JP2012235544A - Motor manufacturing method, and motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a motor in which a distributed winding coil using a flat conductive wire can be easily inserted into a slot from a shaft center direction.SOLUTION: A motor manufacturing method comprises: a first step which winds a flat conductive wire 20 in a triangular shape; a second step which folds the coil conductive wire wound in the triangular shape to be a L-shape; and a third step which expands the L-shape flat conductive wire 20 so as to form two in-slot conductive wire parts. In the second step, a tip-contact part 21a of a first rotary jig 21 that performs press molding for a longest side part T1 of the triangular shape, is in contact with a contact point T1a which is a same position in the longest side part T1; and a rotation center of the folded part of a shortest side part T3 of the triangular shape is the same position P1 as a rotation center of a second rotary jig 23 that performs press molding for the shortest side part T3.

Description

  The present invention relates to a motor having a stator including a distributed winding coil using a flat conductor and a stator core, and a rotor having a central axis.

For example, inserting and assembling a distributed winding coil using a flat conducting wire having a cross section of about 1 mm × about 10 mm into a slot of the stator core, unlike a round thin wire, the flat conducting wire has strong rigidity and is difficult to deform. It was difficult. Various proposals have been made to solve the problem.
In Patent Document 1, when a coil wound with a conducting wire is inserted into a slot formed around the teeth from the inside to the outside in the radial direction, the width of the conducting wire or the coil is easily inserted. It has been proposed to devise an inclination angle.
On the other hand, in Patent Document 2, a coil is configured by overlappingly winding a conductive wire inserted into a slot, mounting the coil on an insertion jig, and placing the insertion jig in the stator core. A method for inserting a coil into a slot is disclosed.
Further, Patent Document 3 discloses that in a distributed winding coil, a distal end portion to be inserted is bent toward the axial center side.

JP 2002-051489 A JP 2008-167567 A International Publication WO 92/01327

However, the conventional method of inserting a coil into a stator core has the following problems.
That is, as in Patent Document 1, in the method of inserting a coil separately for each tooth, insertion has to be performed a number of times corresponding to the number of teeth, and there is a problem that it takes time to insert. In addition, there is a problem that the insertion device becomes complicated and large.
Further, as in Patent Document 2, when an insertion jig is used, even if the insertion is successful, the coil is spring-loaded after the coil that has been elastically deformed in the insertion jig is inserted into the slot. There was a problem that a part of the conductive wire jumped out of the slot due to deformation by the back.

In the techniques of Patent Documents 1 and 2, since the coil is inserted from the inside to the outside in the radial direction with respect to the teeth slot, the above problem occurs. The present applicant has come to realize that the above problem can be solved if it can be inserted into the slot from the direction.
However, in the case of concentrated winding coils, it is easy to insert the remaining portion into the slot if the tip end to be inserted is bent to the axial center side, but in the distributed winding coil, the shape of the bent portion is complicated. There was a problem that it was difficult to bend itself.
As a technique for bending a tip portion to be inserted with a concentrated winding coil, the technique of Patent Document 3 is disclosed. However, in the technique of Patent Document 3, a plurality of conductors having different bent portions are individually manufactured and combined. Therefore, it takes time to manufacture and there is a problem of high cost.

In order to solve the above problems, the present applicants filed Japanese Patent Application No. 2010-095759, and a motor of a motor having a stator having a distributed winding coil wound with a flat conductive wire and a rotor having a central shaft In the manufacturing method, a first step of winding the coil lead wire in a triangular shape, a second step of bending the coil lead wire wound in a triangular shape into an L shape, and the L shape of the coil lead wire in two slots A motor manufacturing method having a third step of expanding so as to form an inner conductor portion is proposed.
The present applicants continue to develop after the filing of Japanese Patent Application No. 2010-095759, and in the second step, the accuracy of bending the coil conducting wire wound in a triangular shape into an L-shape is improved in the subsequent step (particularly the third step). It was discovered that it greatly affects the efficiency of the process. Therefore, in the second step, a method of bending into an L shape with high accuracy is required.
In the second step, if slip occurs between the forming jig and the flat wire, the flat wire may be extended or the surface insulating film may be damaged.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a low-cost motor in which a distributed winding coil using a flat wire can be easily inserted into a slot from the axial direction. .

In order to solve the above problems, the motor and the motor manufacturing method of the present invention have the following configurations.
(1) In a motor manufacturing method for a motor having a stator including a distributed winding coil wound with a flat conductive wire and a rotor having a central axis, a first step of winding the coil conductive wire in a triangular shape, and winding in a triangular shape A second step of bending the coiled conductor wire into an L-shape, and a third step of expanding the L-shaped coil conductor wire so as to form two in-slot conductor portions. In the second step, During this period, the tip of the first rotating jig that press-molds the longest side of the triangle is in contact with the same position of the longest side, the bent portion of the shortest side of the triangle, and the shortest side The rotation center of the 2nd rotation jig which press-molds a part exists in the same position, It is characterized by the above-mentioned.

(2) In the motor manufacturing method described in (1), in the second step, a third rotating jig is disposed on the middle side of the longest side portion, and the coil end portion at one end of the coil is concentric. Forming a semicircular shape.
(3) In the motor manufacturing method described in (1) or (2), the motor includes a fourth step of inserting the distributed winding coil into the slot of the stator from the axial direction. .

(4) In any one of the motor manufacturing methods described in (1) to (3), the radius of curvature of the inner circumference circle formed by the longest side portion and the intermediate side portion, and the inner circumference circle formed by the intermediate side portion and the shortest side portion The curvature radius of the inner circumferential circle formed by the intermediate side portion and the shortest side portion does not change before and after the second step, the length of the intermediate side portion does not change before and after the second step, It is characterized by.
(5) A motor manufactured by any one of the motor manufacturing methods described in (1) to (4), wherein a coil end portion at one end of the coil is connected to the in-slot conductor of the stator core. It is bent toward the rotor side, the coil end portion at the one end is positioned on the axial center side of the rotor from the inner peripheral surface of the stator core, the coil end portion at the one end, and the coil end portion at the other end A plurality of the rectangular conductor wires are wound in a flatwise direction, the coil end portion at one end forms a concentric semicircle, and the coil end portion at the other end is concentric. It is characterized by forming a semicircle.

Next, the operation and effect of the motor and the motor manufacturing method according to the present invention will be described.
(1) In a motor manufacturing method for a motor having a stator having a distributed winding coil wound with a rectangular conductor and a rotor having a central axis, a first step of winding the coil conductor in a triangular shape, and winding in a triangular shape A second step of bending the coiled conductor wire into an L-shape, and a third step of expanding the L-shaped coil conductor wire so as to form two in-slot conductor portions. In the second step, During this period, the tip of the first rotating jig that press-molds the longest side of the triangle is in contact with the same position of the longest side, the bent portion of the shortest side of the triangle, and the shortest side Since the rotation center of the second rotating jig that press-molds the part is at the same position, slippage may occur between the first rotating jig / second rotating jig and the flat wire. There is no extension of the flat wire or surface insulation. There is no risk of damage to the coating. Further, it can be bent into an L-shape with high accuracy, and can contribute to the efficiency of the subsequent process (particularly the third process).

  Furthermore, when the coil is to be inserted from the axial center side into the stator slot with the coil end portion A side at one end as the head, the coil end A at one end passes inside the inner peripheral surface of the stator core. Therefore, the coil can be easily inserted into the slot from the axial direction. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back. In addition, since a plurality of rectangular conductive wires that are overlapped in the flatwise direction are bent at the same time in a state where they are overlapped, the manufacturing process can be simplified and the cost can be reduced.

(2) In the motor manufacturing method described in (1), in the second step, a third rotating jig is disposed on the middle side of the longest side portion, and the coil end portion at one end of the coil is concentric. Therefore, it can be bent into an L-shape with high accuracy, and can contribute to the efficiency of the subsequent process (particularly the third process).

(3) In the motor manufacturing method described in (1) or (2), the motor includes a fourth step of inserting the distributed winding coil into the slot of the stator from the axial direction. Therefore, when the coil is to be inserted from the axial center side into the stator slot with the coil end portion A side at one end as the head, the coil end A at one end passes inside the inner peripheral surface of the stator core. Therefore, the coil can be easily inserted into the slot from the axial direction. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back.

(4) In any one of the motor manufacturing methods described in (1) to (3), the radius of curvature of the inner circumference circle formed by the longest side portion and the intermediate side portion, and the inner circumference circle formed by the intermediate side portion and the shortest side portion The curvature radius of the inner circumferential circle formed by the intermediate side portion and the shortest side portion does not change before and after the second step, the length of the intermediate side portion does not change before and after the second step, Therefore, it is possible to form each dimension of the L-shaped part after the bending with high accuracy.

(5) The motor of the present invention is a motor manufactured by any one of the motor manufacturing methods described in (1) to (4), wherein a coil end portion at one end of the coil is in a slot of the stator core. The conductor is bent toward the rotor side, the coil end portion at the one end is positioned closer to the axial center of the rotor than the inner peripheral surface of the stator core, the coil end portion at the one end, and the like The coil end portion at the end is formed by wrapping a plurality of the flat conductor wires in the flatwise direction, the coil end portion at the one end forms a concentric semicircle, and the coil at the other end Since the end part forms a concentric semicircle, the coil is inserted from the axial center side into the stator slot with the coil end part A side at one end as the head. When trying to, coil end A of the one end, to pass inside the inner circumferential surface of the stator core can be easily inserted into the slot coil from axially. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back. In addition, since a plurality of rectangular conductive wires that are overlapped in the flatwise direction are bent at the same time in a state where they are overlapped, the manufacturing process can be simplified and the cost can be reduced.

3 is a perspective view of a reference unit 11. FIG. 3 is a front view of a reference unit 11. FIG. 3 is a plan view of a reference unit 11. FIG. 4 is a right side view of the reference unit 11. FIG. It is a figure which shows a winding process among the manufacturing processes of the reference | standard unit 11. FIG. It is a figure which shows the shape of the flat conducting wire 20 after a bending process among the manufacturing processes of the reference | standard unit 11. FIG. It is a figure which shows the shape of the flat conducting wire 20 before a bending process among the manufacturing processes of the reference | standard unit 11. FIG. FIG. 3 is a first diagram illustrating a bending process among the manufacturing processes of the reference unit 11. FIG. 3 is a second view showing a bending step in the manufacturing process of the reference unit 11. It is FIG. 3 which shows a bending process among the manufacturing processes of the reference | standard unit 11. FIG. FIG. 4 is a fourth view showing a bending step among the manufacturing steps of the reference unit 11. FIG. 3 is a first diagram illustrating an expansion process among the manufacturing processes of the reference unit 11. FIG. 3 is a second view showing an expansion process in the manufacturing process of the reference unit 11. It is FIG. 3 which shows an expansion process among the manufacturing processes of the reference | standard unit 11. FIG. FIG. 3 is a first diagram illustrating an insertion process for inserting a reference unit 11 into a stator core 13. It is a figure which shows the whole coil cage | basket 12. As shown in FIG. It is a top view which shows the whole coil cage | basket 12. FIG. It is a front view of the coil cage | basket 12. FIG. FIG. 3 is a first diagram illustrating an insertion process for inserting a reference unit 11 into a stator core 13. FIG. 4 is a second diagram illustrating an insertion process for inserting the reference unit 11 into the stator core 13. FIG. 4 is a third view showing an insertion process for inserting the reference unit 11 into the stator core 13. FIG. 4 is a fourth diagram illustrating an insertion process for inserting the reference unit 11 into the stator core 13. FIG. 3 is a first view showing an insertion process for inserting a rotor 42 into a stator 10. FIG. 4 is a second diagram illustrating an insertion process for inserting the rotor 42 into the stator 10.

Next, a motor and a motor manufacturing method according to an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of a reference unit 11 in which five flat conductors are simultaneously formed. 2 is a front view of the reference unit 11 of FIG. 1, FIG. 3 is a plan view of FIG. 1 viewed from above, and FIG. 4 is a right side view of FIG.
The reference unit 11 includes an in-slot conductor part SA and an in-slot conductor part SB arranged in the slot.
As shown in FIG. 1, the in-slot conductor portion SA is obtained by superposing five flat conductor wires with their long side surfaces (flatwise surfaces) in contact with each other, and in the first slot conductor portion SA1 and the second slot. An assembly of the conductor portion SA2, the third slot conductor portion SA3, the fourth slot conductor portion SA4, and the fifth slot conductor portion SA5 is shown. In addition, as shown in FIG. 4, the in-slot conductor SB is formed by superposing five flat conductors with the long side surfaces (flatwise surfaces) in contact with each other, and the first in-slot conductor SB1, An assembly of the in-slot conductor SB2, the third slot conductor SB3, the fourth slot conductor SB4, and the fifth slot conductor SB5 is shown.

An upper concentric circle G is formed at the center of the coil end portion located on the upper side in FIG. As shown in FIG. 4, the upper concentric circle part G is an aggregate of four rectangular conductors of a second concentric circle part G2, a third concentric circle part G3, a fourth concentric circle part G4, and a fifth concentric circle part G5. The reason why the first concentric circle portion is not included is that an inclined portion EA1 described later protrudes to the outside as a terminal M.
A bent portion IA is formed at the upper end of the in-slot conductor portion SA. The flat conductive wire is bent at the bent portion IA in the direction of the upper concentric circle portion G as shown in FIG. An inclined part EA is formed between the upper concentric circle part G and the in-slot conductor part SA. As shown in FIG. 3, the bent portion IA indicates an assembly of bent portions IA1, IA2, IA3, IA4, and IA5 of five flat conductors. As shown in FIGS. 1 and 4, the inclined portion EA indicates an aggregate of inclined portions EA1, EA2, EA3, EA4, and EA5 of five flat conductors.
In the inclined portion EA, as shown in FIG. 4, five rectangular conductors are overlapped in the radial direction (left-right direction in FIG. 4) in the same manner as the in-slot conductor SA.

A bent portion IB is formed at the upper end of the in-slot conductor portion SB. The flat conductive wire is bent at the bent portion IB in the direction of the upper concentric circle portion G as shown in FIG. An inclined portion EB is formed between the upper concentric circle portion G and the in-slot conductor portion SB. As shown in FIG. 3, the bent portion IB indicates an aggregate of bent portions IB1, IB2, IB3, IB4, and IB5 of five flat conductors. As shown in FIG. 4, the inclined portion EB indicates an aggregate of inclined portions EB1, EB2, EB3, EB4, and EB5 of five flat conductors.
In the inclined portion EB, as shown in FIG. 4, five flat conductors are overlapped in the radial direction (the left-right direction in FIG. 4), like the in-slot conductor SB.

As shown in FIG. 4, the terminal M of EA1 located in the innermost peripheral part of the inclination part EA is bend | folded and protrudes outside. Moreover, the terminal N of EB5 located in the outermost periphery of the inclination part EB is bend | folded and protrudes outside.
A bent portion JA is formed at the lower end of the in-slot conductor portion SA. As shown in FIG. 3, the flat conducting wire is bent at a 90 ° inner peripheral side (left direction in the drawing) at the bent portion JA. As shown in FIG. 4, the bent portion JA indicates an aggregate of bent portions JA1, JA2, JA3, JA4, and JA5 of five flat conductor wires.
A bent portion JB is formed at the lower end of the in-slot conductor SB. As shown in FIG. 3, the flat conducting wire is bent at an inner peripheral side of 90 degrees (the left direction in the drawing) at the bent portion JB. As shown in FIG. 4, an assembly of bent portions JB1, JB2, JB3, JB4, and JB5 of five rectangular conductors is shown.

A lower concentric circle H is formed at the inner circumferential tip. As shown in FIG. 2, a horizontal portion FA is formed between the bent portion JA and the lower concentric circle portion H. A horizontal part FB is formed between the bent part JB and the lower concentric part H.
As shown in FIG. 4, the lower concentric part H indicates an aggregate of lower concentric parts H 1, H 2, H 3, H 4, and H 5 of five flat conductors.
As shown in FIG. 2, the horizontal portion FA indicates an aggregate of horizontal portions FA1, FA2, FA3, FA4, and FA5 of five rectangular conductors. Here, in the horizontal portion FA, the horizontal portions of the five rectangular conductive wires are overlapped in the axial direction (vertical direction in FIG. 2) as shown in FIG.
Moreover, the horizontal part FB has shown the aggregate | assembly of the horizontal parts FB1, FB2, FB3, FB4, and FB5 of five flat conducting wires, as shown in FIG. Here, in the horizontal portion FB, the horizontal portions of the five flat conducting wires are overlapped in the axial direction (vertical direction in FIG. 2) as shown in FIG.

Next, a method for manufacturing the reference unit 11 will be described. The manufacturing method of the reference unit 11 includes a winding process, a bending process, and an expansion process.
FIG. 5 shows a winding process among the manufacturing processes of the reference unit 11.
A triangular mold 19 having a flat cross section is provided to be rotatable about a central axis 19a.
The tip 20 a of the flat conductor 20 is fixed to the mold 19, the mold 19 is rotated in the direction indicated by the arrow P around the central axis 19 a, and the flat conductor 20 is wound around the five-round mold 19. At this time, the rectangular conducting wire 20 is wound in the flatwise direction. That is, the long side of about 3.3 mm of a flat conducting wire having a cross section of about 1.8 mm × about 3.3 mm is overlapped and wound.

Next, the bending process will be described.
FIG. 6 shows the shape of the flat conducting wire 20 after the bending process in the manufacturing process of the reference unit 11. FIG. 7 shows the shape of the rectangular conducting wire 20 before the bending step in the manufacturing process of the reference unit 11.
In FIG. 7, the rectangular conductive wire 20 wound in a triangular shape includes a longest side portion T1, an intermediate side portion T2, and a shortest side portion T3. Here, the radius of curvature of the inner circumferential circle T1a formed by the longest side portion T1 and the intermediate side portion T2 is r3. The radius of curvature of the inner circumference circle T2a formed by the intermediate side portion T2 and the shortest side portion T3 is r2. The radius of curvature of the inner circumference circle T3a formed by the shortest side portion T3 and the longest side portion T1 is r1.
The length of the intermediate side portion T2 (the length of the straight line portion) is l1. The radius of the outer circumference circle formed by the intermediate side portion T2 and the longest side portion T1 is l2.

After the bending process described later, as shown in FIG. 6, the longest side portion T1 of the rectangular conductor wire 20 formed in an L shape is separated into a long side portion T4 and a short side portion T5. Further, an intermediate side portion T2 and a shortest side portion T3 are provided. Here, the radius of curvature of the inner circumferential circle T1a formed by the long side portion T4 and the intermediate side portion T2 is R3. Further, the radius of curvature of the inner circumferential circle T2a formed by the intermediate side portion T2 and the shortest side portion T3 is R2. The radius of curvature of the inner circumference circle T3a formed by the shortest side portion T3 and the short side portion T5 is R1.
The length of the intermediate side portion T2 (the length of the straight line portion) is L1. Further, the radius of the outer circumferential circle formed by the intermediate side portion T2 and the long side portion T4 is L2. Here, in this embodiment, L1 = l1, L2 = l2, R1 = r1, R2 = r2, R3 = r3 It is said.

Next, the bending process will be described with reference to FIGS. 8 to 11 show the time-series changes in the bending process in sequence.
In the winding process, the flat conducting wire 20 wound up for five turns is removed from the mold 19 and set at the position shown in FIG. In this state, the intermediate side portion T <b> 2 of the triangular flat wire 20 is in contact with the tip surfaces of the pair of contact portions 24 a and 24 b of the load receiving jig 24. The weight receiving jig 24 is fixed to the base. A shape matching jig 28 is disposed on the inner peripheral surface of the shortest side T3 of the triangular flat wire 20. The shape matching jig 28 is attached to the base by a spring (not shown) and moves in accordance with the deformation of the flat wire 20. Moreover, after the bending process is completed, when the flat conducting wire 20 is carried out, it returns to its original position by a spring.

  The second rotating jig 22 is disposed so as to face the shortest side T3. The second rotating jig 22 is fixed to the driven gear 26, and is held so as to be rotatable around a point P2 (indicated by x in the figure) located on the inner periphery of the shortest side T3. Here, the bent part of the triangular shortest side T3 is also a point P2. The driven gear 26 is in gear connection with the drive gear 122. The surface facing the shortest side T3 of the second rotating jig 22 includes two contact surfaces 22a and 22b having different inclinations.

Further, the first rotating jig 21 is disposed so as to face the longest side portion T1. The first rotating jig 21 is fixed to the driven gear 25, and is held so as to be rotatable about a point P1 located in the inner periphery of the longest side T3. The driven gear 25 is in gear connection with the drive gear 121. A portion of the first rotating gear 21 facing the longest side portion T1 includes a contact portion 21a having a protruding shape.
Further, the third rotating jig 23 is arranged so as to face the longest side portion T1 side of the outer peripheral surface formed by the longest side portion T1 and the intermediate side portion T2. The third rotating jig 23 is fixed to the driven gear 27, and is held so as to be rotatable around a point P3 (not shown) located on the outer periphery of the intermediate side portion T2. The driven gear 27 is in gear connection with the drive gear 123. The surface facing the longest side portion T1 of the third rotating gear 23 includes two contact surfaces 23a and 23b having different inclinations.

Next, the drive gears 121, 122, and 123 are all appropriately rotated clockwise. Motors are connected to the drive gears 121, 122, and 123, and can be individually controlled.
First, the contact portion 21a of the first rotating jig 21 contacts the contact point T1b of the longest side portion T1. At the same time, the contact surface 22b of the second rotating jig 22 contacts the vicinity of the outer peripheral tip of the shortest side T3. By the cooperative work of the first rotating jig 21 and the second rotating jig 22, the longest side portion T1 starts to be bent at the contact portion 21a. A state in the middle of the bending is shown in FIG.
Here, since the contact point T1b of the longest side portion T1 rotates around the point P1, the contact point 21a of the first rotating jig 21 is always in contact with the contact point T1b. Therefore, no slip occurs between the longest side T1 and the first rotating jig 21, and the insulating coating of the flat conducting wire 20 is not damaged.

Next, FIG. 10 shows a state in which the contact portion 21a of the first rotating jig 21 presses the longest side portion T1 over the entire surface of the intermediate side portion T2. In this state, the shortest side T3 is in the middle of bending. In the state of FIG. 10, the first rotating jig 21 stops rotating. Next, with reference to the side surface 21b of the first rotating jig 21, the second rotating jig 22 further bends the shortest side portion T3, so that the shortest side portion T3 is entirely formed on the side surface 21b as shown in FIG. It will be in a state of being pressed over. Thereby, the long side part T4 and the short side part T5 in which the longest side part T1 is orthogonal to each other are formed.
At the same time, the contact surface of the third rotating jig 23 comes into contact with the outer side of the outer peripheral circle formed as the intermediate side portion of the longest side portion T1, thereby adjusting the shape of a concentric semicircle.

  As described above in detail, in the bending process, the tip contact portion 21a of the first rotating jig 21 that press-molds the longest side portion T1 having a triangular shape is the contact point T1b at the same position of the longest side portion T1. In addition, during the bending process, it is always in contact, the bent portion P2 of the triangular shortest side T3 (indicated by x in the figure), and the second rotating jig 22 for press-molding the shortest side T3. Since the center of rotation is at the same position P2, no slip occurs between the first rotating jig 21 and the second rotating jig 22 and the flat wire 20, and the flat wire 20 extends. There is no risk of occurrence of damage or damage to the insulating film on the surface. Further, it can be bent into an L-shape with high accuracy, and can contribute to the efficiency of the subsequent process (particularly the third process).

Further, in the bending step, the third rotating jig 23 is disposed on the intermediate side T2 side of the longest side T1, and the coil end part of one end of the flat conducting wire 20 is formed in a concentric semicircle. Therefore, an accurate semicircular shape can be formed, and it can be bent into an L shape with high accuracy, thereby contributing to the efficiency of the subsequent process (particularly the third process).
Here, the concentric semicircle is overlapped with the concentric semicircle of the other rectangular conductor at the coil end portion. At that time, since it is accurately formed into a semicircle, it can be densely integrated and the coil end can be made compact.

  Further, the radius of curvature R3 of the inner circumference circle T1a formed by the longest side portion T1 and the intermediate side portion T2, the radius of curvature R2 of the inner circumference circle T2a formed by the intermediate side portion T2 and the shortest side portion T3, and the longest side portion T1 and the shortest side. Since the curvature radius R1 of the inner circumference circle T3a formed by the portion T3 does not change before and after the second step, and the length L1 of the intermediate side portion does not change before and after the second step, the bending is performed. Each dimension of the L-shaped part after molding can be molded with high accuracy.

Next, the expansion process will be described.
FIG. 9 shows the first step of the expansion process in the manufacturing process of the reference unit 11. FIG. 13 shows a second diagram of the expansion process. FIG. 14 shows a side view of FIG.
As shown in FIGS. 9 and 14, the pair of chuck claws 33 (33 </ b> A, 33 </ b> B) grips the upper concentric part G (five rectangular conductive wires). The lower concentric part H (five flat conductors) is fixed to the pair of guide claws 40 (40A, 40B). The in-slot conductor part SA (five flat conductors) is gripped by the pair of chuck claws 32 (32A, 32B). The in-slot conductor SB (five rectangular conductors) is gripped by the pair of chuck claws 31 (31A, 31B).
Here, the pair of chuck claws 32 (32A, 32B) and the pair of chuck claws 31 (31A, 31B) are held rotatably about the central axis 34, respectively. The base plate 36 is fixed to the tips of the two guide bars 38. The two guide bars 38 are slidably held by a fixed portion 39 that is fixed. A main body of a pair of air cylinders 37 is fixed on both sides of the fixed portion 39. Further, the rod tips of a pair of air cylinders 37 are connected to the base plate 36, and the guide rod 38 and the base plate 36 slide relative to the fixed portion 39 by driving the air cylinder 37. A pair of link mechanisms 35A and 35B are attached to the base plate 36, the link mechanism 35A is connected to the base plate of the chuck claw 32, and the link mechanism 35B is connected to the base plate of the chuck claw 31.

With this configuration, as shown in FIG. 9, the air cylinder 37 is driven in a state where each of the rectangular conductive wires 20 is held. As a result, when the base plate 36 slides and reaches the position of FIG. 13, the pair of chuck claws 32 (32A, 32B) rotate clockwise in FIG. 13 while holding the in-slot conductor portion SA. Then, the in-slot conductor portion SA is plastically deformed to a predetermined clockwise position with respect to the upper concentric circle portion G and the lower concentric circle portion H.
At the same time, the pair of chuck claws 31 (31A, 31B) rotate counterclockwise in FIG. 13 while gripping the in-slot conductor SB, and the in-slot conductor SB is moved to the upper concentric circle G and the lower concentric circle. The portion H is plastically deformed to a predetermined position counterclockwise.
Next, the terminal M and the terminal N are bent and plastically deformed. Thereby, the reference unit 11 is completed.

Next, a plurality of manufactured reference units are overlaid.
FIG. 15 shows six reference units 11, a U-phase first reference unit U1, a U-phase second reference unit U2, a V-phase first reference unit V1, a V-phase second reference unit V2, and a W-phase second reference unit V2. A state in which the first reference unit W1 and the W-phase second reference unit W2 are overlapped is shown in a perspective view. Since the in-slot conductors of the first reference unit and the second reference unit are inserted on both sides of one tooth, the six reference units 11 become one unit.
In the inclined portions U1EB, U2EB, V1EB, V2EB, W1EB, and W2EB of the reference units U1, U2, V1, V2, W1, and W2, five rectangular wires (EB1 to EB5) are arranged in the radial direction of the stator core 13 (rotor). Is superimposed.

The inclined portion U2EB of the U-phase second reference unit U2 is superimposed on the lower side (in the direction of the stator core 13) in the axial direction with respect to the inclined portion U1EB of the U-phase first reference unit. Similarly, the inclined portion V1EB of the V-phase first reference unit V1 is superimposed on the lower side in the axial direction of the inclined portion U2EB of the U-phase second reference unit U2.
That is, in the reference units U1, U2, V1, V2, W1, and W2 arranged in the adjacent slots, the inclined portions U1EB, U2EB, V1EB, V2EB, W1EB, and W2EB are clockwise, and sequentially the immediately preceding inclined portions. The EB is superposed on the lower side in the axial direction of the EB.

In the inclined portions U1EA, U2EA, V1EA, V2EA, W1EA, and W2EA of the reference units U1, U2, V1, V2, W1, and W2, five rectangular wires (EA1 to EA5) are arranged in the radial direction of the stator core 13 (rotor). Is superimposed.
The inclined portion U2EA of the U-phase second reference unit U2 is overlapped with the inclined portion U1EA of the U-phase first reference unit 4 axially (in the direction opposite to the stator core 13) in the axial direction. Similarly, the inclined portion V1EA of the V-phase first reference unit V1 is superimposed on the upper side in the axial direction of the inclined portion U2EA of the second-phase second reference unit U2.
That is, in the reference units U1, U2, V1, V2, W1, and W2 arranged in adjacent slots, the inclined portions U1EA, U2EA, V1EA, V2EA, W1EA, and W2EA are clockwise, and the immediately preceding inclined portions are sequentially arranged. It is superimposed on the upper side in the axial direction of the EB.

Horizontal parts UFB1, U2FB, V1 of reference units U1, U2, V1, V2, W1, W2
In FB, V2FB, W1FB, and W2FB, five rectangular conductive wires (FB1 to FB5) are overlapped in the axial direction of the stator core 13 (rotor).
The horizontal portion U2FB of the U-phase second reference unit U2 is superimposed on the horizontal portion U1FB of the U-phase first reference unit U1 at the outer peripheral position in the clockwise direction in the radial direction. The horizontal portion V1FB of the V-phase reference unit V1 is overlapped with the horizontal portion U2FB of the U-phase second reference unit U2 at the outer peripheral position in the clockwise direction in the radial direction.
That is, as shown in FIG. 15, in the reference units U1, U2, V1, V2, W1, and W2 arranged in adjacent slots, the horizontal portions U1B1, U2FB, V1FB, V2FB, W1FB, and W2FB are clockwise. Thus, they are sequentially overlapped at the outer peripheral position in the clockwise direction in the radial direction of the immediately preceding horizontal portion FB.

In the horizontal portions U1FA, U2FA, V1FA, V2FA, W1FA, and W2FA of the reference units U1, U2, V1, V2, W1, and W2, the five rectangular wires (FA1 to FA5) are the axis of the stator core 13 (rotor). It is superimposed in the direction.
The horizontal portion U2FA of the U-phase second reference unit U2 is overlapped with the horizontal portion U1FA of the U-phase first reference unit U1 at the position of the inner periphery in the clockwise direction in the radial direction. The horizontal portion V1FA of the V-phase reference unit V1 is overlapped with the horizontal portion U2FA of the U-phase second reference unit U2 at the position of the inner periphery in the clockwise direction in the radial direction.
That is, as shown in FIG. 15, in the reference units U1, U2, V1, V2, W1, and W2 arranged in adjacent slots, the horizontal portions U1FA, U2FA, V1FA, V2FA, W1FA, and W2FA are clockwise. Thus, the images are sequentially overlapped at the position of the inner circumference in the clockwise direction in the radial direction of the immediately preceding horizontal portion FB.

The upper concentric circles U1G, U2G, V1G, V2G, W1G, and W2G are sequentially aligned in the radial direction.
The lower concentric circles U1H, U2H, V1H, V2H, W1H, and W2H are sequentially aligned in the radial direction.

When 24 reference units 11 are overlapped, a semicircular shape is obtained. Two sets of these are manufactured and combined to complete a circular coil cage 12 in which 48 reference units 11 are overlaid.
FIG. 16 is a perspective view showing the configuration of the coil rod 12 in which 48 reference units 11 are overlaid. FIG. 17 shows a plan view of the coil cage 12 (a diagram when FIG. 16 is viewed from above). A front view of the coil cage 12 is shown in FIG. The stator core of the stator of the motor according to the present embodiment has 48 slots and 48 teeth.
Each reference unit 11 has two in-slot conductors SA and SB, and the in-slot conductor SA and the in-slot conductor SB are arranged in the radial direction (upper and lower in FIG. 4). In the direction) is shifted by the thickness of five flat conductors.

As shown in FIG. 17, a U-phase first reference unit U1, a U-phase second reference unit U2, a V-phase first reference unit V1, a V-phase second reference unit V2, and a W-phase first reference unit. W1 and W-phase second reference units W2 are sequentially stacked. Subsequently, two U-phase reference units, two V-phase reference units, and two W-phase reference units are sequentially superposed, and finally, the U-phase fifteenth reference unit U15 and the U-phase sixteenth reference unit. The unit ends with a V-phase 15th reference unit V15, a V-phase 16th reference unit V16, a W-phase 15th reference unit W15, and a W-phase 16th reference unit W16. Since there are 16 reference units 11 for each of the three phases U, V, and W, a total of 48 reference units 11 are provided.
In one slot, one set of five flat conductors is inserted in two sets (a total of ten).

Next, a method for inserting the coil cage 12 into the stator core 13 will be described. FIG. 19 shows a state where the lower side portion of the coil rod 12 is inserted into the stator core 13 by about half. In FIG. 19, since it becomes difficult to understand when the entire coil cage 12 is described, six sets of reference units U1, U2, V1, V2, W1, and W2 that are part of the coil cage 12 (the same as those shown in FIG. 7) .) Only. Here, the insertion action of the six sets of reference units U1, U2, V1, V2, W1, and W2, which are a part of the coil cage 12, will be described, but the entire coil cage 12 has the same insertion action as described here. . In addition, although the description of the insulator is omitted, it is preferable to install the insulator in each slot portion S of the stator core 13 before inserting the coil rod 12.
As shown in FIG. 19, the lower concentric parts U1H, U2H, V1H, V2H, W1H, W2H, horizontal parts UFB1, U2FB, V1FB, V2FB, W1FB, W2FB, and horizontal parts U1FA, U2FA, V1FA, V2FA, W1FA, W2FA is located closer to the center line side of the stator 13 than the inner peripheral surface 13b at the tip of the teeth 13a of the stator core 13.

Accordingly, the in-slot conductors U1SB, U2SB, V1SB, V2SB, W1SB, W2SB and the in-slot U1SA, U2SA, V1SA, V2SA, W1SA, W2SA are directed downward in the axial direction of the central axis of the stator 13 from the upper side of FIG. In addition, when the first concentric slot S1 is inserted into the twelfth slot S12, the lower concentric part H, the horizontal part FB, and the horizontal part FA do not interfere with the stator core 13, so that the coil rod 12 is inserted into the slot of the stator core 13. S can be inserted.
Here, for example, the five in-slot conductors U1SB (SB1 to SB5) of the U-phase first reference unit U1 are inserted on the outer peripheral side (back side) of the first slot S1. The other in-slot conductor U1SA (SA1 to SA5) is inserted on the inner peripheral side (front side) of the seventh slot S7.

Five in-slot conductors U16SB (SB1 to SB5) of a U-phase sixteenth reference unit U16 (not shown) are inserted on the inner peripheral side of the first slot S1. As a result, a total of 10 rectangular conductors, that is, the in-slot conductor U1SA and the in-slot conductor U16SB, are inserted into the first slot.
Similarly, five in-slot conductors U3SB (SB1 to SB5) of a U-phase third reference unit U3 (not shown) are inserted on the outer peripheral side of the seventh slot S7. As a result, a total of ten rectangular conductors including the in-slot conductor U1SA (SA1 to SA5) and the in-slot conductor U3SB (SB1 to SB5) are inserted into the seventh slot.

FIG. 20 shows a state where the coil rod 12 is inserted into the stator core 13 up to a predetermined position. FIG. 21 is a plan view of FIG. 20 when the stator core 13 is viewed from above along the axis. FIG. 22 shows a front view of FIG.
In FIG. 21, the terminal N is located below the terminal M and cannot be seen. In FIG. 21, the terminal U1N is visible because U16M is omitted.
As shown in FIG. 22, the positions of the lower concentric part H, the horizontal part FB, and the horizontal part FA are spaced from the end face of the stator core 13 in order to avoid electromagnetic influences with the rotor. is there.
Although only a part of the coil rod 12 is shown in FIG. 20, the assembly of the coil rod 12 to the stator core 13 is completed by inserting the coil rod 12 up to the state of FIG. 20. Thereafter, a resin having excellent heat transfer performance is molded into the space in the state where the in-slot conductors SA and SB are inserted into the slot S. Further, the terminals M and N are sequentially connected by a bus bar for each of the U phase, the V phase, and the W phase. Thereby, the stator 10 is completed.

Next, a method for assembling the motor rotor 42 to the completed stator 10 will be described.
FIG. 23 shows a central sectional view of the stator 10. A coil rod 12 is incorporated in the stator core 13. In this state, the coil rod 12 does not exist on the inner side of the inner peripheral surface 13b of the teeth 13a of the stator core 13 on the upper side of the stator 10 in FIG. On the other hand, on the lower side of the stator 10 in FIG. 23, the lower concentric circular portion H, the horizontal portion FA, and the horizontal portion FB, which are bent portions of the coil rod 12, are located on the inner side of the inner peripheral surface 13 b of the teeth 13 a of the stator core 13. doing.
On the other hand, the rotor 42 of the motor has a rotor portion 43 formed on the outer periphery of the central shaft 41.
The rotor 42 cannot be inserted from the lower side of the stator 10, but can be inserted along the axis from the upper side of the stator. A state in which the rotor 42 is inserted into the stator 10 is shown in FIG.
As shown in FIG. 24, the central shaft 41 of the rotor 42 protrudes outward from a central hole formed by the inner peripheral surface of the lower concentric part H of the coil rod 12.

  As described in detail above, according to the motor manufacturing method of the present embodiment, (1) the stator 10 including the coil rod 12 and the stator core 13 which are distributed winding coils wound with the flat conducting wire 20, and the central shaft 41 are provided. In a motor manufacturing method for a motor having a rotor 42, a first step of winding the flat conducting wire 20 in a triangular shape, a second step of bending the coil conducting wire wound in a triangular shape into an L shape, and an L shape And a third step of expanding the rectangular conductor wire 20 to form two in-slot conductor portions, and in the second step, the first rotation treatment for press-molding the longest triangular portion T1 during the step. The tip contact portion 21a of the tool 21 is in contact with the contact point T1a which is the same position of the longest side portion T1, the bent portion of the shortest side portion T3 in the triangular shape, and the shortest side portion T3 is press-molded. 2 rotation jig 2 The center of rotation of the flat wire 20 is located at the same position P1, so that no slip occurs between the first rotating jig 21 and the second rotating jig 22 and the flat wire 20, and the flat wire 20 There is no risk of stretching or damage to the insulating film on the surface. Further, it can be bent into an L-shape with high accuracy, and can contribute to the efficiency of the subsequent process (particularly the third process).

  Furthermore, when the coil is to be inserted from the axial center side into the stator slot with the coil end portion A side at one end as the head, the coil end A at one end passes inside the inner peripheral surface of the stator core. Therefore, the coil can be easily inserted into the slot from the axial direction. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back. In addition, since a plurality of rectangular conductive wires that are overlapped in the flatwise direction are bent at the same time in a state where they are overlapped, the manufacturing process can be simplified and the cost can be reduced.

Further, in the bending step, the third rotating jig 23 is disposed on the intermediate side T2 side of the longest side T1, and the coil end part of one end of the flat conducting wire 20 is formed in a concentric semicircle. Therefore, it can be bent into an L-shape with high accuracy and can contribute to the efficiency of the post-process (especially the third process).
And a fourth step of inserting the coil rod 12 which is a distributed winding coil from the axial direction into the slot S of the stator core 13. When the coil is to be inserted into the slot S of the stator core 13 from the axial center side, the coil end A at one end passes through the inside of the inner peripheral surface of the stator core. Can be easily inserted into. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back.

  Further, the radius of curvature R1 of the inner circumference circle T1a formed by the longest side portion T1 and the intermediate side portion T2, the radius of curvature R2 of the inner circumference circle T2a formed by the intermediate side portion T2 and the shortest side portion T3, and the shortest side of the intermediate side portion T2 The bending radius R3 of the inner circumferential circle T3a formed by the portion T3 does not change before and after the bending process, and the length L1 of the intermediate side T2 does not change before and after the bending process. The subsequent L-shaped part dimensions can be formed with high accuracy.

  Further, in the motor of this embodiment, the coil end portion at one end of the coil rod 12 is bent toward the rotor side with respect to the in-slot conductor of the stator core 13, and the coil end portion at one end is inside the stator core 13. It is located on the axial center side of the rotor 42 from the peripheral surface, the coil end part at one end and the coil end part at the other end are a plurality of rectangular conducting wires 20 stacked in the flatwise direction, and the coil at one end Since the end part forms a concentric semicircle and the coil end part at the other end forms a concentric semicircle, the coil end part A side at one end is When the coil rod 12 is to be inserted into the slot S of the stator core 13 from the axial center side, the coil end A at one end passes through the inside of the inner peripheral surface of the stator core. The cage coil 12 can be easily inserted from the axial direction into the slot. Since the coil is not elastically deformed when inserted, a part of the coil does not jump out of the slot by the spring back. In addition, since a plurality of rectangular conductor wires 20 that are overlapped in the flatwise direction are bent at the same time in a state where they are overlapped, the manufacturing process can be simplified and the cost can be reduced.

The motor and the motor manufacturing method of the present invention are not limited to the above embodiments, and various applications are possible.
For example, in the present embodiment, a motor having 48 slots S has been described, but the number of slots S may be changed.

DESCRIPTION OF SYMBOLS 10 Stator 11 Reference | standard unit 12 Coil cage 13 Stator core 21 1st rotation jig 21a Contact part 22 2nd rotation jig 23 3rd rotation jig 24 Load receiving jig 41 Center axis 42 Rotor 43 Rotor part Un U phase n reference unit Vn V phase nth reference unit Wn W phase nth reference unit G upper concentric circle portion H lower concentric circle portion SA, SB in-slot conductor EA, EB inclined portion FA, FB horizontal portion JA, JB bent portion T1 longest side T2 middle side T3 shortest side T4 long side T5 short side

Claims (5)

In a motor manufacturing method of a motor having a stator including a distributed winding coil wound with a flat conductive wire and a rotor including a central axis,
A first step of winding the coil conductor in a triangular shape;
A second step of bending the coil conductor wire wound in a triangular shape into an L-shape;
A third step of expanding the L-shaped coil conductor to form two in-slot conductors, and
In the second step, during the step,
The tip of the first rotating jig that press-molds the longest side of the triangle is in contact with the same position of the longest side,
The bent portion of the shortest side of the triangular shape and the rotation center of the second rotating jig for press-molding the shortest side are at the same position;
A motor manufacturing method characterized by the above. In the motor manufacturing method according to claim 1,
In the second step, a third rotating jig is disposed on the middle side of the longest side portion, and the coil end portion at one end of the coil is formed into a concentric semicircle,
The motor manufacturing method characterized by having. In the motor manufacturing method according to claim 1 or 2,
A fourth step of inserting the distributed winding coil into the slot of the stator from the axial direction;
The motor manufacturing method characterized by having. In any one motor manufacturing method as described in Claim 1 thru | or 3,
The curvature radius of the inner circumference circle formed by the longest side portion and the intermediate side portion, the curvature radius of the inner circumference circle formed by the intermediate side portion and the shortest side portion, and the curvature radius of the inner circumference circle formed by the intermediate side portion and the shortest side portion, Not change before and after the second step,
The length of the intermediate side does not change before and after the second step,
A motor manufacturing method characterized by the above. A motor manufactured by any one of the motor manufacturing methods according to claim 1,
A coil end portion of one end of the coil is bent toward the rotor with respect to the in-slot conductor of the stator core;
The coil end portion of the one end is positioned on the axial center side of the rotor from the inner peripheral surface of the stator core;
The coil end part at the one end and the coil end part at the other end are a plurality of the rectangular conductor wires which are wound in a flatwise direction,
The coil end portion of the one end forms a concentric semicircle;
The coil end portion of the other end forms a concentric semicircle;
A motor characterized by