JP2012165484A - Manufacturing method of stator of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator of a rotary electric machine which ensures high cover edge performance and suppresses pin holes concurrently.SOLUTION: A manufacturing method of a stator 3 of this invention has: a heating process 101 where a terminal part of a joining part 33e, with which a segment conductor 33 connects, is immersed in a liquid insulation resin material 36A having a high gelation reactivity and the insulation resin material 36A near a tip of the terminal part is heated to be turned into a gel; and a hardening process 102 where a gelled insulation resin material 36B adhered to a surface of the tip of the terminal part is hardened.

Description

  The present invention relates to a method for manufacturing a stator of a rotating electrical machine mounted on a vehicle.

  Conventionally, what was indicated by patent documents 1 is known as a stator of a rotary electric machine used as an electric motor or a generator in vehicles. This stator includes an annular stator core having a plurality of slots in the circumferential direction, and a stator winding wound around the stator core by connecting ends of a plurality of segment conductors inserted and disposed in the slots. With a line.

  And in patent document 1, after connecting the terminal parts of a segment conductor by welding etc., the insulation of a stator coil | winding is ensured by covering the surface of the connected terminal part with insulating resin. It is disclosed. In this case, in order to ensure a high cover edge property, the insulating resin covering the end portion of the segment conductor is fixed to the surface of the end portion by applying powder coating.

  This powder coating is performed on the surface of the end portion of the segment conductor by immersing the end portion of the segment conductor heated to the curing temperature of the powder resin in a bath of powder resin mainly composed of epoxy resin, for example. This is to melt and fix the powder resin. At this time, the thickness of the insulating resin to be formed is uniformed by using a fluidized immersion tank in which the powder resin is floated by sending compressed air inside the powder resin. It becomes possible to do.

Japanese Patent No. 3770263

  However, as disclosed in the above-mentioned Patent Document 1, when powder coating is performed using a fluidized immersion tank, after the completion of coating, due to entrainment of gas or compressed air existing between the powder resins. A void may be formed in the insulating resin fixed to the end portion of the segment conductor. For this reason, if the distance between the conductors is reduced due to a request for downsizing of the stator or the like, voids may become pinholes and cause insulation failure.

  The present invention has been made in view of the above circumstances, and should solve the problem of providing a method for manufacturing a stator of a rotating electrical machine capable of achieving both ensuring of high cover edge properties and suppression of pinholes. It is to be an issue.

  The invention according to claim 1, which has been made to solve the above-described problem, includes an annular stator core having a plurality of slots in the circumferential direction, and end portions of a plurality of segment conductors inserted and arranged in the slots. A stator winding that is connected and wound around the stator core, and the terminal portion to which the segment conductor is connected is formed by curing an insulating resin applied to the surface of the terminal portion. In the method of manufacturing a stator of a rotating electrical machine covered with an insulating film, the tip of the terminal portion connected to the segment conductor is immersed in a liquid insulating resin material having high gelation reactivity, A heating step of heating and gelling the insulating resin material in the vicinity of the tip portion of the terminal portion, and a curing step of hardening the insulating resin material gelled and adhered to the tip portion surface of the terminal portion. And butterflies.

  According to the first aspect of the present invention, by performing the above heating step, the insulating resin material gelled in the insulating resin material is adhered to the surface of the end portion of the end portion of the segment conductor. . Therefore, when performing the next hardening process, it can suppress that the insulating resin material adhering to the front-end | tip part surface of the terminal part of a segment conductor droops with dead weight. Thereby, since the insulating resin material tends to remain at the corners of the end portions of the segment conductors, high cover edge properties can be realized. In addition, since a liquid insulating resin material is used, the generation of pinholes can be suppressed as compared with the case where a powdered insulating resin material is used. Therefore, according to the present invention, it is possible to realize a stator of a rotating electrical machine that can achieve both high cover edge property and pinhole suppression.

  In the present invention, a liquid material having high gelation reactivity is used as the insulating resin material. For the insulating resin material, for example, a thixotropic agent that accelerates the gelation reaction in the heating step and a curing agent that accelerates the curing in the curing step can be added to the main component that is a main component such as epoxy. Examples of the main agent include resins such as epoxy, polyester, urethane, and silicone. As the thixotropic agent, for example, silica having a hydroxyl group, aerosil, organic clay, talc and the like can be suitably used. These thixotropy imparting agents are thickened by the primary reaction of the hydroxyl group with the main agent or curing agent by heating. Examples of the curing agent include acid anhydrides, aliphatic amines, aromatic amines, tertiary amines, maleic anhydride, imidazole series, and polymercaptan. In addition to these, additives such as dicyanamide and organic acid hydrazide may be added as needed.

  The invention according to claim 2 is characterized in that the heating step is performed by energization heating in which the segment conductor is energized and heated or preheating applied to the segment conductor.

  According to the second aspect of the present invention, since the gelation reaction of the insulating resin material can be favorably progressed in the heating step, dripping due to the weight of the insulating resin material can be reliably suppressed.

  According to a third aspect of the present invention, in the curing step, the distal end portion of the terminal portion is taken out from the insulating resin material, and the insulating resin material attached to the surface of the distal end portion of the terminal portion is stored by heat storage or later. It is characterized by being cured by heating.

  According to the invention described in claim 3, in the curing step, the insulating resin material attached to the tip portion surface of the terminal portion can be reliably cured. Thereby, sufficient dielectric breakdown strength can be ensured.

  The invention described in claim 4 is characterized in that the post-heating is performed by energizing heating, energizing the segment conductors, heating a hot stove, or an electromagnetic heater.

  According to the invention described in claim 4, it is possible to promote the curing of the insulating resin material attached to the tip portion surface of the terminal portion, and to more reliably suppress the sagging due to the weight of the insulating resin material.

  The invention described in claim 5 is characterized in that at least one selected from the group consisting of epoxy, polyester, urethane, and silicone is used as the main component in the insulating resin material.

  According to the invention described in claim 5, by using the main agent, an insulating film having excellent insulating properties can be formed.

  In the invention according to claim 6, one or more selected from fused silica having a hydroxyl group on the surface, aerosil, organic clay, and talc is used as the thixotropic agent in the insulating resin material. It is characterized by being.

  According to the invention described in claim 6, by using the thixotropic agent, the gelation reaction of the insulating resin material in the heating step can be favorably promoted. Thereby, the dripping by the dead weight of insulating resin material can be suppressed reliably.

  In the invention according to claim 7, the insulating resin material is selected from acid anhydrides, aliphatic amines, aromatic amines, tertiary amines, maleic anhydride, imidazole series and polymecaptane as a curing agent. One or more types are used.

  According to the invention described in claim 7, by using the above curing agent, the insulating resin material can be reliably cured in the curing step. Thereby, sufficient dielectric breakdown strength of the insulating film can be ensured.

1 is a cross-sectional view illustrating an overall configuration of a rotating electrical machine according to a first embodiment. FIG. 3 is a perspective view of a segment conductor constituting the stator winding according to the first embodiment. FIG. 3 is a plan view showing a part of the stator according to the first embodiment when viewed from the inner peripheral side. FIG. 3 is a cross-sectional view of a terminal portion of a segment conductor that constitutes the stator winding according to the first embodiment. FIG. 5 is a cross-sectional view taken along line VV in FIG. 3. It is a block diagram which shows the manufacturing process of the insulating film and insulating resin in Embodiment 1. It is a figure which shows the heating process in the manufacturing process of FIG. It is a figure which shows the state of the insulating resin material adhering to the front-end | tip part of a segment conductor in the manufacturing method of Embodiment 1, (a) shows the state at the time of a heating process, (b) is the terminal part of a segment conductor The state when the tip is extracted from the insulating resin material is shown, and (c) shows the state during the curing step. It is a graph which shows the relationship between the heating temperature in the manufacturing method of Embodiment 1, and time. 4 is a graph showing the relationship between the viscosity of an insulating resin material and time in the manufacturing method of Embodiment 1. It is a figure which shows the process of attaching insulating resin to the 1st coil end group in Embodiment 1. FIG.

  Hereinafter, embodiments of a method for manufacturing a stator of a rotating electrical machine according to the present invention will be specifically described with reference to the drawings.

Embodiment 1
Initially, the schematic structure of the rotary electric machine to which the stator manufactured by the manufacturing method of this embodiment is applied is demonstrated. FIG. 1 is a cross-sectional view illustrating the overall configuration of the rotating electrical machine according to the first embodiment. FIG. 2 is a perspective view of a segment conductor constituting the stator winding according to the first embodiment. FIG. 3 is a front view illustrating a part of the stator according to the first embodiment when viewed from the inner peripheral side. FIG. 4 is a cross-sectional view of a terminal portion of a segment conductor constituting the stator winding according to the first embodiment. 5 is a cross-sectional view taken along line VV in FIG.

  The stator 3 of this embodiment is used for the AC generator 1 mounted on a vehicle. The AC generator 1 has a pulley 20 that receives the rotational force from the engine. The pulley 20 is fixed together with the rotor 2 on the shaft. The rotor 2 includes a Landell core configured by combining a pair of pole cores 71 and 72, and a field winding 8. Further, a cooling fan is provided at the end of the rotor 2. In the present embodiment, the cooling fan 11 is provided on the front side which is one end face, and the cooling fan 12 is provided on the rear side which is the other end face. The cooling fan 12 has a blade that blows air only in the centrifugal direction. The cooling fan 12 is a larger fan than the cooling fan 11 in order to cool the rectifier 5 and the regulator circuit mounted on the frame 4.

  Further, slip rings 9 and 10 are provided on the shaft. The shaft is rotatably supported by the frame 4. A stator 3 is fixed to the frame 4 on the outer peripheral side of the rotor 2.

  The stator 3 is wound around the stator core 32 by welding the annular stator core 32 having a plurality of slots in the circumferential direction and the end portions of the plurality of segment conductors 33 inserted and disposed in the slots. Stator winding 31.

  A sheet-like insulator 34 is arranged along the inner wall surface of the groove-like slot formed in the stator core 32. The stator winding 31 is constituted by a copper wire 33h having a flat cross section. The surface of the copper wire 33h is covered with a resin film layer 33g. Accordingly, the copper wire 33h is electrically insulated from the stator core 32 by the resin film layer 33g and the insulator 34 in the slot.

  The stator winding 31 is configured by arranging a plurality of U-shaped segment conductors 33 in accordance with a predetermined rule and electrically connecting the ends of the plurality of segment conductors 33 in accordance with the predetermined rule. Has been. In this embodiment, the electrical connection part is connected by welding. In this embodiment, two U-shaped segment conductors 33a and 33b as schematically shown in FIG. 2 are used as a basic unit, and a plurality of these units are arranged to make one turn on the stator core 32. A series of windings is formed.

  The U-shaped segment conductor 33 is connected by welding to a turn portion 33c formed by bending a copper wire 33h covered with a thin insulating resin film 33g and a joint portion 33c at the end of another segment conductor 33. It has the junction part 33e of a terminal part. The turn part 33c forms a first coil end together with the skew part 33d that follows the turn part 33c. The plurality of turn portions 33c of the plurality of segment conductors 33 are regularly arranged on the rear side (the side opposite to the pulley 20) shown in FIG. 1 to form the first coil end group 31a. The joint portion 33e forms a second coil end together with the skew portion 33f that follows the joint portion 33e. The plurality of joint portions 33e are arranged on the front side (pulley 20 side) shown in FIG. 1 to form the second coil end group 31b.

  As shown in FIG. 3, the inclination angle θ1 of the skew portion 33d in the first coil end group 31a with respect to the axial direction is smaller than the inclination angle θ2 of the skew portion 33f in the second coil end group 31b. As a result, a larger interval is formed between the plurality of skew feeding portions 33d. Thereby, even if the joint part 33e extending straight in the axial direction is formed, the axial height of the second coil end group 31b can be suppressed.

  In the present embodiment, the first coil end group 31a is configured by mainly disposing the turn portion 33c. Further, the second coil end group 31b is configured by mainly disposing the joining portion 33e. However, these are mainly arranged with the turn part 33c and the joint part 33e of the basic unit. Also in the first coil end group 31a, the joint portion 33e can be partially arranged. For example, a junction for obtaining a neutral point or a junction for realizing connection to the rectifier 5. Moreover, the turn part 33c can be partially arranged in the second coil end group 31b.

  A thin insulating resin 37 made of a resin material mainly composed of epoxy is attached to the first coil end group 31a. The thin insulating resin 37 attached to the first coil end group 31a is attached to such an extent that it covers the surfaces of the plurality of conductors constituting the first coil end group 31a. As a result, in the first coil end group 31a, there is formed a cooling air passage that communicates through the first coil end group 31a from the radially inner side to the outer side. The insulating resin 37 is applied in a range from the entire first coil end group 31 a to the axial end of the stator core 32. In the first coil end group 31a, a film is partially stretched between the conductors adjacent in the radial direction, and the portions are connected to increase the rigidity. Further, at the end portion of the stator core 32, the stator core 32, the insulator 34, and the segment conductor 33 are bridged and bonded together.

  As shown in FIGS. 3 and 4, a thick insulating film 36 is attached to the end portion of the conductor segment 33 (joint portion 33 e connected by welding). The end portion of the conductor segment 33 is exposed by peeling off the insulating resin film 33g at a predetermined length (about 4 mm) from the edge, thereby exposing the copper wire 33h. After being connected to each other by welding, an insulating film 36 is fixed so as to cover the exposed portion. The method for manufacturing the insulating film 36 will be described in detail later.

  The insulating film 36 is disposed so that the vicinity of the tip end of the second coil end 31b is connected in an annular shape while maintaining the state where the adjacent joint portions 33e are separated from each other. The insulating coating 36 is applied with the viscosity and amount adjusted so as to form a radially extending groove 36c at the axial tip of the second coil end group 31b. The groove 36c contributes to the maintenance of the heat dissipation area.

  Further, a portion of the second coil end group 31b other than the portion to which the insulating coating 36 is attached is made of the same resin material as the insulating resin 37 and the second insulating coating 36b attached to the first coil end group 31a. An insulating resin 37 is attached. That is, the entire second coil end group 31 b is covered with the thin insulating resin 37. In particular, as shown in FIG. 3, in the second coil end 31 b, the skewed portion 33 f as a conductor not covered with the insulating film 36 is covered only with the insulating resin 37. The insulating resin 37 forms a space portion 37a at the root portion of the second coil end group 31b near the stator core 32.

  As shown in FIG. 5, the insulating resin 37 penetrates and adheres to the inside of the second coil end group 31b. In particular, it penetrates between a plurality of skewed portions 33f arranged in multiple layers in the radial direction and aligned in the circumferential direction. The insulating resin 37 is attached so as to stretch a film between the plurality of skew portions 33f, and bridges the plurality of skew portions 33f. The insulating resin 37 penetrates almost all between the radially adjacent conductors in the second coil end group 31b. The insulating resin 37 is attached so as to enter and stretch between the conductors adjacent in the circumferential direction in the second coil end group 31b.

  The insulating resin 37 is formed by a process of attaching a liquid resin having a low normal temperature viscosity and curing it. The insulating resin 37 is applied to the second coil end group 31b with the viscosity and amount adjusted so that the bubble-shaped space 37b and the groove 37c as shown in FIG. 5 are formed. The insulating resin 37 is provided in a range from the entire second coil end group 31b to the axial end of the stator core 32. At the end of the stator core 32, the stator core 32, the insulator 34, and the segment conductor 33 are cross-linked and bonded together.

  Between the plurality of skew portions 33f, the circumferential interval is smaller toward the inner side in the radial direction. For this reason, the insulating resin 37 substantially fills the gaps 33f as conductors both in the radial direction and in the circumferential direction on the radially inner side of the second coil end group 31b. The insulating resin 37 is adhered to the skewed portion 33f leaving a large space 37b because the interval between the skewed portions 33f is relatively wide outside the second coil end group 31b in the radial direction. In particular, the plurality of skewed portions 33f arranged on the outermost side as the outer layer cover their surfaces, but are attached leaving a groove 37c as a space between them.

  As a result, the second coil end group 31b has a corrugated surface corresponding to the skewed portion 33f on the outer side to provide a large surface area, and the inner side has a smoother surface than the outer side. In other words, the shape that the insulating resin 37 exhibits in the second coil end group 31b is a shape in which the outside is larger than the inside in the radial direction. In other words, a large number of deeper grooves 37c are provided on the radially outer side than on the radially inner side. In other words, the density of the insulating resin 37 is denser on the inner side in the radial direction than on the outer side. Further, the insulating resin 37 is thickly attached only to one of the two coil end groups. In the present embodiment, the first coil end group 31a including the turn part 33c is more thickly attached to the second coil end group 31b including the joint part 33e. The insulating resin 37 is thickly attached to the coil end on the front side from the rear side.

  Next, the manufacturing method of said insulating film 36 and insulating resin 37 is demonstrated with reference to FIGS. FIG. 6 is a block diagram showing a manufacturing process of the insulating film and the insulating resin in the present embodiment. In the manufacturing method of this embodiment, as shown in FIG. 6, a heating process 101 and a curing process 102 are sequentially performed to form an insulating film 36, and then an insulating resin adhesion process 103 is performed to form an insulating resin 37. Is.

(Heating step 101)
When performing the heating step 101, as shown in FIG. 7, a liquid insulating resin material 36A for forming the insulating film 36 is put into the tank 303 and prepared. In the present embodiment, as the insulating resin material 36A, epoxy as a main agent: 50 to 55% by weight, silica as a thixotropic agent: 3 to 5% by weight, acid anhydride as a curing agent: 40 to 44% by weight, Other additives: A mixture of 1 to 2% by weight is used.

  Then, with respect to the insulating resin material 36 </ b> A in the tank 303, the stator 3 is lowered from above in a state where the stator 3 is horizontally placed so that the second coil end group 31 b is positioned downward to fix the insulating film 36. The segment conductor 33 is dipped from the junction 33e to the vicinity of the junction root. Thereby, the exposed part of the copper wire 33h at the end of the terminal part of the joint part 33e is immersed in the insulating resin material 36A.

  In this state, the segment conductor 33 of the stator winding 31 is energized and the segment conductor 33 is heated to a predetermined temperature (150 ° to 200 °) to perform the heating step 101. At this time, the heating temperature of the segment conductor 33 is maintained at a predetermined substantially constant temperature as shown in FIG. As a result, as shown in FIG. 10, the insulating resin material 36A in the vicinity of the tip of the joint portion 33e immersed in the insulating resin material 36A is heated, so that during the initial period (about 20 seconds), Although the viscosity of the insulating resin material 36A gradually decreases, the gelling reaction is started after a predetermined time. That is, the condensation reaction between the epoxy (main agent) and silica (thixotropic agent) and the addition reaction between the acid anhydride (curing agent) and silica (thixotropic agent) are started almost simultaneously. Thereby, as shown to Fig.8 (a), the insulating resin material 36B of the front-end | tip part vicinity of the junction part 33e gelatinizes (thickens).

  And after predetermined time progress, the front-end | tip part of the junction part 33e is taken out out of the insulating resin material 36A, and it transfers to the following hardening process 102. FIG. When the tip of the joint 33e is taken out from the insulating resin material 36A, as shown in FIG. 8B, the gelled insulating resin material 36B is transferred to the copper wire 33h at the tip of the joint 33e. It adheres so as to cover the entire exposed part. At this time, since the attached insulating resin material 36B is gelled and has a high viscosity, the shape is maintained as it is, and sagging due to the weight of the insulating resin material 36B is suppressed.

(Curing step 102)
In the curing step 102, as shown in FIG. 9, the segment conductor 33 taken out from the insulating resin material 36 </ b> A is energized and heated after the curing step 102 until the segment conductor 33 is fixed. Maintain temperature. As a result, the insulating resin material 36B adhering to the end of the end of the joint 33e is heated, whereby a cross-linking reaction between the epoxy (main agent) and the acid anhydride (curing agent) is started.

  Then, after a predetermined time has elapsed, as shown in FIG. 8C, the insulating resin material 36C adhering to the end of the joint portion 33e is sufficiently cured by the progress of the crosslinking reaction, and the joint portion 33e It will be in the state firmly fixed to the terminal part tip. Thereby, the insulating film 36 which covers the terminal part front-end | tip of the junction part 33e is formed. In this case, the shape of the insulating resin material 36B (FIG. 8B) at the start of the curing step 102 and the shape of the insulating resin material 36C (FIG. 8C) at the end hardly change.

  FIG. 10 shows the relationship between the viscosity and time when the insulating resin material 36A of this embodiment is used and when a general insulating resin material (comparative example) that does not perform a gelation reaction is used. Has been. As is clear from FIG. 10, in the case of this embodiment, the lower limit of the viscosity decrease starting from the start of the heating step 101 is higher than that of the comparative example, and the rise from the lower limit of the viscosity decrease is abrupt. I understand. This proves that when the insulating resin material 36A of the present embodiment is used, droop due to its own weight can be effectively suppressed.

(Insulating resin adhesion process 103)
Subsequently, an insulating resin adhesion process 103 for forming the insulating resin 37 is performed. In the insulating resin adhesion step 103, as a material for forming the insulating resin 37, a liquid resin mainly composed of an epoxy resin or the like: 95 to 97% by weight and a fused silica having a hydroxyl group on the surface layer: 3 to 5% by weight are mixed. Thus, a low viscosity insulating resin material 37A having a normal temperature viscosity of 5 Pa · s or less is prepared in the dispenser 301. In the present embodiment, the same insulating resin material 37A as the second insulating film forming material 36B used in the second insulating film adhesion step 102 is used.

  In FIG. 11, the stator 3 has a fixed inclination angle α with respect to the vertical axis by a jig 300 that rotates in the circumferential direction coaxially with the central axis of the stator core 32 with the first coil end group 31 a facing upward. It is held with. The inclination angle α can be set to about 15 ° as shown in FIG. Thereby, it is possible to prevent the insulating resin material 37 </ b> A from adhering to the tip of the output line 310 of the stator winding 31 connected to the rectifier 5.

  The insulating resin material 37A is dripped in a certain amount from the nozzle 302 of the dispenser 301 fixedly installed above the rotating stator 3 toward the first coil end group 31a. Thereafter, the stator 3 is placed horizontally so that the second coil end group 31b is positioned downward, and is placed in an atmosphere of the curing temperature of the insulating resin material 37A for a predetermined time. During this time, a part of the insulating resin material 37A passes through the slots of the stator core 32 and reaches the skewed portion 33f of the second coil end group 31b below, and the curing is completed. Thereby, the entire surface of the first coil end group 31a is covered with the thin insulating resin 37, and the substantially entire surface of the oblique portion 33f of the second coil end group 31b is thin. It becomes a state covered with.

(Function)
In the vehicle alternator 1 configured as described above, the pulley 20 is rotationally driven by the vehicle traveling engine. An exciting current is passed through the field winding 8 of the rotor 2 via slip rings 9 and 10, and N and S poles are formed in the pole cores 71 and 72, thereby forming a rotating field. As a result, an AC voltage is induced in the stator winding 31, and this AC output is rectified by the rectifier 5 and output as DC from the output terminal.

  The cooling fans 11 and 12 fixed to the pole cores 71 and 72 take in air from the opening 41 in the axial direction of the frame 4 and blow out toward the opening 42 in the radial direction. Both coil ends are cooled by this cooling air.

(effect)
According to the method for manufacturing the stator 3 of the vehicle alternator 1 of the present embodiment, the gel is formed in the insulating resin material 36 </ b> A on the tip surface of the end portion of the segment conductor 33 by performing the heating step 101. The insulated insulating resin material 36A is adhered. Therefore, when performing the next hardening process 102, it can suppress that insulating resin material 36A adhering to the front-end | tip part surface of the terminal part of the segment conductor 33 droops with dead weight. As a result, the insulating resin material 36A is likely to remain at the corners of the end portions of the segment conductors 33, so that high cover edge properties can be realized. Further, since the liquid insulating resin material 36A is used, the generation of pinholes can be suppressed as compared with the case where a powdered insulating resin material is used.

  Therefore, according to the manufacturing method of the present embodiment, it is possible to easily realize the stator 3 of the vehicle alternator 1 capable of ensuring both high cover edge properties and suppressing pinholes.

  In the heating step 101 of the present embodiment, the insulating resin material 36 is heated by energization heating that energizes and heats the segment conductor 33. Therefore, in the heating step 101, the gelation reaction of the insulating resin material 36A can be favorably progressed, and therefore, when the terminal portion of the segment conductor 33 is taken out from the insulating resin material 36A, the insulating resin material 36A has its own weight. Dripping can be reliably suppressed.

  Further, in the curing step 102 of the present embodiment, the distal end portion of the terminal portion is taken out from the insulating resin material 36A, and the insulating resin material 36A attached to the distal end portion surface of the terminal portion is cured by post-heating. . Therefore, in the curing step 102, the insulating resin material 36A adhering to the tip portion surface of the terminal portion can be reliably cured, so that sufficient dielectric breakdown strength can be ensured.

  Further, the post-heating is performed by energization heating in which the segment conductor 33 is energized and heated. Therefore, it is possible to accelerate the curing of the insulating resin material 36A adhering to the front end surface of the terminal portion, and to more reliably suppress the sagging due to the weight of the insulating resin material 36A. Furthermore, since the electric heating apparatus used in the heating step 101 can be continuously shared, it is possible to avoid an increase in equipment cost.

[Other Embodiments]
The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.

  For example, in the first embodiment, in the heating step 101, the energization heating that energizes and heats the segment conductor 33 of the stator winding 31 is performed, but instead, the entire stator 3 is preliminarily heated to a predetermined temperature. The heating step 101 may be performed using preheating applied to the segment conductors.

  In addition, when post-heating is performed in the curing step 102, the same energization heating as in the heating step 101 is performed, but instead, for example, it may be performed by a hot air furnace or an electromagnetic heater. .

  In the first embodiment, the epoxy resin is used as the main component of the insulating resin material 36A. Instead, for example, one or more kinds of resins selected from polyester, urethane, and silicone are used. May be.

  Further, in the first embodiment, the segment conductor 33 as shown in FIG. 2 is used in order to arrange four layers of conductors in the radial direction in the slot, but this may be configured by a single U-shaped segment. Good. The single U-shaped segment provides two layers of conductors in the slot and provides a two layer skew arrangement in the same cross section as FIG. Such a configuration can be selected to suit the required performance.

  The present invention can be applied not only to a vehicle AC generator but also to a vehicle or general-purpose rotating electrical machine having a similar air cooling structure. For example, it can be applied to an electric motor.

  DESCRIPTION OF SYMBOLS 1 ... Alternator, 2 ... Rotor, 3 ... Stator, 31 ... Stator winding, 31a ... First coil end group, 31b ... Second coil end group, 32 ... Stator core, 33, 33a, 33b ... Segment conductor 33c ... Turn part 33d, 33f ... Slant part 33e ... Joint part 33g ... Insulating resin film 33h ... Copper wire 34 ... Insulator 36 ... Insulating film 36A ... Insulating film forming material 36B ... Gelled insulating resin material, 36C ... Cured insulating resin material, 37 ... Insulating resin, 37A ... Insulating resin material, 300 ... Jig, 301 ... Dispenser, 302 ... Nozzle, 303 ... Tank.

Claims (7)

An annular stator core having a plurality of slots in the circumferential direction, and a stator winding wound around the stator core by connecting ends of a plurality of segment conductors inserted and disposed in the slots; In the method of manufacturing a stator of a rotating electrical machine, the terminal portion connected to the segment conductor is covered with an insulating film formed by curing an insulating resin applied to the surface of the terminal portion.
The tip of the end connected to the segment conductor is immersed in a liquid insulating resin material having high gelation reactivity, and the insulating resin material in the vicinity of the tip of the end is heated to be gelled. Heating process;
A curing step of curing the insulating resin material that has gelled and adhered to the tip portion surface of the terminal portion;
The manufacturing method of the stator of the rotary electric machine characterized by having.   2. The method of manufacturing a stator for a rotating electrical machine according to claim 1, wherein the heating step is performed by energization heating that energizes and heats the segment conductor or preheating applied to the segment conductor.   The curing step is characterized in that the distal end portion of the terminal portion is taken out from the insulating resin material, and the insulating resin material attached to the surface of the distal end portion of the terminal portion is cured by heat storage or by post-heating. The manufacturing method of the stator of the rotary electric machine of Claim 1 or 2.   The method of manufacturing a stator for a rotating electrical machine according to claim 3, wherein the post-heating is performed by energization heating that heats the segment conductors by energization, a hot stove, or an electromagnetic heater.   5. The rotation according to claim 1, wherein the insulating resin material includes at least one selected from epoxy, polyester, urethane, and silicone as a main agent. A method of manufacturing an electric stator.   6. The insulating resin material, wherein one or more selected from fused silica having a hydroxyl group, aerosil, organic clay and talc is used as a thixotropic agent. The manufacturing method of the stator of the rotary electric machine as described in any one of these.   In the insulating resin material, at least one selected from acid anhydrides, aliphatic amines, aromatic amines, tertiary amines, maleic anhydride, imidazole series and polymecaptane is used as a curing agent. A method for manufacturing a stator of a rotating electrical machine according to any one of claims 1 to 6, wherein

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