are formed by winding wire wires made of a plurality of strands in a plurality of slots formed in a stator core with a predetermined number of slots distributedly wound. ,
Disposing an insulating member for electrically insulating the stator core and the wire in the plurality of slots;
A step of distributedly winding the wire in the plurality of slots while applying tension to the wire so as to physically fix the stator core, the insulating member, and the coil;
The manufacturing method of the stator of the motor characterized by the above-mentioned.   The method for manufacturing a stator of a motor according to claim 1, wherein the coil end portions of the coils are alternately arranged on the stator core in units of the number of windings of each phase.   The method for manufacturing a motor stator according to claim 1, wherein the insulating member is a resin member having elasticity.   4. The motor according to claim 1, wherein the tension of the wire line is equal to or less than an elastic allowable stress of the wire line and / or an allowable compressive strength of the insulating member. 5. Method of manufacturing the stator.   5. The method of manufacturing a stator of a motor according to claim 1, wherein an opening of the slot opens on an inner diameter surface of the stator core. 6. The multi-phase coil is composed of a three-phase coil of U phase, V phase, and W phase,
The three-phase coil is formed by wave-wrapping the wire wire around the plurality of slots so that coil end portions of the two-phase coil are arranged in a radial direction. 6. A method for manufacturing a motor stator according to claim 5. The distributed winding step
Inserting the wire into the insulating member of the first slot from the one axial end of the stator core toward the other end;
On the other end side in the axial direction of the stator core, holding the wire wire drawn out from the first slot outside the first slot in a state where tension is applied to the wire wire; and
Rotating the stator core together with the wire wire by a predetermined angle to a second slot position through which the wire wire is next inserted;
Holding the wire wire radially outward of the second slot at the other axial end of the stator core;
Inserting the wire into the insulating member of the second slot from the other axial end of the stator core toward one end;
Holding the wire wire drawn out from the second slot on one end side in the axial direction of the stator core outside the second slot in a state of applying tension to the wire wire; and
Rotating the stator core together with the wire wire by a predetermined angle to a third slot position where the wire wire is next inserted;
Holding the wire wire radially outward of the third slot at one axial end of the stator core; and
The method of manufacturing a motor stator according to claim 1, wherein the steps are repeated.

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