JP2012200101A - Rotating electric machine stator and method of manufacturing rotating electric machine stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce radial dimension of a coil end in a joining side of a conductor segment while securing sufficient insulating performance in each segment coil, in a rotating electric machine stator.SOLUTION: A stator includes stator coils of different phases wound on a stator core in distributed winding. The stator coil of each phase includes a segment coil formed by a plurality of U-shaped conductor segments 28 each having two parallel leg parts. At portions projecting from the side face of the stator core at tips of the two leg parts 32 of each conductor segment 28, first bend parts 40 are bent in the circumferential direction or a direction inclined to the circumferential direction, and second bend parts 42a, 42b located on tip sides from the first bent parts 40 are bent toward the axial direction. The second bend parts 42a, 42b provided in the two leg parts 32 adjacent to each other in the radial direction, respectively are arranged in positions different from each other in the axial direction of the stator.

Description

  The present invention relates to a rotating electrical machine stator including a stator core having slots provided at a plurality of locations in the circumferential direction, and a multi-phase stator coil wound around the stator core by distributed winding, and a method of manufacturing the rotating electrical machine stator.

  Conventionally, as a stator of a rotating electrical machine, a stator core provided with a plurality of radially extending grooves called slots is provided in the circumferential direction, and stator coils are distributed in the stator core so as to be inserted into two slots spaced apart from each other in the circumferential direction. Structures that are wound by winding are known.

  Further, in this case, as a stator coil, a plurality of U-shaped conductor segments are inserted into a plurality of slots from one side of the stator core in the axial direction to the other side, and ends of the conductor segments adjacent in the radial direction on the other side in the axial direction It is also considered that a conductor segment coil is formed by connecting them together into a coil shape.

  Further, a plurality of conductor coils are formed in a coil shape by connecting a plurality of conductor segments, and a plurality of unit coils are provided, and a plurality of unit coils are connected in the circumferential direction of the stator core to constitute a stator coil for each phase. Is also considered. Note that there is Patent Document 1 as a prior art document related to the present invention.

JP 2004-15839 A

  In a stator composed of such a conductor segment, the two legs constituting the conductor segment protrude from the other axial side surface of the stator core in order to join the ends of the conductor segments adjacent in the radial direction. The lead side portion may be bent at the first bending portion on the side closer to each other in the circumferential direction, and further, the leading end portion may be bent at the second bending portion at the same position in the circumferential direction of the stator so as to go in the axial direction. Conceivable. The reason for bending the tip portion in the axial direction is to facilitate joining by welding the tip portion. On the other hand, it is conceivable that the positions in the axial direction of the stator are the same in the second bending portion between the conductor segments adjacent in the radial direction. However, in this case, since the bending thickening occurs in the second bending portion, the conductor segments adjacent in the radial direction are prevented from interfering with each other in the radial direction at the second bending portion. It may be required to provide a radial gap between the two. For this reason, it is necessary to bend the coil end constituent parts on the joint side of each leg part greatly in the radial direction, so-called shift bending, and the coil end height is the radial length of the coil end on the joint side of the conductor segment. May become large. Moreover, in this case, the difficulty in the twisting process of each conductor segment increases. In addition, a large gap may be required between the conductor segments arranged in the slot. For this reason, the space factor of the conductor in a slot falls, and causes the enlargement of a stator core.

  On the other hand, when the conductor segments adjacent in the radial direction are excessively in contact with each other in the radial direction at the second bending portion and excessively interfere with each other, there is a possibility that the insulating coating of the conductor segments is rubbed and damaged. In this case, the insulation performance of the conductor segment may be reduced.

  On the other hand, Patent Document 1 simply has a structure in which a stator coil is configured by a plurality of U-shaped conductor segments, and the two straight portions of the conductor segments are inserted into the stator core and then opened to each other or to each other. Only a configuration for folding in the closing direction is described. In such a configuration, the same disadvantage as described above may occur.

  An object of the present invention is to reduce the radial length of the coil end on the joining side of the conductor segment while sufficiently securing the insulation performance of each segment coil in the rotating electrical machine stator and the manufacturing method of the rotating electrical machine stator. Objective.

  A rotating electrical machine stator according to the present invention includes a stator core having slots provided at a plurality of locations in the circumferential direction, and a multi-phase stator coil wound around the stator core in a distributed winding. A segment coil formed of a plurality of U-shaped conductor segments having two parallel legs in the section, and aligned along the radial direction of two slots arranged at a predetermined unit coil interval In addition, a plurality of conductor segments are inserted from one axial direction side of the stator core to the other axial direction side, and a portion protruding from the side surface of the stator core at the distal end portion of the two leg portions of each conductor segment is circumferentially formed by the first bent portion or Bending in the direction inclined in the circumferential direction, bending to the axial direction at the second bending portion on the tip side from the first bending portion, and forming on one side of one conductor segment A portion on the tip side of the second bent portion of the portion and a portion on the tip side of the second bent portion of the leg portion on the other side of the other conductor segment adjacent to the one conductor segment in the radial direction. The second bending portion provided on each of the two leg portions adjacent to each other in the radial direction includes segment coils formed in a coil shape by repeating this for each conductor segment. The rotating electrical machine stator is provided.

  In the rotating electrical machine stator according to the present invention, preferably, each segment coil is configured to have a second bent portion provided in a plurality of conductor segments arranged so as to be aligned in the radial direction of the stator, and a shaft of the stator core. The axial distance between the other side surfaces in the direction alternately changes in magnitude in the radial direction in the plurality of conductor segments.

  The rotating electrical machine stator manufacturing method according to the present invention includes a stator core having slots provided at a plurality of locations in the circumferential direction, and a multi-phase stator coil wound around the stator core in a distributed winding, and each phase stator. The coil is a segment coil formed from a plurality of U-shaped conductor segments each having two parallel legs at both ends, and is in the radial direction of two slots arranged at predetermined unit coil intervals. A plurality of conductor segments are inserted from one axial side of the stator core to the other axial side so as to align along the stator core, and a portion protruding from the side surface of the stator core at the tip of the two leg portions of each conductor segment is bent first. And bent in the circumferential direction or in a direction inclined in the circumferential direction, and bent toward the axial direction at the second bending portion on the tip side of the first bending portion. A portion on the tip side of the second bent portion of the leg portion on one side of the ment, and a tip portion side of the second bent portion of the leg portion on the other side of the other conductor segment radially adjacent to the one conductor segment. A rotating electrical machine stator manufacturing method including a segment coil formed in a coil shape by connecting portions and repeating this for each conductor segment, comprising a plurality of conductor segments from one axial side of the stator core to the other axial side After inserting each leg part, among the leg parts on one side of each conductor segment protruding from the side surface of the stator core, the tip part of the one leg part arranged at the first position which is the same position in the radial direction of the stator core Of the leg portions on the other side of the respective conductor segments that are respectively inserted into the plurality of first insertion holes formed in the first jig and protrude from the side surface of the stator core, the second position is the same in the radial direction of the stator core. The distal ends of the other leg portions arranged in the device are respectively inserted into a plurality of second insertion holes formed in the second jig, and the first jig is twisted toward the stator core and toward one side in the circumferential direction. The tip of the leg on one side is bent at the first and second bent parts by moving the second jig so that the second jig is twisted toward the stator core and the other side in the circumferential direction. Bending the tip of the other leg by the first bent portion and the second bent portion, and the first insertion hole includes a step having an insertion length different from that of the second insertion hole. This is a method of manufacturing a rotating electrical machine stator.

  According to the rotating electrical machine stator according to the present invention, the second bent portion provided in each of the leg portions of the two conductor segments adjacent to each other in the radial direction is provided at a different position with respect to the axial direction of the stator. However, the second bent portions are not opposed to each other, and the coil end constituent portions on the joining side of the conductor segments are not greatly bent in the radial direction, so that the insulating portions covering the respective portions can be prevented from excessively contacting each other. For this reason, it is possible to reduce the length in the radial direction of the coil end on the joining side of the conductor segment while sufficiently ensuring the insulation performance in each segment coil.

It is a perspective view which shows the rotary electric machine stator of embodiment which concerns on this invention. It is a figure which shows the state before arrange | positioning one conductor segment which comprises each phase stator coil of FIG. 1 in a stator core. FIG. 2 is a schematic perspective view illustrating a state in which a stator coil for a U phase that is one phase is wound in the stator of FIG. 1. It is a figure which takes out and shows the stator coil for U phase which is the part for 1 phase in FIG. It is a figure which shows eight unit coils from the 1st to the 8th of the winding start of the front half part among the stator coils of FIG. It is a schematic diagram explaining a mode that eight unit coils of the first half part of FIG. 5 are wound around a stator core. FIG. 7 is a schematic diagram for explaining a state where eight unit coils in the latter half are wound around the stator core following FIG. 6. In FIG. 1, it is a partial expansion perspective equivalent view shown in the state before joining the front-end | tip part of the leg part of two conductor segments adjacent to radial direction. It is the enlarged view which looked at FIG. 8 in radial direction. FIG. 2 is a perspective view showing a state before bending the conductor segment after inserting the leg portion of the conductor segment into the stator core in the stator manufacturing method of FIG. 1. It is a schematic diagram which shows the state which inserted the leg part in the 1st jig and the 2nd jig. It is a figure which shows the 1st annular element which comprises a 1st jig | tool seeing from an insertion side. It is a schematic diagram for demonstrating a mode that the 1st jig and the 2nd jig are moved so that it may be twisted in the case of bending formation of a leg part. It is an AA cross-sectional enlarged view of FIG. (A) is BB sectional drawing of FIG. 14, (b) is CC sectional drawing of FIG. FIG. 9 is a view corresponding to FIG. 8 in the rotating electrical machine stator of the comparative example. It is the enlarged view which looked at FIG. 16 in radial direction. FIG. 5 is a partial cross-sectional view in the circumferential direction corresponding to one slot in a rotating electrical machine stator of a comparative example. It is the D section enlarged view of FIG. 18 which exaggerates and shows the bending thickness of a 2nd bending part.

  Hereinafter, an embodiment according to the present invention will be described with reference to FIGS. The rotating electrical machine stator (hereinafter simply referred to as “stator”) of the present embodiment is used to configure a rotating electrical machine such as an electric motor or a generator. The stator 10 includes a stator core 14 made of an annular magnetic material, and three-phase segment annular portions 16, 18, and 20 that are a plurality of phases wound around the stator core 14 by distributed winding. Prepare. When the stator 10 is used, a rotor (not shown) fixed to the rotating shaft is arranged on the radially inner side of the stator 10, and the stator 10 and the rotor are opposed to each other in the radial direction to constitute a radial rotating electric machine. To do. The stator core 14 is composed of, for example, a powder magnetic core formed by press-molding magnetic powder, or a laminate of metal plates such as electromagnetic steel plates. The stator core 14 has slots 12 formed radially at a plurality of locations on the inner peripheral surface in the circumferential direction.

  The segment annular portions 16, 18, and 20 of each phase are formed by connecting conductor segment coils (hereinafter simply referred to as “segment coils”) 22 that are a plurality of stator coils in a ring shape, and are connected to each other. It includes an element 24 (FIG. 5) and a second turn element 26 (FIG. 7). Each segment coil 22 is formed by arranging a plurality of substantially U-shaped conductor segments 28 shown in FIG. Each conductor segment 28 includes two parallel leg portions 32 having straight portions 30 respectively inserted into two slots 12 (FIG. 1) at both ends in the width direction (left-right direction in FIG. 2), and leg portions 32. And a connecting portion 34 that connects one ends of the two. In addition, the conductor segment 28 is covered with an insulating coating 38 which is an insulating portion made of polyamide imide or the like around the conductor wire 36 except for both ends.

  That is, the stator 10 (FIG. 1) according to the present embodiment is a so-called “segment coil winding type”, in which a conductor wire 36 that is a rectangular wire such as a rectangular wire having a rectangular cross section is covered with an insulating film 38. A plurality of segment coils 22 (FIG. 1) in which coil wires are formed in a coil shape are provided. And the segment annular parts 16, 18, and 20 of each phase are comprised by connecting the some segment coil 22 by the circumference direction of the stator core 14 for at least 1 round (in this embodiment, 2 rounds). In FIG. 1, the portions denoted by “u”, “v”, and “w” represent the U phase, the V phase, and the W phase, respectively.

  FIG. 3 is a schematic perspective view showing a state in which the segment annular portion 16 for the U phase that is one phase is wound around the stator core 14 in the stator 10 of FIG. 1. The segment annular portions 16, 18, and 20 of each phase (hereinafter, described as the U-phase segment annular portion 16 as a representative) are unit coil intervals D1 (FIG. 5) each having a predetermined circumferential width. The stator core 14 is wound around the stator core 14 so that the segment coils 22 as eight unit coils are connected in a ring shape, and the stator core 14 is turned around once as a first-round element 24. The segment annular portion 16 is configured by causing the stator core 14 to make one turn around the stator core 14 wound around the stator core 14 so as to be connected in an annular shape. In this case, the slot 12 in which the first-round element 24 is arranged and the slot 12 in which the second-round element 26 are arranged are shifted one by one in the circumferential direction.

  FIG. 4 is a view showing the U-phase segment annular portion 16 taken out. The basic shapes of the V-phase and W-phase segment annular portions 18 and 20 are the same as in the U-phase. The U-shaped segment annular portion 16 is configured by combining 16 segment coils 22 which are unit coils each having a coil wire formed in a coil shape. In FIG. 4, C1, C2,..., C16 are coil numbers for distinguishing the 16 segment coils 22, and the segment in which the winding start of the U-phase segment annular portion 16 is the first unit coil. In the coil C1, the winding end is a segment coil C16 which is the 16th unit coil.

  As shown in FIG. 4, the segment coil C2 is disposed adjacent to the segment coil C1, and subsequently disposed adjacent to C3, C4,. For this reason, the coil number is i, and the i-th coil and the (i + 8) -th coil are arranged so as to partially overlap in the radial direction although they are shifted by one slot.

  FIG. 5 is a diagram showing the first-round element 24 extracted from the segment annular portion 16 of FIG. The first circumference element 24 of the segment annular portion 16 is configured by connecting eight segment coils 22 in an annular shape. Each segment coil 22 includes a plurality of conductor segments 28. In FIG. 5, the ninth to sixteenth segment coils 22 of the second-round element 26 (see FIG. 7) of the segment coil 22 are omitted, but the basic shape is the first-round element of FIG. Similar to the shape of 24, the arrangement position is shifted in the circumferential direction with respect to the first-round element 24.

  FIG. 6 is a schematic diagram for explaining a state in which the first-round element 24 is arranged on the stator core 14 in the segment annular portion 16 in FIG. 4. FIG. 7 is a schematic diagram for explaining a state in which the second-round element 26 is arranged on the stator core 14 in the segment annular portion 16 in FIG. 4. In FIG. 7, the first-round element 24 of FIG. 6 is omitted. 6 and 7 show a plan view of the stator core 14 and a plurality of segment coils 22 on the outside thereof. The segment coil 22 is wound around a plurality of locations in the circumferential direction of the stator core 14 so as to be inserted into two slots 12 that are separated in the circumferential direction so as to straddle several slots 12. The two slots 12 are separated by a predetermined unit coil interval D1. Hereinafter, the segment coil 22 may be described with a coil number. The segment coil C1 shown in FIG. 6 is connected to the input terminal side (IN side), which is the power line side of the rotating electrical machine, at the start of winding of the segment annular portion 16 (FIG. 4). The segment coil C1 is formed in a coil shape by winding a coil wire a plurality of times between the slots S4 and S10. This winding start is on the outer peripheral side of the stator core 14 on the input terminal side, and is wound around the slot 12 in a coil shape so as to go from the outer peripheral side to the inner peripheral side. Next, the segment coil C1 is connected to the segment coil C2 at the end of winding. That is, the segment coil C1 is formed into a coil shape by winding the coil wire a plurality of times between the slots S10 and S16 over the slot S16 that is separated from the slot S10 by the unit coil interval D1 at the end of the winding of the segment coil C1. C2 is configured. Subsequently, this is sequentially repeated to form the segment coil C1 to the segment coil C8, whereby the first-round element 24 is configured.

  The winding end of the first turn element 24 is connected to the segment coil C9 of the second turn element 26 shown in FIG. At this time, the segment coil C9 is formed in a coil shape by being wound one slot from the segment coil C1 and wound a plurality of times between the slots S3 and S9. Next, it is connected to the segment coil C10 at the end of winding of the segment coil C9. That is, the segment coil C9 is formed in a coil shape by winding a coil wire a plurality of times between the slots S9 and S15 over the slot S15 that is separated from the slot S9 by the unit coil interval D1 at the end of winding of the segment coil C9. C10 is constituted. Subsequently, this is sequentially repeated to form the segment coil C9 to the segment coil C16, whereby the second circuit element 26 is configured.

  Further, the winding end of the segment coil C16 is taken out from the outermost peripheral side of the stator core 14 and connected to the neutral point of the rotating electrical machine. In FIG. 7, the winding end of the segment coil C16 is shown as OUT (neutral point). As described above, the slot 12 in which the first-round element 24 and the second-round element 26 of the segment annular portion 16 are arranged is shifted in the circumferential direction. Although the U-phase segment annular portion 16 has been described above, the V-phase and W-phase segment annular portions 18 and 20 are similarly configured, and as shown in FIG. 1, the V-phase segment annular portion 18 is arranged. The slot 12 to be shifted is shifted by 2 in the circumferential direction, and the slot 12 in which the W-phase segment annular portion 20 is arranged is further shifted by 2 in the circumferential direction.

  In constructing the segment annular portions 16, 18, and 20 of each phase, a plurality of substantially U-shaped conductor segments 28, one of which is shown in FIG. 2, are used. That is, one segment coil 22 is configured by connecting a plurality of conductor segments 28, and the segment annular portions 16, 18, 20 of each phase are configured by connecting a plurality of segment coils 22. In this case, each conductor segment 28 has two parallel leg portions 32 provided at both ends at the same interval as the unit coil interval D1, and one end of each leg portion 32 is connected by a connecting portion 34. . When each segment coil 22 (FIG. 1) is configured, a plurality of, for example, five conductor segments 28 are used, and along the radial direction of the two slots 12 arranged at a predetermined unit coil interval D1. The stator core 14 is inserted from one axial side to the other axial side so as to be aligned. Then, at the tip ends of the two leg portions 32 of each conductor segment 28, the portions protruding from the other axial side surface of the stator core 14 are mutually circumferential (“circumferential direction” refers to the circumferential direction of the stator unless otherwise specified). The same in the whole specification and claims). Further, the distal end portion of the leg portion 32 on one side of one conductor segment 28 and the radial direction of the one conductor segment 28 (“radial direction” means the radial direction of the stator unless otherwise specified). The same applies to the whole and claims.) The tip of the leg 32 on the other side of the other conductor segment 28 adjacent to each other is connected by welding such as TIG welding, and this is repeated for each conductor segment 28. Thus, the coiled segment coil 22 is formed.

  In particular, in the present embodiment, the axial direction of a part of the bent portion on the joining side of each conductor segment 28 (“axial direction” means the axial direction of the stator unless otherwise specified. The entire specification and patents) The same is applied in the claims.) The positions of the adjacent conductor segments 28 are different from each other. 8 and 9 are diagrams for explaining this, and FIG. 8 is a partially enlarged view of FIG. 1 showing a state before joining the distal ends of the leg portions 32 of the two conductor segments 28 adjacent in the radial direction. FIG. 9 is a perspective equivalent view, and FIG. 9 is an enlarged view of FIG. 8 viewed in the radial direction.

  As shown in FIGS. 8 and 9, the tip end portion of the leg portion 32 of the conductor segment 28 extends from one axial side (lower side in FIG. 8) to the other axial side (upper side in FIG. 8) in the slot 12 of the stator core 14. Bending after insertion. At this time, a plurality of conductor segments 28 are inserted in the axial direction of the stator core 14, and project from the other axial end surface (upper side surface in FIG. 8) of the stator core 14 at the tip ends of the two leg portions 32 of each conductor segment 28. The portion is bent in the circumferential direction or the direction inclined in the circumferential direction by the first bending portion 40, and is axially formed by the second bending portions 42a and 42b at the same position in the circumferential direction on the tip side of the first bending portion 40, respectively. Bend to face. Further, a portion of the leg 32 on one side of one conductor segment 28 (on the left side in FIGS. 8 and 9) on the tip side of the second bent portion 42a and the one conductor segment 28 in the radial direction (FIG. 8, 9 is connected by welding to a portion on the tip side of the second bent portion 42b of the other leg portion 32 on the other side of the other conductor segment 28 (on the right side in FIGS. 8 and 9) adjacent to the front and back direction in FIG. By repeating this for each conductor segment 28, a segment coil 22 (FIG. 3) formed in a coil shape is formed.

  Further, the second bent portions 42a and 42b provided in the two leg portions 32 adjacent to each other in the radial direction are provided at different positions with respect to the axial direction of the stator core 14 (y direction in FIGS. 8 and 9). Yes. For example, in FIG. 9, the second bent portion 42 a of the leg portion 32 on one side of one conductor segment 28 is provided at the P position, and is adjacent to the leg portion 32 on one side in the radial direction (front and back direction in FIG. 9). The second bent portion 42b of the leg portion 32 on the other side of the other matching conductor segment 28 is provided at a Q position different from the P position in the axial direction. More specifically, as shown in FIG. 9, when the conductor segment 28 is viewed in the radial direction, the straight lines A1 and B1 passing through the central portion in the width direction of the leg portion 32 inclined with respect to the circumferential direction. The intersections P and Q with the straight lines A2 and B2 passing through the central portion in the width direction of the tip, which is a portion parallel to the axial direction, are provided at different positions in the axial direction. Accordingly, the axial distance L1 between the second bent portion 42a provided in one conductor segment 28 and the other axial side surface S of the stator core 14 and another conductor adjacent to the one conductor segment 28 in the radial direction. Unlike the axial interval L2 between the second bent portion 42b provided in the segment 28 and the other axial side surface S of the stator core 14, in FIG. 9, L1 is smaller than L2 (L1 <L2). . In FIG. 8, the tip end edge of the leg portion 32 on one side of one conductor segment 28 and the tip edge of the leg portion 32 on the other side of another conductor segment 28 are illustrated in the same axial direction. The axial positions of both tip edges may be slightly shifted.

  Further, each segment coil 22 (FIG. 3) constitutes a second bent portion 42a, 42b provided in a plurality of conductor segments 28 arranged so as to be aligned in the radial direction, and the other axial side surface of the stator core 14; The axial distances L1 and L2 (FIG. 9) are alternately changed in magnitude in the radial direction at the plurality of conductor segments. More specifically, two radially adjacent leg portions 32 each having the shape shown in FIG. 9 are arranged in the radial direction.

  Next, a method for forming the segment coil 22 so that the second bent portions 42a and 42b are different in the axial direction will be described. First, as an “insertion step”, as shown in FIG. 10, a plurality of conductor segments 28 constituting each segment coil 22 (FIG. 3) of each phase are respectively inserted into two slots 12 separated in the circumferential direction of the stator core 14. Insert from one axial side (lower side in FIG. 10) to the other side (upper side in FIG. 10) so as to align along the direction. Then, as the “bending preparation step”, the leading end portions of the conductor segments 28 are inserted into the first jig 48 and the second jig 50 each having a plurality of annular elements 44 and 46. The plurality of first annular elements 44 included in the first jig 48 and the plurality of second annular elements 46 included in the second jig 50 are different from each other in diameter, and as illustrated in a schematic diagram in FIG. 44 and second annular elements 46 are alternately arranged in the radial direction. The first annular elements 44 are connected to each other, and the second annular elements 46 are also connected to each other. Then, as shown in FIG. 12, the first annular element 44 is formed so that the first insertion holes 52 are arranged at a plurality of positions in the circumferential direction on the insertion side surface of the distal end portion of the conductor segment 28 (FIG. 11). . Similarly, in the second annular element 46 (FIG. 11), the second insertion holes 54 (FIG. 11) are formed at a plurality of locations in the circumferential direction on the insertion side surface of the distal end portion of the conductor segment 28.

  As shown in FIG. 11, the insertion length La of the first insertion hole 52 of the first annular element 44 is different from the insertion length Lb of the second insertion hole 54 of the second annular element 46, where La is Lb. (La> Lb). And the front-end | tip part of the leg part 32 of the one side of the conductor segment 28 arrange | positioned in each radial element 44,46 among the several conductor segments 28 at the radial direction same position is inserted. In addition, an engagement portion for maintaining the shape of the root portion is provided at the root portion of the portion protruding from the other axial side surface of the stator core 14 at the tip end portion of the leg portion 32 of each conductor segment 28, and the ring is arranged in the circumferential direction. A root support jig (not shown) having a shape divided at a plurality of locations is engaged.

  As the “bending step”, the jigs 48 and 50 are moved so as to be twisted in the circumferential direction and the axial direction, whereby the tip end portions of the leg portions 32 of the conductor segments 28 are bent. In this regard, with reference to FIGS. 13 to 15, one first annular element 44 constituting the first jig 48 and the second jig 50 are constituted, and the first annular element 44 is adjacent to the first annular element 44 in the radial direction. A description will be given using the second annular element 46. 13-15, the 2nd annular element 46 is arrange | positioned in the radial direction outer side of the 1st annular element 44. In FIG. In the “bending preparation step”, as shown in FIGS. 14 and 15, the plurality of first insertion holes 52 formed in the first annular element 44 have the same radial direction among the leg portions 32 on one side of each conductor segment 28. The tip of the leg portion 32 on one side arranged at the first position, which is the position, is inserted. In addition, in the plurality of second insertion holes 54 formed in the second annular element 46, the other side legs 32 arranged on the other side of the leg portions 32 on the other side of the conductor segments 28 are arranged on the other side. The tip of the leg 32 is inserted. In this state, the first jig 48 is moved to twist toward the lower stator core 14 (FIG. 10) in FIG. 14 and toward one side in the circumferential direction (in the direction of arrow α in FIGS. 13 to 15). Thus, the tip end portion of the leg portion 32 on one side is bent by the first bending portion 40 (FIG. 9) and the second bending portion 42a (FIG. 9). Further, the tip of the leg 32 on the other side is moved by twisting the second jig 50 toward the stator core 14 and toward the other side in the circumferential direction (in the direction of arrow β in FIGS. 13 to 15). The first bent portion 40 and the second bent portion 42b (FIG. 9) are bent.

  Accordingly, as shown in part in FIGS. 8 and 9, the second bent portions 42a and 42b provided on the two leg portions 32 adjacent to each other in the radial direction are provided at different positions in the axial direction. . Then, the conductor wires 36 which are ends exposed from the insulating coating 38 of the two leg portions 32 are connected to each other by welding such as TIG welding, and the segment coil is repeated by the conductor segments 28 adjacent in the radial direction. 22 (FIG. 3) is formed. In addition, the segment coils 22 adjacent to each other in the circumferential direction are connected to the end portions of the bent portions of the distal end portions of the conductor segments 28 on the radially inner side or radially outer side, so that the segment annular portions of each phase described above are connected. 16, 18, and 20 (FIG. 1) are formed.

  In addition, each 1st annular element 44 which comprises the 1st jig | tool 48 of FIG. 11 is not mutually connected, and each 2nd annular element 46 which comprises the 2nd jig 50 is not mutually connected, In a bending step, each 1st annular element 44 is connected. It is also possible to move the annular element 44 and each second annular element 46 separately in the circumferential direction and the axial direction, and bend the distal end portion of the leg portion 32 of the corresponding conductor segment 28. Further, in FIG. 9, one side in the circumferential direction from the center with respect to the circumferential distance D1 of the two slots 12 (FIG. 8) of the stator core 14 for inserting the leg portions 32 of each conductor segment 28 in the circumferential direction (FIG. 9). Although the second bent portions 42a and 42b are illustrated in a position close to the right side), the circumferential positions of the second bent portions 42a and 42b are not limited to such positions. The second bent portions 42a and 42b may be provided at circumferential positions that coincide with the center position of the direction interval D1.

  According to the stator 10 and the manufacturing method of the stator 10, the second bent portions 42 a and 42 b provided in the leg portions 32 of the two conductor segments 28 that are adjacent to each other in the radial direction are provided in the axial direction of the stator 10. Are provided at different positions. For this reason, the conductor segments 28 are not opposed to each other between the second bent portions 42a and 42b, and the coil end constituent portions on the joining side of the conductor segments 28 are largely bent in the radial direction, that is, without being greatly shifted and bent, respectively. It is possible to prevent the insulating coating 38 covering the surface from being excessively contacted. For this reason, it is possible to reduce the length in the radial direction of the coil end on the joining side of the conductor segment 28 while sufficiently ensuring the insulation performance in each segment coil 22.

  In addition, since it is not necessary to perform a large shift bending in the radial direction on the joining side of each conductor segment 28, the twisting process in the bending step can be facilitated. In addition, since the gap between the conductor segments 28 arranged in the slot 12 can be reduced or eliminated, the space factor of the conductor in the slot 12 can be increased, and the stator core 14 can be downsized.

  In addition, each segment coil 22 is configured to include second bent portions 42a and 42b provided on a plurality of conductor segments 28 arranged so as to be aligned in the radial direction of the stator 10 and the other axial side surface of the stator core 14. The intervals in the axial direction are alternately changed in magnitude in the radial direction in the plurality of conductor segments 28. For this reason, while preventing the 2nd bending parts 42a and 42b of all the conductor segments 28 adjacent to radial direction facing radial direction, the structure where the radial direction length of a coil end is small can be implement | achieved more easily. .

  On the other hand, FIGS. 16 to 19 show a configuration of a comparative example that departs from the present invention. FIG. 16 is a view corresponding to FIG. 8 in the stator of the comparative example. FIG. 17 is an enlarged view of FIG. 16 viewed in the radial direction. FIG. 18 is a partial cross-sectional view in the circumferential direction corresponding to one slot 12 in the stator 10 of the comparative example. FIG. 19 is an enlarged view of a portion D in FIG. 18, exaggerating the bending thickness of the second bending portion 56.

  In this comparative example, unlike the present embodiment, each segment coil 22 (see FIG. 3) is configured, and the conductor segments 28 adjacent to each other in the radial direction are arranged in the axial direction ( The position in the y direction in FIG. 16 is the same. That is, as shown in detail in FIG. 17, the second bent portion 56 of the one leg portion 32 of the one conductor segment 28 (on the left side in FIG. 17) is provided at the P2 position. Q2 position where the second bent portion 56 of the leg 32 on the other side of another conductor segment 28 (on the right side in FIG. 17) adjacent in the radial direction (front and back direction in FIG. 17) is the same position as the P2 position in the axial direction. Is provided. Other configurations are the same as those in the present embodiment.

  In such a comparative example, as shown in FIGS. 18 to 19, the conductor segments 28 adjacent to each other in the radial direction (left and right directions in FIGS. 18 and 19) are provided at the coil ends on the joining side of the conductor segments 28. Since the second bent portion 56 thus formed is opposed to the radial direction, as shown in an exaggerated manner in FIG. 19, the bending thickness associated with the formation of the second bent portion 56 is also opposed to the radial direction. Thus, there is a possibility that the coil end constituent portion on the joining side of each conductor segment 28 needs to be greatly bent in the radial direction. For this reason, the radial length of the coil end on the joining side of the conductor segment 28 may be increased. Further, when a radial gap is provided between the second bent portions 56, the radial length of the coil end on the joining side of the conductor segment 28 may be further increased. On the other hand, according to the present embodiment shown in FIGS. 1 to 15, the second bent portions 42 a and 42 b (FIGS. 8 and 9) do not face each other in the radial direction. Inconvenience can be eliminated, and the radial length of the coil end on the joining side of the conductor segment 28 can be reduced while sufficiently ensuring the insulation performance of each segment coil 22 (FIG. 3).

  Insulating paper composed of annular PPS or the like is arranged on each of the connecting portion 34 (FIG. 2) side of the conductor segment 28 constituting the coil end and the joining side, and is adjacent in the radial direction at the coil end. The insulation between the outer surfaces of the conductor segments 28 can also be made higher.

  10 stator, 12 slots, 14 stator core, 16, 18, 20 segment annular part, 22 conductor segment coil, 24 1st element, 26 2nd element, 28 conductor segment, 30 straight part, 32 legs, 34 connecting part , 36 conductor wire, 38 insulating coating, 40 first bent portion, 42a, 42b second bent portion, 44 first annular element, 46 second annular element, 48 first jig, 50 second jig, 52 first insertion hole 54 2nd insertion hole, 56 2nd bending part.

Claims (3)

A stator core having slots provided at a plurality of locations in the circumferential direction;
A multi-phase stator coil wound in a distributed manner around the stator core,
The stator coil of each phase
Segment coils formed from a plurality of U-shaped conductor segments each having two parallel legs at both ends, aligned along the radial direction of two slots arranged at predetermined unit coil intervals The plurality of conductor segments are inserted from one axial side of the stator core to the other axial side so that the end of the two leg portions of each conductor segment protrudes from the side surface of the stator core with the first bent portion. Bending in the direction inclined in the direction or circumferential direction, bending to the axial direction at the second bending portion on the tip side from the first bending portion, and the second bending of the leg portion on one side of one conductor segment A portion closer to the tip than the portion and a portion closer to the tip than the second bent portion of the leg on the other side of the other conductor segment radially adjacent to the one conductor segment are connected to each conductor. Repeat in segment Includes a segment coil formed into a coil shape by,
The rotating electrical machine stator, wherein the second bending portion provided in each of the two leg portions adjacent to each other in the radial direction is provided at a different position with respect to the axial direction of the stator. The rotating electrical machine stator according to claim 1,
An axial interval between the second bent portion provided in the plurality of conductor segments arranged to be aligned in the radial direction of the stator and the other side surface in the axial direction of the stator core is constituted by a plurality of segment coils. A rotating electrical machine stator, wherein the conductor segments alternately change in size in the radial direction. A stator core having slots provided at a plurality of locations in the circumferential direction;
A multi-phase stator coil wound in a distributed manner around the stator core,
The stator coil of each phase
Segment coils formed from a plurality of U-shaped conductor segments each having two parallel legs at both ends, aligned along the radial direction of two slots arranged at predetermined unit coil intervals The plurality of conductor segments are inserted from one axial side of the stator core to the other axial side so that the end of the two leg portions of each conductor segment protrudes from the side surface of the stator core with the first bent portion. Bending in the direction inclined in the direction or circumferential direction, bending to the axial direction at the second bending portion on the tip side from the first bending portion, and the second bending of the leg portion on one side of one conductor segment A portion closer to the tip than the portion and a portion closer to the tip than the second bent portion of the leg on the other side of the other conductor segment radially adjacent to the one conductor segment are connected to each conductor. Repeat in segment A method of manufacturing a rotary electric machine stator comprising a segment coil formed into a coil shape by,
After inserting the respective leg portions of the plurality of conductor segments from the one axial side of the stator core to the other axial side, among the leg portions on one side of the respective conductor segments protruding from the side surface of the stator core, the stator core is in the same radial position. Of the leg portions on the other side of the respective conductor segments, the tip portions of the one leg portions arranged at the first position are respectively inserted into the plurality of first insertion holes formed in the first jig, and project from the side surfaces of the stator core. The distal ends of the other leg portions arranged at the second position, which is the same radial position of the stator core, are respectively inserted into a plurality of second insertion holes formed in the second jig, and the first jig is attached to the stator core. The tip of the leg on one side is bent by the first and second bent portions by moving the wire so as to twist toward the one side in the circumferential direction, and the second jig is moved toward the stator core, and , On the other side in the circumferential direction The step of bending the tip of the other leg by bending the first and second bent portions by moving the first insert hole so that the first insert hole has an insertion length different from that of the second insert hole. The manufacturing method of the rotary electric machine stator characterized by including the step which has these.

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