JP2011234504A - 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 capable of eliminating or simplifying a lacing process, a varnish treatment, etc.SOLUTION: In the method for manufacturing stator of motor 10, a wire 20 is wound around multiple slots 16 which are formed on a stator core 11 by distributed winding with a space of the predetermined slot number to form a coil 13 which has multiple phases, and the wire 20 is configured by a single wire. The method comprises: steps of: arranging an insulation member 12 which electrically insulates the stator core 11 from the wire 20, at the multiple slots 16; winding the wire 20 around the multiple slots 16 by distributed winding; and arranging the wire 20 inside the insulation member 12 in a state that a tension is applied, to fix the stator core 11, the insulation member 12 and the coil 13 physically.

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 addition, a single wire having high bending rigidity is also manufactured by previously forming a plurality of divided wires into a predetermined shape and bonding them together. Further, in the stator of the motor, in order to ensure insulation between the stator core and the wire wire and insulation between the different-phase coils, an insulating member such as insulating paper is used between the stator core and the wire wire or between the different-phase wires. An insulation distance is secured by inserting between lines (for example, refer to Patent Document 1).

  FIG. 24 is a cross-sectional view of a main part of the stator described in Patent Document 1 and a perspective view showing a manufacturing method. The stator 1 has a cylindrical shape in which end portions of sheet-like electrical insulating members 2 are overlapped with each other and placed in a slot 4 formed in the stator core 3, and then a segment 5 formed in a U-shape in advance. Is inserted into the tubular electrical insulating member 2, and the distal ends of the segments 5 are bent to the opposite sides in the circumferential direction and joined to the distal ends of the other segments 5.

Japanese Patent Laid-Open No. 2000-14068

  However, in the stator 1 described in Patent Document 1, since the electric insulating member 2, the stator core 3, and the wire wire (segment 5) are fixed only by their frictional forces, the fixing force is not always sufficient. It wasn't. For this reason, after winding a wire wire, a lacing process, a varnish process, etc. are needed, and many man-hours were required for stator preparation, and there existed a problem which cost increased. Moreover, since the electrical insulating member 2 is a sheet-like member, the wire wire is wound loosely without applying a large force so that dielectric breakdown does not occur. As a result, there has been a problem that the length of the wire is longer than necessary and affects the motor efficiency.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a method of manufacturing a stator of a motor that can eliminate or simplify racing processing, varnish processing, and the like.

To achieve the above object, the invention according to claim 1 is directed to a plurality of slots (for example, slots 16 in the embodiments described later) formed in a stator core (for example, stator core 11 in the embodiments described later). Manufacture of a stator of a motor (for example, a stator 10 of a motor in an embodiment described later) which is distributedly wound with a predetermined number of slots to form a multi-phase coil (for example, a coil 13 in an embodiment described later). A method,
The wire wire is composed of a single wire (for example, wire wires 20 and 20A in the embodiments 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;
Distributedly winding the wire in the plurality of slots, and
The wire wire is disposed in the insulating member in a state where a tension is applied, thereby physically fixing the stator core, the insulating member, and the coil.

In the invention according to claim 2, in addition to the configuration of claim 1, the step of distributedly winding the wire line includes:
Inserting the plurality of wire wires formed into a substantially U shape in advance into the slot;
Bending the tip of the wire wire inserted into the slot (e.g., the tip 21 in an embodiment described later) in the circumferential direction of the stator core to apply tension to the wire wire;
Bonding the tips of the wire wires in phase with each other.

  In the invention according to claim 3, in addition to the configuration of claim 1 or claim 2, the coil end portion of the coil (for example, the coil end portion 17 in the embodiment described later) is a unit of the number of turns of each phase. It is characterized by being alternately arranged on the stator core.

According to a fourth aspect of the present invention, in addition to the configuration of the third aspect, the coil includes a U-phase, V-phase, and W-phase three-phase coil (for example, a U-phase coil 13u and a V-phase coil in an embodiment described later). 13v, W-phase coil 13w)
The three-phase coil is formed by wrapping the wire wire around the plurality of slots so that the coil end portions of the two-phase coil are arranged in the radial direction.

  According to a fifth aspect of the present invention, in addition to the structure of any one of the first to fourth aspects, the single wire includes an inorganic particle (for example, an inorganic particle 42 in an embodiment described later) made of a resin (for example, an after-mentioned one). It is characterized by being coated with a composite insulating film (for example, a composite insulating film 41A in an embodiment described later) dispersed in the resin 43) in the embodiment.

  The invention according to claim 6 is characterized in that, in addition to the structure of any one of claims 1 to 4, the single wire is covered with an inorganic insulating film.

  According to a seventh aspect of the invention, in addition to the structure of any of the first to sixth aspects, the insulating member is an elastic resin member (for example, an insulating member 12 in an embodiment described later). Features.

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

  In the invention according to claim 9, in addition to the structure of any one of claims 1 to 8, the slot has an opening (for example, an opening 18 in an embodiment to be described later) having an inner diameter surface of the stator core (for example, An opening is formed in an inner peripheral surface 19) in an embodiment described later.

  According to a tenth aspect of the present invention, in addition to the structure of any one of the first to ninth aspects, the wire wire has a flat single wire (for example, described later) having a different cross-sectional shape for each winding number and a constant cross-sectional area. It is a wire wire 20A) in the embodiment.

  According to the first aspect of the invention, the racing process, the varnish process, and the like can be eliminated or simplified, the manufacturing process can be simplified, and the manufacturing cost of the motor stator is suppressed.

  According to invention of Claim 2, even if it uses the wire wire which consists of a single wire with high bending rigidity, a coil can be manufactured easily.

  According to the invention of claim 3, the amount of coils can be reduced, and coil efficiency and copper loss can be suppressed to improve motor efficiency. Further, the motor weight can be reduced and the motor size can be reduced.

  According to the invention of claim 4, it is possible to reduce the coil amount, and it is possible to improve the motor efficiency by suppressing coil resistance and copper loss. In addition, the motor weight can be reduced and the motor size can be reduced.

  According to the invention of claim 5, even if a discharge phenomenon occurs between the different phase wire wires of the coil, for example, the deterioration of the insulating coating can be suppressed, and the insulation life can be extended.

  According to invention of Claim 6, the tolerance with respect to the discharge of an insulating film can be improved, and the insulation lifetime is prolonged.

  According to the seventh aspect of the present invention, when a multi-phase coil is formed, 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 8, when forming a coil of a plurality of phases, even if the wire wire is disposed on the insulating member in a state where tension is applied, the wire wire or the insulating member does not plastically deform, Motor performance is maintained.

  According to invention of Claim 9, it can be used conveniently as a stator of an inner rotor type motor.

  According to the invention of claim 10, since the wire wire is a flat single wire with a different cross-sectional shape for each number of windings and a constant cross-sectional area, the wire wire is aligned so that the gap in the slot is the minimum gap. It can arrange | position and can raise a space factor and can improve motor efficiency.

It is a principal part expansion perspective view of the stator of the motor manufactured by the manufacturing method which concerns on this invention. It is a schematic diagram which shows the winding state of the wire wire of the stator of the motor manufactured by the manufacturing method of 1st Embodiment. 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) And (b) is sectional drawing which shows the state of the wire wire from which cross-sectional area inserted in the slot differs. It is a graph which shows the relationship between a wire diameter in case insulation film thickness is the same, and an insulation film ratio. It is a graph which shows the relationship between the insulation film thickness based on Dakin's formula, and PDIV (partial discharge start voltage). It is sectional drawing of the single wire covered with the insulating film. It is sectional drawing of the single wire with which the inorganic particle was coat | covered with the composite insulating film formed by disperse | distributing in resin. (A) is a manufacturing process figure which shows the manufacturing method of the stator of the motor which concerns on 1st Embodiment, (b) is a manufacturing process figure which shows the conventional manufacturing method. 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. 13 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 schematic diagram which shows the winding state of the wire wire of the stator of the motor manufactured by the manufacturing method of 2nd Embodiment. It is a manufacturing process figure which shows the manufacturing method of the stator of the motor which concerns on 2nd Embodiment. It is a perspective view of the divided | segmented single wire. It is the schematic diagram of the state by which the divided | segmented single wire was inserted in the slot. It is a schematic diagram of the state by which the wire line of FIG. 20 was bent. It is the elements on larger scale of the stator seen from the inner diameter side explaining axial fixation at the time of bending a wire. It is sectional drawing which shows the state by which the several single wire with different cross-sectional shape was inserted in the slot with the minimum clearance gap. (A) is principal part sectional drawing of the conventional stator, (b) is a principal part perspective view which shows the manufacturing process of this stator.

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

(First embodiment)
As shown in FIG. 1, the stator 10 of the motor manufactured by the manufacturing method according to the first embodiment of the present invention is a three-phase eight-pole distributed winding stator, and includes a stator core 11, an insulating member 12, 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. The opening 18 of the slot 16 is open 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.

  The U-phase coil 13u, the V-phase coil 13v, and the W-phase coil 13w are formed by inserting a wire 20 made of a single wire as a conductor into a predetermined slot 16 and winding it 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 is a double slot type stator, and two wire wires 20 of each phase are connected to two adjacent in-phase slots 16 (U-phase slots 16 u of the stator core 11). , V-phase slot 16v and W-phase slot 16w) are distributed by wave winding. The slots 16 are repeatedly arranged in the order of the U-phase slot 16u, the V-phase slot 16v, and the W-phase slot 16w in the circumferential direction of the stator core 11 (from the right side to the left side in FIG. 2).

  Specifically, first, the two wire wires 20 constituting the U-phase coil 13u are respectively connected to the 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 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, respectively, 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, the two 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 17v of the U-phase coil 13u and the V-phase coil 13v intersect each other is defined as the W-phase coil 13w. Coil end portion 17w 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 shows 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. The same applies to the subsequent turns (between the (n-1) th turn and the nth turn).

  For this reason, the coil end portion 17u is formed by being slightly displaced outward in the radial direction every turn, and a radial clearance is secured. 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. Here, being physically fixed by tension means a state in which the relative positional relationship between the stator core 11, the insulating member 12, and the phase coils 13 hardly moves due to tension. Therefore, it is sufficient to abolish the lacing process and the varnish process, which have been performed with the conventional stator, and to perform a simple fusion heat treatment using a self-bonding line as necessary.

  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 arranged in each slot 16 via the insulating member 12, and the coil end portions 17u, 17v, 17w of the U, V, W phase are as shown in FIG. Since the coils are alternately arranged in the radial direction of the stator core 11 in units of the number of windings, when the coils of other phases are wound, the coils of the already wound phases do not get in the way, and the coil 13 is not occupied. Winding can be performed with the volume factor S increased, and the space factor S of the stator 10 can be 40% or more, and approximately 55% in FIG. Further, the wire 20 has a substantially rectangular cross section having a width substantially equal to the circumferential gap T of the insulating member 12 in the slot 16. For this reason, the wire wires 20 can be arranged in the slot 16 without gaps, and the space factor S is further improved. Here, the space factor S, as shown in FIG. 6, is the sum of the cross-sectional areas S1 of the electrical conductor portions 20b excluding the insulating coating 20a from the wire 20 inserted into the slot 16, and the slot 16 Is defined as a ratio to the cross-sectional area S2.

  The cross-sectional shape of the wire 20 is not limited to that shown in FIG. 5, but may have a circular cross-section as shown in FIGS. 7 (a) and 7 (b). Referring to FIGS. 7A and 7B, when the thin wire wire 20 inserted into the slot 16 is compared with the large wire wire 20, the space factor S appears to be a small wire. Although the wire 20 seems to be higher, as shown in FIG. 8 showing the relationship between the wire diameter and the insulating film ratio when the insulation film thickness is the same, the insulation film 41 is cut off as the wire diameter increases. The area ratio is reduced, and the space factor S is advantageous. Further, in the case of the same space factor, by increasing the thickness of the conductive wire 40 that is a single wire, the film thickness of the insulating coating 41 can be increased, and there is an advantage that the insulating performance is improved. Furthermore, the gap in the slot 16 can be made smaller in the wire wire 20 having the rectangular cross section shown in FIG. 5 than in the wire wire 20 having the circular cross section shown in FIG.

  Moreover, although the enamel coating about 40-50 micrometers in thickness is given and insulated by the normal wire wire, the voltage which can be used with an enamel-coated electric wire is generally said to be 500 V or less, When the voltage is 500 V or higher, partial discharge is started and insulation deterioration may occur. In the case of an electric vehicle motor whose voltage is increasing, a withstand voltage of about 1000 V is required in consideration of a surge voltage. For this reason, it may be possible to insulate the phases by arranging insulating paper between the wire wires 20 of the respective phase coils 13u, 13v, 13w. However, an insulating paper insertion step is required when the stator 10 is manufactured. There is a problem that the work becomes complicated.

  FIG. 9 is a graph showing the relationship between the insulation film thickness based on Dakin's equation and PDIV (partial discharge start voltage (withstand voltage)). From this graph, the insulation film thickness is approximately 110 μm to make PDIV 1000V. It turns out that it is necessary. Therefore, as shown in FIG. 10, an insulating coating 41 such as an enamel coating having a thickness of 110 μm or more is baked on the wire 20 as an insulating coating of the wire 20, so that the conductor between the conductive wires 40 is formed by the insulating coating 41 of 220 μm. A distance can be secured. Accordingly, partial discharge can be suppressed only by the insulating coating 41 of the wire wire 20 without arranging insulating paper or the like between the wire wires 20 to insulate the phases, and manufacture of the coil 13 is facilitated. As the insulating coating 41, an insulating tape or an insulating film having the same performance as the enamel coating may be wound to a thickness of 110 μm or more.

  Further, as shown in FIG. 11, a composite insulating film 41A can be used as the insulating film. In the composite insulating coating 41 </ b> A, the inorganic particles 42 are dispersed in the resin 43, and the deterioration rate of the insulating performance due to partial discharge is suppressed by the inorganic particles 42, so that the insulation life can be extended. In addition, an inorganic insulating film having high discharge resistance may be used as the insulating film. As the inorganic insulating film, an inorganic material such as glass, mica, nomex, and kapton can be formed in a tape shape or a film shape, and the conductor (single wire) 40 is directly or enameled. It is covered by being wound around the conductive wire 40.

  Next, a method for manufacturing the motor stator 10 according to this embodiment will be described with reference to FIGS. FIG. 12 is a manufacturing process diagram comparing the manufacturing process (a) of the motor stator according to the present invention and the conventional manufacturing process (b). As shown in FIG. According to this manufacturing method, after assembling an insulating member in each slot of the stator core (iron core) (step S1), the wire wire divided through the insulating member is inserted into the stator core (step S2), and the divided wire wire Next, a bending process is performed (step S3), and then the joining process between the ends of the adjacent divided wire lines 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, the method for manufacturing the stator of the motor according to the present invention includes a step of assembling the insulating member 12 in each slot 16 of the stator core (iron core) 11 (step S11), as shown in FIG. The process can be shortened to a two-step process including the step of winding the wire 20 around the stator core 11 via the insulating member 12 (step S12), and the manufacturing time can be greatly reduced along with the reduction of materials. Cost can be suppressed. If the wire 20 is a self-bonding wire to which a resin that can be bonded by heat treatment is applied, the wire wire 20 is simply fixed by a heat treatment step (step S13), so that the coil Immobilization can be simplified.

  Specifically, as shown in FIG. 13 and FIG. 14, the stator core 11 is horizontally disposed, and three nozzles 31 for U, V, and W phases that discharge two wire wires 20 respectively, and a predetermined position. The wire wire 20 is wound around the stator core 11 by the plurality of hooks 32 that hold the wire wire 20.

  The nozzle 31 includes a U-phase nozzle 31u that discharges the two wire wires 20 constituting the U-phase coil 13u, a V-phase nozzle 31v that discharges the two wire wires 20 constituting the V-phase coil, and a W-phase coil. And a W-phase nozzle 31w that discharges two wire wires 20 constituting 13w, and is arranged on the inner diameter side of the stator core 11. Each phase nozzle 31u, 31v, 31w is guided by the nozzle guide rail 30 while discharging the two 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. 15A, a specific process of winding the wire 20 around the stator core 11 (wave winding) is performed by connecting the two wire wires 20 from one axial end side (lower end in the drawing) of the stator core 11. 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. 15 (b)), and the tension is applied to the wire wire 20 in the first slot 16a. (Fig. 15 (c)).

  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.15 (d)). Here, the wire wire 20 is held radially outward of the second slot 16b (FIG. 15E), and the wire wire 20 is moved from the other axial end side (upper side) of the stator core 11 to one end side (lower side). ) Through the second slot 16b through the insulating member 12 (FIG. 15 (f)).

  Thereafter, similarly, as shown in FIG. 16, 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 to a position of a third slot (not shown) through which the wire wire 20 is next inserted. Move. The wire 20 discharged from the nozzle 31 and arranged along the outer peripheral side of the stator core 11 is held by the hook 32 on the outer side in the radial direction of the third slot. 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 from the plurality of slots 16 is disposed, the single wire By applying the wire wire 20 to the plurality of slots 16 while applying tension to the wire wire 20 which is a wire, the wire wire 20 is disposed in the insulating member 12 in a state where the tension is applied. As a result, the stator core 11, the insulating member 12, and the coil 13 are physically fixed, the racing process and the varnish process can be eliminated or simplified, the manufacturing process can be simplified, and the stator of the motor. The manufacturing cost of 10 is suppressed.

  In addition, since the coil end portions 17 of the coil 13 are alternately arranged on the stator core 11 in units of the number of turns of each phase, the coil amount can be reduced, and coil efficiency and copper loss can be suppressed to improve motor efficiency. it can. Further, the motor weight can be reduced and the motor size can be reduced.

  Further, the multi-phase coil 13 is composed of a U-phase, V-phase, and W-phase three-phase coil, and the three-phase coil is a wire so that the coil end portions 17 of the two-phase coil 13 are arranged in the radial direction. Since the wire 20 is wound around the plurality of slots 16, the amount of coils can be reduced, and the motor efficiency can be improved by suppressing coil resistance and copper loss. In addition, 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, even when the wire wire 20 is distributed and wound around the insulating member 12 in a state where tension is applied when the multi-phase coil 13 is formed, the wire wire 20 is not wound. There is no risk of damage and the predetermined motor performance is maintained.

  In addition, since the tension of 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 wire 13 is subjected to tension when the multi-phase coil 13 is formed. Even if the wire 20 is distributedly wound around the insulating member 12, 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 the stator 10 of the inner rotor type motor.

(Second Embodiment)
Next, a method for manufacturing the stator of the motor according to the second embodiment of the present invention will be described.
FIG. 17 is a schematic view showing a winding state of a wire wire of a stator of a motor manufactured by the manufacturing method of the second embodiment. In the second embodiment, the ends of single-wire wires 20A divided in advance are joined (connected) to form the coils 13 of each phase, and one end side or the other end of the stator core 11 in the axial direction. Except for the joint part 23 on the side, it has the same configuration as the stator of the motor manufactured by the manufacturing method of the first embodiment. Therefore, the same parts as those of the stator 10 of the motor manufactured by the manufacturing method of the first embodiment are denoted by the same reference numerals or the corresponding symbols, and the description thereof is omitted, and the manufacturing method of the present embodiment will be described in detail.

  As shown in FIG. 18, the method for manufacturing the stator 10 of the motor according to the present embodiment includes a step of assembling the insulating member 12 in each slot 16 of the stator core (iron core) 11 (step S <b> 21), The step of inserting the stator core 11 into the separated wire 20A (step S22), the step of bending the divided wire 20A (step S23), and the ends of the adjacent in-phase divided wire 20A The step of performing the bonding process (step S24) can be shortened to a four-step process, and the production time can be greatly reduced along with the reduction of materials, and the production cost can be suppressed. If the wire 20A is a self-bonded wire or the like to which a resin that can be bonded by heat treatment is applied, the wire 20 is simply fixed by a heat treatment step (step S25), so that the coil Immobilization can be simplified.

  Specifically, first, a plurality of wire wires 20A formed in advance in a substantially U shape shown in FIG. 19 and having coil end portions 17 having different displacement amounts radially outward for each number of windings are shown in FIG. As shown, the stator core 11 is inserted through the insulating member 12 into two sets of U-phase slots 16 u arranged with the two V-phase slots 16 v and the W-phase slots 16 w interposed therebetween, for example. Subsequently, as shown by an arrow in FIG. 20, one end side of the wire 20A is bent to one side in the circumferential direction, and the other end side is bent to the other side in the circumferential direction. The tips 21 of the matching wire 20A are arranged close to each other.

  At this time, as shown in FIG. 5, the wire 20 </ b> A has a width substantially equal to the circumferential gap T of the insulating member 12 in the slot 16, and is thus fixed in the circumferential direction by the insulating member 12. At the same time, as shown in FIG. 22, the coil end portion 17 formed in advance is fixed in the axial direction by engaging with the insulating member 12. That is, by bending the wire wire 20 </ b> A, a tension is applied to the wire wire 20 </ b> A and the wire wire 20 </ b> A is physically fixed to the stator core 11. And the 1st turn 13u1 of the U-phase coil 13u is formed by joining the front-end | tips 21 of the wire wire 20A used as an in-phase, and forming the junction part 23. FIG.

  By winding the V-phase coil 13v and the W-phase coil 13w in the same manner, a first turn 13v1 of the V-phase coil 13v and a first turn 13w1 of the W-phase coil 13w are formed. 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,. The coils are wound around the stator core 11 in this order, and finally, as shown in FIG. 1, three coils 13 of a U-phase coil 13u, a V-phase coil 13v, and a W-phase coil 13w are alternately wound on the stator core 11 in units of the number of windings. Placed in.

  Also in the motor stator 10 formed in this way, when the wire wire 20A is formed in a substantially U shape in advance, the coil end portion 17 having a different amount of displacement is formed radially outward for each winding number. A gap into which the coil end portion 17 of the other phase can be inserted is formed between the coil end portions 17 of the first turn and the second turn. Further, each phase of the wire wire 20A is disposed in the insulating member 12 in a state where tension is applied, so that the stator core 11, the insulating member 12, and the phase coils 13u, 13v, 13w are connected to the wire wire 20. It is physically fixed by tension and can eliminate or simplify lacing and varnishing.

  FIG. 23 is a cross-sectional view showing a state in which a plurality of single wire wires having different cross-sectional shapes are inserted into the slots. According to the present embodiment, as shown in FIG. 23, a plurality of wire wires 20 </ b> A having different widths for each number of turns using the insulating member 12 having a uniform thickness in the circumferential direction in accordance with the circumferential width of the slot 16. By winding the stator core 11 using a single wire), the gap between the slot 16 and the wire 20A can be minimized, and the space factor S can be further improved.

  Each wire 20A desirably has a constant cross-sectional area of the conductive wire 40 even if the cross-sectional shape is different so that the electric resistance of each turn is constant in order to prevent reduction in motor efficiency. Moreover, although the cross-sectional shape of the conductive wire 40 can be made into arbitrary shapes, in order to raise the space factor S, it is good to make the cross-sectional shape of the conductive wire 40 into a rectangular shape.

  As described above, according to the method of manufacturing the motor stator 10 according to the present embodiment, the coil 13 inserts the plurality of wire wires 20 </ b> A in which the single wire is formed into a substantially U shape into the slot 16, and the wire Since the wire wire 20A is tensioned by bending the tip of the wire 20A so that the wire wire 20A is placed in the tension member, the stator core 11, the insulation member 12, and Each of the coils 13 can be physically fixed, thereby eliminating or simplifying the lacing process, the varnish process, and the like, thereby simplifying the manufacturing process and reducing the manufacturing cost of the motor stator 10. It is suppressed.

  Further, according to the method for manufacturing the stator 10 of the motor according to the present embodiment, the coil 13 inserts a plurality of wire wires 20A in which a single wire is formed into a substantially U shape into the slot 16, and the tip of the wire wire 20A. Since the two wires 21 are joined to each other, the coil can be easily manufactured using the wire wire 20A made of a single wire having high bending rigidity.

  Further, since the conductive wire 40 has a constant cross-sectional area and a different cross-sectional shape for each winding, the wire wire 20 can be arranged and arranged so that the gap in the slot 16 is the minimum gap, and the space factor is increased. S can be increased and motor efficiency can be improved.

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-described embodiment, the wire wire is wound with each of the two slots arranged in the circumferential direction straddling the four slots as the slot for the in-phase coil. The wire wire may be wound with the slot as the slot for the in-phase coil, and the wire wire is wound with the predetermined number of slots arranged in the circumferential direction across the slots for the other phase as slots for the in-phase coil. Also good.

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 17 Coil end portion 18 Opening portion 19 Inner circumferential surface 20, 20A of stator core Wire wire (single wire)
21 wire wire tip 23 joint 40 conductive wire 41 insulating coating 41A composite insulating coating 42 inorganic particle 43 resin T circumferential gap of insulating member

Claims (10)

A method of manufacturing a motor stator, wherein wire wires are distributedly wound with a predetermined number of slots in a plurality of slots formed in a stator core to form a multi-phase coil,
The wire is composed of a single wire;
Disposing an insulating member for electrically insulating the stator core and the wire in the plurality of slots;
Distributedly winding the wire in the plurality of slots, and
The stator of a motor characterized in that the stator core, the insulating member, and the coil are physically fixed by arranging the wire wire in the insulating member in a state where tension is applied. Manufacturing method. The step of distributed winding the wire wire,
Inserting the plurality of wire wires formed into a substantially U shape in advance into the slot;
Bending the tip of the wire line inserted into the slot in the circumferential direction of the stator core to apply tension to the wire line;
The method for manufacturing a stator of a motor according to claim 1, further comprising a step of joining tips of the wire wires in phase.   3. The method of manufacturing a stator of a motor according to claim 1, wherein coil end portions of the coils are alternately arranged on the stator core in units of the number of windings of each phase. The coil is composed of a three-phase coil of U phase, V phase, and W phase,
4. The three-phase coil is formed by wrapping the wire wire around the plurality of slots so that the coil end portions of the two-phase coil are arranged in a radial direction. Of manufacturing the stator of the motor.   The method of manufacturing a motor stator according to any one of claims 1 to 4, wherein the single wire is covered with a composite insulating film in which inorganic particles are dispersed in a resin.   The method for manufacturing a motor stator according to any one of claims 1 to 4, wherein the single wire is covered with an inorganic insulating coating.   The method for manufacturing a motor stator according to claim 1, wherein the insulating member is an elastic resin member.   The tension applied to 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. The manufacturing method of the stator of the motor of description.   The method for manufacturing a stator of a motor according to any one of claims 1 to 8, wherein the slot has an opening that opens on an inner diameter surface of the stator core.   The method for manufacturing a motor stator according to any one of claims 1 to 9, wherein the wire wire is a flat single wire having a different cross-sectional shape for each winding number and having a constant cross-sectional area. .

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