JP2012161148A - Method of manufacturing armature for rotary electric machine, and armature for rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To assure insulation between coils of different phase with ease and with sure, relating to an armature for rotary electric machine equipped with the coils of a plurality of phases, wound on an armature core by lap winding.SOLUTION: The method of manufacturing an armature equipped with a core in which the slots extending axially are distributed along circumferential direction, and a coil wound on the core by lap winding, includes an insulating member enclosing step S2 for enclosing a protruding part at a linear portion by inserting a pair of insulating members between a pair of linear portions of winding coil formed by circulating a linear conductor, a winding coil arrangement step S3 for arranging the winding coil in each slot of the core so that only one insert part among the pair of linear portions is inserted, a coil machining step S4 for collectively applying all winding coils with a process for deforming the protruding part by relatively moving the insert part of the pair of linear portions in circumferential direction, and an insert step S5 for inserting a non-insert part among the winding coils after machining into the slot.

Description

  The present invention relates to an armature core in which a plurality of slots extending in the axial direction of a cylindrical core reference surface are distributed in the circumferential direction of the core reference surface, and a plurality of phases wound around the armature core in an overlapping manner. The manufacturing method of the armature for rotary electric machines provided with the coil, and such an armature for rotary electric machines.

  As a method for manufacturing an armature for a rotating electrical machine as described above, for example, a technique described in Patent Document 1 below is known. Hereinafter, in the column of this background art, the member name and code | symbol of patent document 1 are quoted suitably in a parenthesis, and is demonstrated. The manufacturing method described in Patent Document 1 includes a step of forming a winding coil (coil 4131) by rotating a linear conductor (element wire 421) a plurality of times, and a portion (slot (slot)) facing the winding coil. 22) a step of bundling and fixing each of the portions disposed in the slot by an in-slot insulating member (insulating material 422), a step of inserting a part of a portion of the circulating coil that is bundled by the insulating member into the slot, A portion different from the slot insertion portion of the coil is collectively moved relative to the circumferential direction and inserted into another slot. According to such a manufacturing method, using the in-slot insulating member for ensuring the insulation between the coil and the armature core, the coil as a whole can have both the flexibility and the formability. The coil can be easily formed into a winding shape, and can be fixed so that the coil does not come loose after being inserted into the slot of the armature core.

  Generally, when a coil is wound in a slot by lap winding, coils in different phases overlap each other at a portion where the coil protrudes in the axial direction from the stator core (so-called coil end portion). It is necessary to ensure insulation between these different phase coils. However, in Patent Document 1, no special consideration is given in this regard. Although it is conceivable to provide an interphase insulating member between the different phase coils in the coil end portion in order to ensure the insulation between the different phase coils based on a general technique, the armature core manufactured by the manufacturing method described in Patent Document 1 is used. In a configuration in which multiple-phase coils are wound in an overlapping manner, the multiple-phase coils intersect in a complicated manner in a relatively narrow space at the coil end portion. It is very difficult to place.

JP 2009-195008 A

  Therefore, in an armature for a rotating electrical machine including a multi-phase coil wound around an armature core in a wrapping manner, it is desired to realize a technique that can easily and reliably ensure insulation between different-phase coils. .

  An armature core according to the present invention in which a plurality of slots extending in the axial direction of a cylindrical core reference surface are arranged in a distributed manner in the circumferential direction of the core reference surface, and a plurality of coils wound around the armature core in an overlapping manner. A characteristic configuration of a method for manufacturing an armature for a rotating electrical machine including a phase coil is formed by rotating a linear conductor one or more times on the same plane, and a pair of linear portions arranged in parallel. A connecting portion connecting the pair of linear portions at each of both ends in the extending direction of the linear portion, and a portion inserted into the slot in the linear portion is an insertion portion, and the armature Using a circular coil in which a portion protruding from the core is a protruding portion, and after inserting a pair of sheet-like insulating members into a linear gap between the pair of linear portions of the circular coil, the pair of linear shapes A pair of protrusions in each of the parts An insulating member surrounding step of surrounding each of the insulating members, and a state in which only one of the pair of linear portions is inserted into each of all the slots provided in the armature core; A rotating coil arrangement step of arranging a plurality of the rotating coils so that one of the pair of linear portions is inserted into one of the pair of linear portions inserted into the slot. A coil machining step in which the other insertion portion is relatively moved in the circumferential direction to deform at least the protruding portion in a lump for all the circumferential coils, and the entire circumferential coil after the machining is performed in the radial direction. And an insertion step of inserting the uninserted insertion portion into the slot.

  According to the above characteristic configuration, a plurality of circular coils having a pair of linear portions composed of an insertion portion and a projecting portion are used, and the armature core is overlapped through the circular coil arrangement step, the coil machining step, and the insertion step. An armature for a rotating electrical machine including a multi-phase coil wound by winding can be manufactured. At this time, in the coil processing step, all the processing of deforming the protruding portion by relatively moving the other insertion portion in the circumferential direction with respect to one insertion portion of the pair of linear portions inserted into the slot, Therefore, when the insertion process is completed, the protruding portions of the respective rotating coils are parallel and the same as the protruding portions of the rotating coils inserted in the slots adjacent to each other in a relatively narrow space. They are densely arranged so as to be aligned in the radial direction. Therefore, normally, it is very difficult to appropriately dispose the insulating member between the projecting portions constituting the coils of different phases so that the interphase insulation can be reliably performed. However, in the above characteristic configuration, in the insulating member surrounding step performed prior to the winding coil placement step, a pair of sheet-like insulating members inserted from the linear gap formed in the central portion of the winding coil, The protrusions in each of the linear portions are previously surrounded. Therefore, in the armature for a rotating electrical machine manufactured through the subsequent coil arrangement process, coil machining process, and insertion process, the insulating member is appropriately arranged at the site where interphase insulation is already required when the insertion process is completed. Will be. Therefore, in an armature for a rotating electrical machine including a multi-phase coil wound around an armature core in a wrapping manner, it is possible to provide a manufacturing method that can easily and reliably ensure insulation between different-phase coils. .

  Here, of the pair of insertion parts included in each of the circular coils, the insertion part arranged on one side in the radial direction in a state of being inserted into the slot is a first insertion part, and on the other side in the radial direction The insertion portion to be arranged is a second insertion portion, and the coil is the second insertion of the second circular coil different from the first insertion portion of the first circular coil and the first circular coil. Is a two-layer wound coil that is disposed adjacent to each other in the radial direction in one slot and in which no other insertion portion is disposed in the slot. In the insulating member surrounding step, One of the pair of inserted insulating members surrounds the one projecting portion of the pair of linear portions, is joined on the opposite side to the linear gap, and is inserted into the linear gap. The other side of the insulating member is a pair of the linear portions Wherein the said linear gap surrounding the projecting portion of it is preferable to configured to be joined on the opposite side.

  According to this configuration, in the insulating member surrounding step, the pair of insulating members inserted into the linear gap surrounds the protruding portions of the pair of linear portions and is joined to the opposite side of the linear gap, respectively. The Therefore, each of the pair of insulating members can be easily joined at a position where there is almost no spatial restriction on the outside of the coil on the plane where the linear conductors constituting each coil are arranged. In addition, each joint formed on the side opposite to the linear gap is finally divided on both sides in the radial direction with respect to the entire coil, and each of them is on the entire circumference toward one side in the radial direction or the other side in the radial direction. It will be arranged over. At this time, since the coil is a two-layer wound coil in which only the first insertion portion and the second insertion portion of the circular coils different from each other are arranged adjacent to each other in the radial direction in one slot, A joint portion arranged toward the other side in the radial direction does not interfere with a joint portion in another layer. Therefore, as described above, one of the pair of insulating members inserted into the linear gap surrounds the protruding portion in one of the pair of linear parts and is joined on the opposite side to the linear gap, The configuration including the insulating member surrounding step in which the other of the pair of inserted insulating members surrounds the protruding portion of the other of the pair of linear portions and is joined on the side opposite to the linear gap includes a two-layer wound coil It is particularly suitable for a method for manufacturing an armature for a rotating electrical machine.

  Further, the interval between the pair of linear portions of the circular coil is formed wider at the center portion than both ends in the extending direction of the linear portion, and the pair of insulating members are relatively connected by the connection member. It is preferable to adopt a configuration in which displacement is possible.

  According to this configuration, since the pair of insulating members are connected by the connecting member, the interval between the pair of insulating members is prevented from being widened, and the interval between the center portions of the pair of linear portions is increased. Suppressing downward sliding of the pair of insulating members with respect to the rotating coil is above the center of the pair of linear portions in the rotating coil formed in the middle bulging shape that is wider than the distance between the both ends in the direction of movement. be able to. Therefore, at the time after the insulating member surrounding process and before the coil processing process is completed, the protruding portion of the circulating coil can be formed without using a special jig or the like for holding the pair of insulating members. The state surrounded by the pair of insulating members can be appropriately maintained. Therefore, it is possible to facilitate the coil arrangement process and the coil machining process, and it is possible to more reliably ensure the insulation between the different-phase coils. Moreover, according to this structure, a pair of insulation member can be appropriately displaced relatively so that the deformation | transformation of the protrusion part in each of a pair of linear part may follow at the time of a coil processing process.

  An armature core according to the present invention in which a plurality of slots extending in the axial direction of a cylindrical core reference surface are arranged in a distributed manner in the circumferential direction of the core reference surface, and a plurality of coils wound around the armature core in an overlapping manner. And a coil of a phase, the characteristic configuration of the armature for a rotating electrical machine is that the coil is formed by joining a plurality of winding coils formed by rotating a linear conductor once or a plurality of times, and the winding coil Each including a pair of insertion portions arranged at different radial positions in the different slots, and a projection portion extending from the insertion portion and protruding in the axial direction from the armature core, Among the insertion portions, the insertion portion arranged on the radial first direction side that is one side in the radial direction is the first insertion portion, and the insertion portion arranged on the radial second direction side that is the other radial side Is the second insertion portion, and the protrusion is A first extending portion extending in the circumferential direction from the first inserting portion toward the second inserting portion, and from the second inserting portion on the radial second direction side with respect to the first extending portion, A second extending portion extending in the circumferential direction toward the first insertion portion; and a radial connecting portion connecting the first extending portion and the second extending portion in the radial direction, The first extending portions of the two orbiting coils into which the first insertion portions are inserted into the slots adjacent to each other are arranged adjacent to each other in parallel and at the same radial position, and adjacent to each other. The second extending portions of the two orbiting coils into which the second insertion portions are inserted into the slots are adjacently arranged so as to be parallel to each other and aligned at the same radial position, and the first extending portions of all the orbiting coils are arranged. Each of the existing portion and the second extending portion is a pair of sheet-like insulating members. Ri is surrounded, in that the pair of insulating members are connected to each other at a connecting member.

  According to this characteristic configuration, a pair of first insertion portions and second insertion portions disposed at different circumferential positions and different radial positions, and the first insertion portion and the second insertion portion extending in the circumferential direction and the radial direction. Are connected to each other, thereby forming an armature for a rotating electrical machine including a multi-phase coil wound around the armature core in an overlapping manner. At this time, in the above-described characteristic configuration, each of the first extending portion and the second extending portion of all the circular coils is surrounded by the sheet-like insulating member, so that they are arranged in parallel and at the same radial position. It is possible to appropriately insulate between the first extending portions arranged adjacent to each other and between the second extending portions arranged adjacently so as to be arranged in parallel and at the same radial position. Therefore, in an armature for a rotating electrical machine that includes a plurality of phases of coils wound around an armature core, it is possible to easily and reliably ensure insulation between different-phase coils.

  Further, in this characteristic configuration, a pair of insulating members surrounding the first extending portion and the second extending portion are connected to each other by the connecting member. Therefore, for example, a circular coil formed by rotating the linear conductor once or a plurality of times on the same plane is used, and the plurality of circular coils are partially inserted into the slots, and the uninserted portions are circumferentially arranged. When the armature for a rotating electrical machine is manufactured by relatively moving the first extending portion and the second extending portion constituting the rotating coil, the insulating member is surrounded by the insulating member in advance. Sliding can be suppressed. Therefore, manufacture of the armature for rotary electric machines can be facilitated.

It is a perspective view showing the whole composition of the stator concerning the embodiment of the present invention. It is a perspective view which shows the shape of the surrounding coil joined to each other based on embodiment of this invention. It is a flowchart which shows the procedure of the manufacturing method of the stator which concerns on embodiment of this invention. It is a perspective view which shows 1 aspect of the insulating member surrounding process which concerns on embodiment of this invention. It is a perspective view which shows 1 aspect of the insulating member surrounding process which concerns on embodiment of this invention. It is a perspective view which shows 1 aspect of the insulating member surrounding process which concerns on embodiment of this invention. It is a perspective view which shows 1 aspect of the insulating member surrounding process which concerns on embodiment of this invention. It is a perspective view which shows the surrounding coil arrangement | positioning process which concerns on embodiment of this invention. It is an expanded view which shows arrangement | positioning of the circumference coil in the circumference coil arrangement | positioning process which concerns on embodiment of this invention. It is a perspective view which shows the processing process which concerns on embodiment of this invention. It is an expanded view which shows arrangement | positioning of the surrounding coil in the manufacturing process which concerns on embodiment of this invention. It is sectional drawing which shows the surrounding aspect of the insulating member which concerns on other embodiment.

  An embodiment of an armature for a rotating electrical machine according to the present invention will be described with reference to the drawings. Here, the case where the armature for a rotating electrical machine according to the present invention is applied to the stator 1 of an inner rotor type rotating electrical machine will be described as an example. As shown in FIG. 1, the stator 1 according to the present embodiment includes a stator core 2 and a coil 3. The coils 3 are provided for a plurality of phases, and are wound around the stator core 2 by lap winding. And this stator 1 has the characteristics in the manufacturing method in order to implement | achieve the structure for ensuring the insulation between the coils 3 of a different phase easily. Hereinafter, the configuration of the stator 1 according to the present embodiment and the manufacturing method thereof will be described in detail. In the present embodiment, the stator 1 corresponds to the “armature for rotating electrical machine” in the present invention, and the stator core 2 corresponds to the “armature core” in the present invention.

  In the following description, unless otherwise specified, “axial direction L”, “circumferential direction C”, and “radial direction R” are defined with reference to the axial center of a cylindrical core reference surface 21 described later. . Further, in the following description, “first axial direction L1” represents the lower side along the axial direction L in FIG. 1, and “second axial direction L2” represents the upper side along the axial direction L in FIG. To do. In the following description, as shown in FIG. 1, the “circumferential first direction C1” is a timepiece viewed in the axial direction L from the second axial direction L2 side (when the stator 1 is viewed along the axial direction L). The “circumferential second direction C2” represents a counterclockwise direction as viewed in the axial direction L from the second axial direction L2 side. The “radially outward direction R1” represents a direction toward the outside of the radial direction R of the core reference surface 21, and corresponds to the “radial first direction” in the present invention. The “inner radial direction R2” represents a direction toward the inner side of the radial direction R of the core reference surface 21, and corresponds to the “second radial direction” in the present invention. In the following description, the directions of the coil 3 and the rotating coil 31 are defined as directions in a state where these are mounted on the stator core 2.

1. Overall Configuration of Stator The overall configuration of the stator 1 according to this embodiment will be described with reference to FIG. As shown in FIG. 1, the stator 1 includes a stator core 2 and a coil 3 and is configured as an armature for a rotating electrical machine. In this specification, “rotary electric machine” is used as a concept including a motor (electric motor), a generator (generator), and a motor / generator that performs both functions of the motor and the generator as necessary. Yes.

  The stator core 2 is formed using a magnetic material. The stator core 2 is formed, for example, as a laminated structure in which a plurality of annular plate-shaped electromagnetic steel plates are laminated, or a powder material formed by pressing a magnetic material, which is a magnetic material powder, as a main component. be able to. In the stator core 2, a plurality of slots 22 extending in the axial direction L of the cylindrical core reference surface 21 are distributed in the circumferential direction C of the core reference surface 21 so that the coil 3 can be wound.

  Here, the “cylindrical core reference surface 21” is a virtual surface that serves as a reference for the arrangement and configuration of the slots 22. In the present embodiment, as shown in FIG. 1, the core inner periphery is a virtual cylindrical surface including the end surface on the radially inner direction R2 side of the tooth 23 positioned between the slots 22 adjacent to each other in the circumferential direction C. A surface can be defined, and this cylindrical inner peripheral surface can be used as the “cylindrical core reference surface 21” in the present invention. Also, a cylindrical surface (imaginary surface) that is concentric with the inner circumferential surface of the cylindrical core and whose cross-sectional shape in the axial L view is similar to the sectional shape in the axial L view of the core inner circumferential surface. Can also be the “cylindrical core reference surface 21” in the present invention. For example, the outer peripheral surface of the stator core 2 excluding the mounting protrusion 24 provided for mounting to a case or the like may be the “cylindrical core reference surface 21”.

  The stator core 2 has a plurality (48 in this example) of slots 22 distributed in the circumferential direction C with respect to the core body. The plurality of slots 22 are equally distributed at predetermined circumferential intervals. In the present embodiment, the plurality of slots 22 have the same shape as each other, and are each formed in a groove shape extending in the axial direction L and the radial direction R and having a constant width in the circumferential direction C. Each slot 22 is formed so as to open in the radial direction R2 side (open in the inner peripheral surface of the core), and the stator core 2 according to the present embodiment has a so-called open slot type structure. Each slot 22 is also formed so as to open on both sides in the axial direction L of the stator core 2 (both end surfaces in the axial direction). As described above, the stator core 2 is formed with the plurality of slots 22 extending radially in the radial direction R from the axis of the stator core 2.

  In the present embodiment, the stator 1 is a stator used in a rotating electrical machine driven by three-phase alternating current (U phase, V phase, W phase). Therefore, the U-phase, V-phase, and W-phase slots 22 are arranged in the stator core 2 so as to repeatedly appear along the circumferential direction C. In this example, the stator core 2 has two slots 22 adjacent to each other for the U phase and two slots 22 adjacent to each other for the V phase so that the number of slots per pole per phase is “2”. And two adjacent slots 22 for the W phase are formed so as to repeatedly appear along the circumferential direction C in the order described. The coil 3 is also divided into three phases (U phase, V phase, W phase). Note that the number of slots per phase per pole and the number of phases of the AC power source that drives the rotating electrical machine can be appropriately changed.

  In the present embodiment, the coils of each phase included in the coil 3 have the same configuration. Therefore, in the following description, the coils for each phase will be described without distinction unless necessary. In the present embodiment, the coil 3 is wound around the stator core 2 by lap winding. Further, as will be described later, the coil 3 is configured by joining a plurality of winding coils 31.

  In addition, a rotor as a field magnet including a permanent magnet and an electromagnet is disposed on the inner radial direction R2 side of the stator 1 (stator core 2) so as to be rotatable relative to the stator 1 (not shown). Then, the rotor is rotated by the rotating magnetic field generated from the stator 1. That is, the stator 1 according to the present embodiment is an inner rotor type rotating field type stator for a rotating electrical machine.

2. Configuration of Circulating Coil Next, a plurality of circulating coils 31 constituting the coil 3 will be described. The circular coil 31 is a divided coil corresponding to the coil 3 of each phase divided into a plurality of parts. In FIG. 2, one of the winding coils 31 is extracted and shown in FIG. As shown in FIG. 2, the circular coil 31 is formed by rotating one linear conductor a plurality of times (in this example, five times). The circling coil 31 is formed in a hexagonal shape as a whole. In this embodiment, the circular coil 31 is configured by a linear conductor having a rectangular cross section perpendicular to the extending direction (equal to the energizing direction). Further, the coil 31 has basically the same cross-sectional shape regardless of the position in the extending direction except for the bent portions 61 to 64. The material constituting this linear conductor can be, for example, copper or aluminum. The surface of the linear conductor is covered with an insulating film made of resin or the like (for example, enamel or polyimide) except for a part of the connection end portion 56 and the like.

  Each of the circular coils 31 includes a pair of insertion portions 4 disposed in the slot 22 and a protrusion portion 5 extending from the insertion portion 4 and protruding in the axial direction L from the stator core 2. Here, in this embodiment, the linear coil 31 is formed by rotating the linear conductor a plurality of times (in this example, five times), so that each of the pair of insertion portions 4 is parallel to each other along the axial direction L. In addition, it is an aggregate of a plurality (five in this example) of conductor portions arranged adjacent to each other in a line in the radial direction R. In the present example, each conductor portion constituting the insertion portion 4 out of one linear conductor is referred to as an “insertion conductor portion”. The protrusions 5 are aggregates of a plurality (five in this example) of conductor portions arranged adjacent to each other in parallel with each other along the axial direction L and in a line in the radial direction R. In this example, each conductor part which comprises the protrusion part 5 among one linear conductor is called a "protrusion conductor part." In addition, when the linear conductor which comprises the winding coil 31 is extended in one linear form, an insertion conductor part and a protrusion conductor part appear alternately at predetermined intervals.

  Each of the insertion conductor portions constituting the insertion portion 4 has a shape that matches the shape of the slot 22 of the stator core 2. Here, the insertion conductor portion is formed in a straight line extending in parallel with the axial direction L, as shown in FIGS. Further, as shown in FIG. 9A and the like, the insertion conductor portion has a short side in a rectangular cross section orthogonal to the extending direction of the linear conductor parallel to the radial direction R and a long side parallel to the circumferential direction C. Is arranged in the slot 22 in such a direction. The set of five insertion conductor portions are arranged adjacent to each other in the radial direction R in the slot 22. Therefore, the insertion portion 4 is formed in a rectangular parallelepiped shape extending in parallel with the axial direction L while having a predetermined width in the radial direction R as a whole.

  The pair of insertion portions 4 are disposed at different radial R positions in different slots 22. In the present embodiment, of the pair of insertion portions 4 included in each of the circular coils 31, the insertion portion 4 disposed on the radially outward direction R <b> 1 side in a state of being inserted into the slot 22 is the first insertion portion 41. Further, the insertion portion 4 that is disposed on the radial inner side R2 side in the state of being inserted into the slot 22 on the circumferential second direction C2 side than the slot 22 into which the first insertion portion 41 is inserted is defined as the second insertion portion 42. The That is, all of the five insertion conductor portions constituting the first insertion portion 41 are arranged closer to the circumferential first direction C1 side and the radially outer direction R1 side than all of the five insertion conductor portions constituting the second insertion portion 42. Is done.

  The protrusions 5 are formed so as to extend from the pair of insertion portions 4 and protrude from the stator core 2 to both sides in the axial direction L. In this embodiment, the shape of the protrusions 5 on both sides in the axial direction L is basically the same except for the connection line 56 for connecting to the power line, the neutral point, or another circulating coil 31. (Symmetric with respect to a plane passing through the central portion of the stator core 2 in the axial direction L and orthogonal to the axial direction L). Therefore, in the following description, it will be described without distinguishing the protruding portions 5 on both sides in the axial direction L unless necessary.

  Each of the protruding conductor portions constituting the protruding portion 5 has a shape extending in the circumferential direction and the radial direction so as to connect the insertion conductor portions arranged at different radial R positions in different slots 22. ing. Accordingly, the projecting portion 5 as a whole is connected in the circumferential direction and the radial direction so as to connect the pair of first insertion portions 41 and the second insertion portions 42 arranged at different radial R positions in the different slots 22. It has an extending shape. In the present embodiment, the protruding portion 5 includes at least a first extending portion 51 and a second extending portion 52 that extend in the circumferential direction C, and a radial direction connecting portion 53 that extends at least in the radial direction R. Yes.

  The first extending portion 51 is a portion of the protruding portion 5 that extends in the circumferential direction C from the first insertion portion 41 toward the second insertion portion 42 side. The first extending portion 51 has a circumferential second direction C2 side (second inserting portion 42 side) from the first inserting portion 41 to the first bent portion 61 on the radially outward direction R1 side with respect to the second extending portion 52. ) To extend in a rectangular parallelepiped shape as a whole. Further, the first extending portion 51 extends from the insertion portion 4 so as to gradually move away from the axial L end surface of the stator core 2 as the direction toward the second circumferential direction C2 (the protruding height from the stator core 2 increases). It is formed so as to extend while being inclined in the circumferential direction C with respect to the existing direction (axial direction L).

  The second extending portion 52 is a portion of the projecting portion 5 that extends in the circumferential direction C from the second insertion portion 42 toward the first insertion portion 41 side. The second extending portion 52 is located on the radially inward direction R2 side with respect to the first extending portion 51, from the second insertion portion 42 to the fourth bent portion 64 in the circumferential first direction C1 side (first insertion portion 41 side). ) To extend in a rectangular parallelepiped shape as a whole. The second extending portion 52 is inclined in the circumferential direction C with respect to the extending direction of the insertion portion 4 so as to gradually move away from the axial L end surface of the stator core 2 toward the circumferential first direction C1 side. It is formed to extend. Further, in this example, all of the five protruding conductor portions constituting the first extending portion 51 are on the circumferential first direction C1 side and outside the diameter than all of the five protruding conductor portions constituting the second extending portion 52. Arranged on the direction R1 side.

  In the present embodiment, although the extending directions of the first extending portion 51 and the second extending portion 52 are different (having circumferential direction C components opposite to each other), the inclination angles thereof coincide with each other. Note that “matching” is a concept that includes not only a case where they are completely equal, but also a case where they can be regarded as being substantially equal in consideration of manufacturing errors and the like. The first extending portion 51 and the second extending portion 52 are inclined in the extending direction in the first extending portion of the circulating coil 31 disposed in the slot 22 adjacent to the rotating coil 31 of interest. It is preferable to set the smallest angle within a range that does not interfere with 51 and the second extending portion 52. If comprised in this way, the height of the axial direction L of the protrusion part 5 (what is called a coil end part) which protrudes from the stator core 2 to the axial direction L can be suppressed to the minimum.

  The radial direction connecting portion 53 is a portion that connects the first extending portion 51 and the second extending portion 52 in the radial direction R in the protruding portion 5. The radial connection portion 53 connects the end portion on the circumferential second direction C2 side of the first extension portion 51 and the end portion on the circumferential first direction C1 side of the second extension portion 52 so as to extend in the radial direction. Formed. The radial direction connecting portion 53 extends at the end of the first extending portion 51 on the circumferential second direction C2 side by bending at the second bent portion 62 toward the radially inward direction R2 which is the second extending portion 52 side. Formed as follows. Further, the radial connecting portion 53 is bent at the end portion on the circumferential first direction C1 side of the second extending portion 52 in the radially outward direction R1 side which is the first extending portion 51 side at the third bent portion 63. It is formed to extend.

  Moreover, in this example, the radial direction connection part 53 is formed so that it may extend in a circular arc shape in the direction along the radial direction R. More specifically, the arrangement order from the radially outward direction R1 side in the five projecting conductor portions arranged adjacent to each other in the radial direction R constituting the first extending portion 51 and the second extending portion 52 are configured. In the five protruding conductor portions arranged adjacent to each other in the radial direction R, the protruding conductor portions having the same arrangement order from the radial inner side R2 side are separated from each other in an arc shape extending along the radial direction R. They are connected by conductor portions (herein referred to as “arc-shaped conductor portions”). At this time, among the five projecting conductor parts constituting the first extending part 51 and the five projecting conductor parts constituting the second extending part 52 and the projecting conductor part arranged on the radially outer side R1 side. The arcuate conductor portion connecting the projecting conductor portion disposed on the inner radial direction R2 side has a larger diameter. These five arcuate conductor portions are arranged concentrically and adjacent to each other in the axial direction L.

3. Next, the configuration of the coil 3 according to this embodiment will be described. As shown in FIG. 1, the coil 3 is configured by joining a plurality of circular coils 31 having the above shape. That is, the coil 3 that circulates the entire stator core 2 in the circumferential direction C is formed by joining the connection end portions 56 of the plurality of circulation coils 31 in a predetermined manner. And the insertion part 4 of the some surrounding coil 31 which comprises the coil 3 is arrange | positioned in the some slot 22 formed in the stator core 2, respectively, and the coil 3 is wound by the stator core 2 by the overlapping winding. .

  Here, in the present embodiment, the coil 3 is configured as a two-layer wound coil. That is, in each slot 22, the first insertion portion 41 of one circular coil 31 (this is the first circular coil 31 </ b> A; see FIG. 11) constituting the coil 3, and the first circular coil A second insertion portion 42 of a rotating coil 31 (this is referred to as a second rotating coil 31B; see FIG. 11) different from 31A is disposed adjacent to the radial direction R. Further, in each slot 22, no other insertion portion 4 other than the first insertion portion 41 of the first circumferential coil 31 </ b> A and the second insertion portion 42 of the second circumferential coil 31 </ b> B is disposed. As described above, the five insertion conductor portions constituting the insertion portions 41 and 42 are all disposed adjacent to each other in the radial direction R in the slot 22. Therefore, in this embodiment, in each slot 22, two sets of five insertion conductor portions are arranged, and the radial direction R is set such that a total of ten insertion conductor portions are arranged in the same circumferential direction C. Are arranged in a row.

  By the way, as described above, the stator core 2 includes two adjacent slots 22 for the U phase, two adjacent slots 22 for the V phase, and two adjacent slots 22 for the W phase. Are repeatedly formed in the order of description along the circumferential direction C. In accordance with such an arrangement configuration of the slots 22, in the present embodiment, the first insertion portion 41 and the second insertion portion 42 in each of the circular coils 31 are formed in the slots 22 that are separated from each other by 6 slots in the circumferential direction C. Be placed. In other words, the first insertion portion 41 and the second insertion portion 42 in each of the circular coils 31 are respectively disposed in a pair of slots 22 that are separated from each other in the circumferential direction C by a distance corresponding to one magnetic pole pitch (electrical angle π). The

  In this embodiment, a set of in-phase coils 31 arranged in two slots 22 adjacent to each other over the entire circumference of the stator core 2 while shifting by a total of 8 sets, 6 slot pitches (1 magnetic pole pitch). Are disposed in the slots 22. Therefore, in the present embodiment, a total of 16 circulating coils 31 per phase are distributed in the circumferential direction C. These 16 circulating coils 31 are connected in series or in parallel in terms of electrical circuit by being joined between the connection ends 56. As a joining method in this case, for example, arc welding such as TIG welding, electron beam welding, laser beam welding, resistance welding, brazing, soldering, or the like can be used.

  The coil 3 including the combination of the surrounding coils 31 having the above-described configuration is formed for each of the U phase, the V phase, and the W phase. The U-phase coil 3, the V-phase coil 3, and the W-phase coil 3 are arranged so as to be shifted from each other in the circumferential direction C by two slot pitches. Therefore, in the stator 1 according to the present embodiment, two adjacent winding coils 31 for the U phase, two adjacent winding coils 31 for the V phase, and two adjacent winding coils for the W phase. 31 are repeatedly formed along the circumferential direction C in the order of description.

  Further, as shown in FIG. 1 and the like, in this stator 1, the first extending portions 51 of the two rotating coils 31 into which the first insertion portions 41 are inserted into the slots 22 adjacent to each other are parallel to each other and have the same diameter. Adjacent to each other so as to be aligned in the direction R position. That is, the protrusions 5 of the plurality of winding coils 31 are adjacently disposed so that the first extending portions 51 extend in parallel and are aligned at the same radial direction R position. Here, “aligned in the same radial direction R position” represents a state in which the positions in the radial direction R are the same and the positions in the circumferential direction C are sequentially shifted. Thereby, the 1st extension part 51 of the some surrounding coil 31 is arrange | positioned in the substantially cylindrical shape as a whole. Further, in the present embodiment, the first extending portions 51 of the two rotating coils 31 arranged in the slots 22 adjacent to each other are part of the region in the circumferential direction C where they exist, specifically, In the central region of the circumferential direction C excluding the region corresponding to one slot pitch at the respective end portions on the one-direction C1 side and the circumferential second direction C2 side, they are arranged so as to face each other in the axial direction L. In the present embodiment, since the inclination angles in the extending direction of all the first extending portions 51 are the same angle, all the first extending portions 51 are arranged so as to extend in parallel to each other. .

  Similarly, the second extending portions 52 of the two circular coils 31 into which the second insertion portions 42 are inserted in the slots 22 adjacent to each other are adjacently arranged so as to be parallel to each other and aligned in the same radial direction R position. In other words, the protruding portions 5 of the plurality of winding coils 31 are adjacently arranged so that the second extending portions 52 extend in parallel and are aligned in the same radial direction R position. Thereby, the 2nd extension part 52 of the some surrounding coil 31 is arrange | positioned as a substantially cylindrical shape as a whole. Further, in the present embodiment, the second extending portions 52 of the two rotating coils 31 arranged in the slots 22 adjacent to each other are part of a region in the circumferential direction C where they exist, specifically, In the central region of the circumferential direction C excluding the region corresponding to one slot pitch at the respective end portions on the one-direction C1 side and the circumferential second direction C2 side, they are arranged so as to face each other in the axial direction L. In this embodiment, since the inclination angles in the extending direction of all the second extending portions 52 are the same angle, all the second extending portions 52 are arranged so as to extend in parallel to each other. .

  On the other hand, the radial connection portions 53 of the two winding coils 31 into which the first insertion portion 41 and the second insertion portion 42 are inserted in the slots 22 adjacent to each other are circumferential in the region occupying the same radial direction R range. Adjacent to each other so as to line up with C. That is, the protrusions 5 of the plurality of winding coils 31 are arranged adjacent to each other so as to be aligned in the circumferential direction C in a region in which the radial connection portions 53 extend in parallel and occupy the same radial direction R range. Thereby, the radial direction connection part 53 of the some winding coil 31 is arrange | positioned so that it may extend in radial direction R as a whole radially, leaving the space | interval for 1 slot pitch in the circumferential direction C, respectively.

  By the way, in the configuration in which the coils 3 for three phases are provided as in the present embodiment and the protruding portions 5 of the coils 3 of each phase are arranged so as to overlap each other, the insulation between the coils 3 of different phases is provided. It is necessary to secure. Although the surface of the linear conductor constituting the coil 3 is provided with an insulating film, a high voltage is applied to the coil 3 of each phase, such as a rotating electrical machine used as a driving force source in an electric vehicle or a hybrid vehicle. When applied, such an insulating film alone may result in insufficient insulation between the different-phase coils. Therefore, in this embodiment, as shown in FIG. 1, interphase insulating members 7 are provided between the coils 3 of different phases separately from the insulating film on the surface of the linear conductor. Insulation between the coil 3 of each phase and the stator core 2 is ensured by the in-slot insulating member 81 disposed in each slot 22. As the interphase insulating member 7 and the in-slot insulating member 81, for example, a sheet formed of a material having high electrical insulation and heat resistance such as a laminate of aramid fiber and polyethylene terephthalate can be used.

  As shown in FIG. 4, the interphase insulating member 7 includes a sheet-like first insulating member 71 and a second insulating member 72. The first insulating member 71 and the second insulating member 72 are both formed in a rectangular shape and have the same size. The pair of first insulating member 71 and second insulating member 72 constituting the interphase insulating member 7 are connected by a sheet-like connecting member 74 so as to be relatively displaceable. In the present embodiment, the first insulating member 71, the second insulating member 72, and the connecting member 74 are integrally formed. Such an interphase insulating member 7 is formed, for example, by providing a pair of notches 75 at the center of two opposing sides of a single rectangular sheet-like member. A region sandwiched between the pair of notches 75 constitutes the connection member 74, and regions extending on both sides of the pair of notches 75 and the connection member 74 serve as the first insulating member 71 and the second insulating member 72. Constitute.

  In the present embodiment, the first insulating member 71 and the second insulating member 72 can be arranged to face each other by displacing the connecting member 74 so as to bend. The first insulating member 71 is provided with two folds 71f, and the first insulating member 71 can be bent toward the opposite side of the opposing second insulating member 72 by the folds 71f. Further, the second insulating member 72 is provided with two folds 72f, and the second insulating member 72 can be bent toward the opposite side of the opposing first insulating member 71 by the folds 72f.

  In this embodiment, two such interphase insulating members 7 are provided for all the circulating coils 31 (see FIG. 10). That is, one interphase insulating member 7 is provided on the first axial direction L1 side with respect to the pair of insertion portions 41 and 42 of the respective circular coils 31, and the second axial direction with respect to the pair of insertion portions 41 and 42. Another interphase insulating member 7 is provided on the L2 side. Then, on both sides in the axial direction L of the stator core 2, the first extending portion 51 and the second extending portion 52 of all the circulating coils 31 are surrounded by sheet-like insulating members 71 and 72, respectively. Thereby, it is possible to ensure sufficient insulation between the coils 3 of different phases.

  Here, in the present embodiment, on both sides of the stator core 2 in the axial direction L, the first extending portions 51 of all the circumferential coils 31 are arranged adjacent to each other so as to be parallel to each other and in the same radial direction R position, The second extending portions 52 of the circular coil 31 are also arranged adjacent to each other so as to be parallel to each other and aligned at the same radial direction R position. Moreover, the first extending portion 51 and the second extending portion 52 are densely arranged in a relatively narrow space so as to minimize the protruding height in the axial direction L from the stator core 2. Therefore, normally, it is very difficult to appropriately arrange the insulating members 71 and 72 between the first extending portion 51 and the second extending portion 52 so that the interphase insulation can be reliably performed. Have difficulty. In this respect, the stator 1 according to the present embodiment is unique to the present application as described below in order to avoid the above-described inconvenience and to appropriately arrange the insulating members 71 and 72 at desired positions. Manufactured by a manufacturing method.

4). Method for Manufacturing Stator A method for manufacturing the stator 1 according to this embodiment will be described. As shown in FIG. 3, the stator 1 according to the present embodiment includes each step of a circular coil forming step S <b> 1, an insulating member surrounding step S <b> 2, a circular coil arrangement step S <b> 3, a coil machining step S <b> 4, and an insertion step S <b> 5 in the order described. It is manufactured after. Hereinafter, it demonstrates in order.

4-1. Circulating Coil Forming Step Circulating coil forming step S1 is a step of forming a circular coil 31 formed by rotating one linear conductor one or more times on the same plane. Here, “turn around on the same plane” means that the whole of the linear conductors constituting the winding coil 31 is turned around concentrically and at least partially adjacent to each other. Such a winding coil 31 can be formed, for example, by concentrically winding a linear conductor toward the outside along the outer surface of a flat-plate core bend jig (not shown). The circular coil 31 thus formed includes a pair of linear portions 32 arranged in parallel and a connecting portion that connects the pair of linear portions 32 at both ends in the extending direction of the pair of linear portions 32. 33 (see FIG. 5).

  Here, in the present embodiment, one of the pair of linear portions 32 arranged in parallel is defined as a first linear portion 32a, and the other is defined as a second linear portion 32b. Further, in relation to the configuration of the rotating coil 31 in the finished product of the stator 1 described above, each linear portion 32 includes an insertion portion 4 that is a portion inserted into the slot 22 and a portion protruding from the stator core 2. A certain protruding portion 5 (excluding the radial connecting portion 53) is included. Here, the 1st linear part 32a contains the 1st insertion part 41 and the two 1st extension parts 51 located in the extension direction both sides of the said 1st insertion part 41. As shown in FIG. The second linear portion 32b includes a second insertion portion 42 and two second extension portions 52 located on both sides of the second insertion portion 42 in the extending direction. Therefore, the length along the extending direction of each linear part 32a, 32b is set to the length corresponding to the sum total of the length of the 1st insertion part 41 and the two 1st extension parts 51. FIG. Specifically, the length is generally set to a length corresponding to the sum of the axial length L of the stator core 2 and the circumferential direction C length corresponding to 6 slot pitches in the stator core 2. The connecting portion 33 includes a radial connecting portion 53 that constitutes a part of the protruding portion 5.

  Here, in the present embodiment, the winding coil 31 is formed using the core bending jig as described above, and therefore, after the core bending jig is removed, between the pair of linear portions 32a and 32b. Is formed with a linear gap 35 corresponding to the shape of the core thread jig. Moreover, in the connection part 33 in the winding coil 31, the extending direction of the linear conductor is reversed within a relatively short length, and the curvature radius of the connection part 33 is set to a considerably small value. Due to the restoring force due to its own elasticity, as shown in FIG. 4, the pair of linear portions 32a and 32b are slightly curved so that the central portions in the extending direction are separated from each other. That is, the distance D between the pair of linear portions 32a and 32b is formed wider at the center portion than both ends in the extending direction of the linear portion 32, and the circular coil 31 is formed in a bulging shape. . Thereby, the coil 31 is formed in a flat elliptical shape having a major axis along the extending direction and a minor axis along the direction orthogonal to the extending direction as a whole. Note that the number of such winding coils 31 is at least the number of slots 22 of the stator core 2.

4-2. Insulating Member Enclosing Step Insulating member surrounding step S <b> 2 is a step of surrounding the protruding portions 5 in the pair of linear portions 32 with the interphase insulating member 7. In the insulating member surrounding step S2, first, a pair of sheet-like first insulating member 71 and second insulating member constituting the interphase insulating member 7 are formed in the linear gap 35 formed between the pair of linear portions 32a and 32b. Member 72 is inserted. A total of two sets of the first insulating member 71 and the second insulating member 72 are inserted into both ends of the linear gap 35 along the extending direction of the linear conductor. Here, as shown in FIG. 4, the connection member 74 is displaced so as to be bent, and the first insulating member 71 and the second insulating member 72 of each set are inserted in such a relationship that they face each other. (See FIG. 5). At this time, each connection member 74 is disposed on both ends of the linear portion 32 in the extending direction (on the connection portion 33 side).

  Thereafter, the first insulating member 71 and the second insulating member 72 of each set are bent at the folds 71f and 72f, respectively, and the protruding portions 5 in the pair of linear portions 32a and 32b are respectively connected to the pair of insulating members 71 and 72. Surround by each of the. Here, as shown in FIG. 6, the first insulating member 71, which is one of the pair of insulating members 71, 72 inserted into the linear gap 35, is the first straight line, which is one of the pair of linear portions 32a, 32b. It bend | folds so that the protrusion part 5 (1st extension part 51) in the shape part 32a may be surrounded. In addition, the second insulating member 72 that is the other of the pair of insulating members 71 and 72 inserted into the linear gap 35 is the protruding portion 5 in the second linear portion 32b that is the other of the pair of linear portions 32a and 32b. It is bent so as to surround (second extending portion 52).

  And a pair of insulating members 71 and 72 surround each protrusion part 5 (the 1st extension part 51, the 2nd extension part 52) in a pair of linear part 32a, 32b, and the linear gap 35 and Are joined on opposite sides. Here, as shown in FIG. 7, the first insulating member 71 surrounds the first extending portion 51 in the first linear portion 32 a and is joined on the side opposite to the linear gap 35. Further, the second insulating member 72 surrounds the second extending portion 52 in the second linear portion 32 b and is joined on the opposite side to the linear gap 35. Therefore, the joint portion 73 in each of the insulating members 71 and 72 is disposed outside the circular coil 31 when viewed from the linear gap 35 on a plane including all of the linear conductors constituting the circular coil 31. In addition, as a joining method in that case, well-known various methods, for example, ultrasonic welding, thermocompression bonding, etc. can be utilized. The above operation is performed for all the circulating coils 31.

  Thus, in this embodiment, since the surrounding member 31 is placed in the slot 22 of the stator core 2 prior to the surrounding coil placement step S3, the insulating member surrounding step S2 is performed. The first extending portion 51 and the second extending portion 52 can be easily surrounded by the pair of insulating members 71 and 72 without any restriction. Moreover, since each joint part 73 is arrange | positioned on the outer side of the winding coil 31 seeing from the linear clearance gap 35, the said operation | work is easily performed in the state without space restrictions also between the other site | parts of the same winding coil 31. It can be performed.

  By the way, in this embodiment, since a pair of insulating members 71 and 72 are connected by the connection member 74 as mentioned above, it is suppressed that the space | interval between the said pair of insulating members 71 and 72 spreads. That is, the pair of insulating members 71 and 72 is configured to maintain a certain shape to some extent in a state where no special external force is applied. In this embodiment, the winding coil 31 is further formed in a middle bulge shape. Therefore, it is possible to suppress the downward sliding of the pair of insulating members 71 and 72 with respect to the rotating coil 31 on the upper side (vertically upper side) of the pair of linear portions 32a and 32b in the rotating coil 31. That is, in the above configuration, of the surrounding surfaces (inner peripheral surfaces) surrounding the first extending portion 51 and the second extending portion 52 in the pair of insulating members 71 and 72, the side opposite to the linear gap 35 ( Since the end 76 on the lower side of the joining portion 73) is in contact with the outer surfaces of the pair of linear portions 32a and 32b in the coil 31, the lower portions of the insulating members 71 and 72 are below. Slip in is suppressed. In addition, since the connection member 74 is supported by the connection part 33 below the center part (vertical lower side) of a pair of linear part 32a, 32b, the pair of insulation members 71, 72 slip down below. Will not be a problem. Therefore, in the subsequent steps, the first extending portion 51 and the second extending portion 52 in the coil 31 can be obtained without using a special holding jig or the like for holding the pair of insulating members 71 and 72. The state surrounded by the pair of insulating members 71 and 72 can be appropriately maintained. Therefore, the subsequent process can be facilitated.

4-3. Circumferential Coil Arrangement Step The circular coil arrangement step S3 is a step of partially arranging the plurality of circular coils 31 in the slots 22 provided in the stator core 2. In the circular coil arrangement step S3, only the insertion portion 4 (first insertion portion 41) of the first linear portion 32a, which is one of the pair of linear portions 32a and 32b, is provided in each of all the slots 22 of the stator core 2. A plurality of (around the 48 number in this example) circulating coils 31 are arranged so as to be inserted. That is, the insertion part 4 (second insertion part 42) of the second linear part 32b, which is the other of the pair of linear parts 32a, 32b, is more radially inner than the end surface of the tooth 23 in the radial direction R2 side. Arranged on the direction R2 side. That is, in each of the circular coils 31, the half on the radial direction R2 side is left uninserted, and only the half on the radial direction R1 side is inserted into the slot 22. At this time, each circular coil 31 may adopt a configuration inserted in the axial direction L or a configuration inserted in the radial direction R. In FIG. 8, only one rotating coil 31 among the plurality of rotating coils 31 is displayed.

4-4. Coil Machining Process The coil machining process S4 is a process in which the circular coil 31 partially disposed in the slot 22 is deformed and processed. In the coil processing step S4, with respect to the first insertion portion 41 inserted into each slot 22, the insertion portion 4 (second portion) of the second linear portion 32b which is the other of the pair of linear portions 32a and 32b. A process is performed in which at least the protrusion 5 is deformed by relatively moving the two insertion portions 42) in the circumferential direction C.

  In the present embodiment, in the coil processing step S4, a substantially cylindrical processing jig (not shown) having the same number of open grooves as the slots 22 of the stator core 2 is used on the outer peripheral surface. Each opening groove is opposed to the slot 22 in the radial direction R. This working jig is arranged in the radial direction of the stator 1 (stator core 2) so that the second insertion portions 42 that are not inserted in the slots 22 in the circular coil arrangement step S3 are arranged in the respective opening grooves. It is inserted along the axial direction L into the space on the R2 side (the space where the rotor of the rotating electrical machine is disposed). Thereafter, with the stator core 2 fixed, the processing jig is rotated in the circumferential direction C with respect to the stator core 2, so that at least the protruding portion 5 of each rotating coil 31 is deformed. Do it all at once.

  More specifically, the processing jig is rotated by 6 slot pitches in the circumferential second direction C2 side with respect to the stator core 2. Then, as can be understood by comparing FIG. 9 and FIG. 11, the first insertion portion 41 and the second insertion portion of each of the circular coils 31 that are initially arranged in the radial direction R at the same circumferential direction C position. 42 are spaced apart from each other by 6 slot pitches in the circumferential direction C after processing. Moreover, the radial direction connection part 53 of each winding coil 31 initially arranged at the same circumferential direction C position as the first insertion part 41 and the second insertion part 42 is the same as the first insertion part 41 in the circumferential direction C after processing. The first insertion portion 41 and the second insertion portion 42 are spaced from each other by a distance of 3 slots from the middle of the second insertion portion 42, that is, the first insertion portion 41 and the second insertion portion 42. In that case, each radial direction connection part 53 moves so that the axial direction L may approach the axial direction L end surface of the stator core 2 in the axial direction L. Furthermore, the first extending portion 51 and the second extending portion 52 of each of the circular coils 31 that were originally arranged along the axial direction L at the same circumferential direction C position as the first insertion portion 41 and the second insertion portion 42 are: After processing, the two bent portions are bent in a predetermined direction, and are inclined with respect to the extending directions of the first insertion portion 41 and the second insertion portion 42. As a result, each circular coil 31 that was initially flat and elliptical is formed into a hexagonal shape after processing.

  At this time, the first extending portion 51 and the second extending portion 52 are relatively displaced so as to be separated from each other in the circumferential direction C while being connected by the radial connecting portion 53. In the present embodiment, the first insulating member 71 and the second insulating member 72 constituting the interphase insulating member 7 are integrally formed via the connecting member 74, but the entire interphase insulating member 7 is formed in a sheet shape. Since the connecting member 74 itself has flexibility, the shape of the interphase insulating member 7 can appropriately follow the relative displacement between the first extending portion 51 and the second extending portion 52. That is, a twisted portion 77 is formed in the connecting member 74 according to the deformation of the rotating coil 31 during the coil machining step S4 (see FIG. 10), and the first insulating member 71 and the second insulating member 72 are respectively the first. Relative displacement is performed so as to maintain a state in which the extending portion 51 and the second extending portion 52 are surrounded.

  Note that when the coil machining step S4 is completed, the arrangement of the circular coils 31 in the circumferential direction C of the slots 22 at the time when the coil machining step S4 is completed is shown in FIG. The 1st insertion part 41 of the 1st circumference coil 31A in (a) is arranged as it is. Further, the second insertion portion 42 of the second winding coil 31B, which is different from the first winding coil 31A, is not inserted into the slot 22 on the radial direction R2 side of the first winding coil 31A. It is the state arrange | positioned adjacent to the 1st insertion part 41 of 31 A of one surrounding coil.

4-5. Insertion Step The insertion step S5 is a step of moving the entire coil 31 after processing in the radial direction R and inserting the non-inserted second insertion portion 42 into the slot 22. In the present embodiment, the processing jig used in the coil processing step S4 is such that the extrusion member for extruding the second insertion portion 42 arranged in the opening groove in the radial direction R appears and disappears radially from the bottom of the plurality of opening grooves. It is provided as possible. By projecting the pushing member toward the radially outward direction R1, the entire circumferential coil 31 after processing is pushed outward in the radially outward direction R1 in the insertion step S5, and all of the uninserted second insertion portions 42 are completely removed. It is inserted into the slot 22. In this way, the coils 3 composed of the two-layer winding coils for each of the three phases are collectively wound around the stator core 2 by lap winding to complete the stator 1.

  As described above, in the present embodiment, a pair of sheet shapes inserted from the linear gap 35 formed at the center of the circulating coil 31 in the insulating member surrounding process S2 performed prior to the circulating coil arranging process S3. By the insulating members 71 and 72, the protruding portions 5 (the first extending portion 51 and the second extending portion 52) in each of the pair of linear portions 32a and 32b are respectively enclosed in advance. Therefore, in the stator 1 manufactured through the subsequent coil placement step S3, the coil machining step S4, and the insertion step S5, the loop coils 31 that are parts that require interphase insulation are already present when the insertion step S5 is completed. Insulating members 71 and 72 are appropriately disposed in the first extending portion 51 and the second extending portion 52, respectively. Therefore, it is very difficult to properly arrange the insulating members 71 and 72 so that the interphase insulation between the coils 3 of different phases can be performed normally, the manufacturing method according to the present embodiment. According to the above, in the stator 1 including the multiple-phase coils 3 wound on the stator core 2 by lap winding, it is possible to easily and reliably ensure insulation between the coils 3 of different phases.

5. Other Embodiments Finally, other embodiments of the armature for a rotating electrical machine according to the present invention will be described. Note that the configurations disclosed in the following embodiments are not applied only in the embodiments, and can be applied in combination with the configurations disclosed in other embodiments as long as no contradiction arises. It is.

(1) In the above-described embodiment, an example has been described in which each winding coil 31 is formed by rotating one linear conductor five times. However, the embodiment of the present invention is not limited to this. That is, the number of turns in each turn coil 31 can be any number of times, or can be only once.

(2) In the above-described embodiment, the case where the circular coil 31 formed by rotating one linear conductor once or a plurality of times on the same plane in the circular coil forming step S1 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, such a circular coil 31 is separately obtained and used, and the stator 1 is manufactured through only the steps of the insulating member surrounding step S2, the circular coil arranging step S3, the coil machining step S4, and the inserting step S5 in the order described. The configuration is also one of the preferred embodiments of the present invention.

(3) In the above embodiment, as an example, a pair of first insulating member 71 and second insulating member 72 constituting the interphase insulating member 7 are connected by a sheet-like connecting member 74 so as to be capable of relative displacement. explained. However, the embodiment of the present invention is not limited to this. That is, for example, a configuration in which the first insulating member 71 and the second insulating member 72 are independent from each other without being connected is also one preferred embodiment of the present invention.

(4) In the above embodiment, the pair of insulating members 71 and 72 surround the respective protruding portions 5 (the first extending portion 51 and the second extending portion 52) in the pair of linear portions 32a and 32b. As an example, the case where the joints are joined on the side opposite to the linear gap 35 has been described. However, the embodiment of the present invention is not limited to this. That is, for example, as shown in FIG. 12, one or both of the first insulating member 71 and the second insulating member 72 are arranged adjacent to each other in the first extending portion 51 and the second extending portion 52 of the rotating coil 31. One of the preferred embodiments of the present invention is a structure in which the plurality of protruding conductor portions are joined so as to surround and overlap so as to surround the periphery of the plurality of protruding conductor portions.

(5) In the above embodiment, the case where the processing jig is rotated in the circumferential direction C with respect to the stator core 2 while the stator core 2 is fixed in the coil processing step S4 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, for example, a configuration in which the stator core 2 is rotated in the circumferential direction C with respect to the processing jig while the processing jig is fixed is also one preferred embodiment of the present invention.

(6) The above embodiment has been described by taking as an example the case where the cross-sectional shape of the linear conductor constituting the coil 31 in the cross section orthogonal to the extending direction is rectangular. However, the embodiment of the present invention is not limited to this. That is, for example, a linear conductor having a cross-sectional shape such as a circular shape, an elliptical shape, a square shape, or a polygonal shape can be used.

(7) In the above embodiment, the case where the armature for a rotating electrical machine according to the present invention is applied to a stator for an inner rotor type rotating electrical machine has been described as an example. However, the embodiment of the present invention is not limited to this. That is, for example, the present invention can be applied to a stator for an outer rotor type rotating electrical machine.

(8) Regarding other configurations as well, the embodiments disclosed herein are illustrative in all respects, and the embodiments of the present invention are not limited thereto. That is, as long as the configuration described in the claims of the present application and a configuration equivalent thereto are provided, a configuration obtained by appropriately modifying a part of the configuration not described in the claims is naturally also included in the present invention. Belongs to the technical scope.

  The present invention relates to an armature core in which a plurality of slots extending in the axial direction of a cylindrical core reference surface are distributed in the circumferential direction of the core reference surface, and a plurality of phases wound around the armature core in an overlapping manner. It can utilize suitably for the manufacturing method of the armature for rotary electric machines provided with the coil, and such an armature for rotary electric machines.

1 Stator (armature for rotating electrical machine)
2 Stator core (armature core)
3 Coil 4 Insertion part 5 Protrusion part 21 Core reference surface 22 Slot 31 Circulating coil 32 Linear part 33 Connection part 35 Linear gap D Spacing 41 First insertion part 42 Second insertion part 51 First extension part 52 Second extension Residential portion 53 Radial connection portion 71 First insulating member (insulating member)
72 Second insulating member (insulating member)
74 Connection member C Circumferential direction L Axial direction R Radial direction R1 Radial outward direction (diameter first direction)
R2 Inner diameter direction (diameter second direction)
S2 Insulating member surrounding process S3 Circulating coil arrangement process S4 Coil machining process S5 Insertion process

Claims (4)

An armature core in which a plurality of slots extending in the axial direction of the cylindrical core reference surface are dispersedly arranged in the circumferential direction of the core reference surface; a plurality of coils wound around the armature core in an overlapping manner; A method of manufacturing an armature for a rotating electrical machine comprising:
A pair of linear portions formed by rotating a linear conductor one or more times on the same plane and connecting the pair of linear portions arranged in parallel and both ends of the linear portions in the extending direction are connected. A connecting portion to be used, a portion inserted into the slot in the linear portion is an insertion portion, and a circular coil in which a portion protruding from the armature core is a protruding portion,
After inserting a pair of sheet-like insulating members into a linear gap between the pair of linear portions of the circular coil, the protruding portions in each of the pair of linear portions are respectively connected to the pair of insulating members. An insulating member surrounding step for surrounding by,
Circumferential coil arrangement in which a plurality of circular coils are arranged so that only one of the pair of linear portions is inserted into each of the slots provided in the armature core. Process,
At least the projecting portion is formed by relatively moving the other insertion portion of the pair of linear portions in the circumferential direction relative to the insertion portion of the pair of linear portions inserted into the slot. A coil processing step for performing a process for deforming the above-mentioned coil in a lump for all the circulating coils,
An insertion step of inserting the non-inserted insertion portion into the slot by moving the entire circular coil after processing in the radial direction;
The manufacturing method of the armature for rotary electric machines provided with. Of the pair of insertion portions included in each of the circular coils, the insertion portion disposed on one radial side in a state of being inserted into the slot is a first insertion portion, and is disposed on the other radial side. The insertion portion is a second insertion portion;
In the coil, the first insertion part of the first circulation coil and the second insertion part of the second circulation coil different from the first circulation coil are adjacent in the radial direction within one slot. Is a two-layer coil in which no other insertion portion is arranged in the slot,
In the insulating member surrounding step, one of the pair of insulating members inserted into the linear gap surrounds the protruding portion in one of the pair of linear portions and is joined on the opposite side to the linear gap. The other of the pair of insulating members inserted into the linear gap surrounds the protruding portion of the other of the pair of linear parts and is joined to the opposite side of the linear gap. Of manufacturing an armature for a rotating electric machine. The interval between the pair of linear portions of the circular coil is formed wider in the central portion than both ends in the extending direction of the linear portions,
The manufacturing method of the armature for rotary electric machines according to claim 1 or 2 with which a pair of said insulating members are connected so that relative displacement is possible by a connection member. An armature core in which a plurality of slots extending in the axial direction of the cylindrical core reference surface are dispersedly arranged in the circumferential direction of the core reference surface; a plurality of coils wound around the armature core in an overlapping manner; An armature for a rotating electrical machine comprising
The coil is configured by joining a plurality of winding coils formed by rotating the linear conductor once or a plurality of times,
Each of the circular coils includes a pair of insertion portions disposed at different radial positions in the different slots, and a projection portion extending from the insertion portion and protruding in the axial direction from the armature core. ,
Of the pair of insertion portions, the insertion portion disposed on the first radial direction side that is one side in the radial direction is the first insertion portion, and the second insertion portion is disposed on the second radial direction side that is the other radial side. The insertion part is the second insertion part,
The projecting portion includes a first extending portion extending in a circumferential direction from the first inserting portion toward the second inserting portion, and a first extending portion on the radial second direction side with respect to the first extending portion. A second extending portion extending in the circumferential direction from the two inserting portions toward the first inserting portion, and a radial connecting portion connecting the first extending portion and the second extending portion in the radial direction And comprising
The first extending portions of the two orbiting coils into which the first insertion portions are inserted into the slots adjacent to each other are arranged adjacent to each other in parallel and at the same radial position, and adjacent to each other. The second extending portions of the two orbiting coils into which the second insertion portion is inserted into the slot are adjacently arranged so that they are parallel to each other and aligned at the same radial position,
Each of the first extending portion and the second extending portion of all the circulating coils is surrounded by a pair of sheet-like insulating members, and the pair of insulating members are connected to each other by a connecting member Armature.

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