JP2013128364A - Manufacturing method of stator of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator of a rotary electric machine that suppresses deformation of wave wound coils in coil formation while improving work efficiency of the coil formation and can prevent insulation deterioration of the wave wound coils.SOLUTION: A manufacturing method of a stator of a rotary electric machine includes: a winding step of winding coil conductors around a spool provided with a guide inclined with respect to an axial line along the guide; a pressure molding step of bringing coil side portions adjacent to one another in a thickness direction of the spool into a close contact with one another, pressure molding the coil side portions and forming sheet-like coils; a winding up step of causing a coil side portion direction of the sheet-like coils and an axial direction of the stator to coincide with each other and spirally winding up the sheet-like coils around a winding core of a winding up jig; and a slot mounting step of moving the winding core of the winding up jig to an inner diameter portion of a stator core while rotating the winding core of the winding up jig in a circumferential direction of the stator and inserting the coil side portions of the sheet-like coils spirally wound up into slots.

Description

  The present invention relates to a method of manufacturing a stator of a wave winding type rotating electrical machine.

  As a method for winding a stator of a rotating electrical machine, a wave winding method in which a coil conductor is wound in a wave shape is known. As an example in which a stator of a rotating electrical machine is configured by a wave winding method, for example, the inventions described in Patent Documents 1 and 2 can be cited. In the invention described in Patent Document 1, the coil conductor is wound so that the slot conductor portion is formed in parallel with the short-side direction of the strip-shaped wave winding jig to form the strip-shaped wave coil. Next, while winding the annular wave winding jig, the strip-shaped wave winding coil is wound in multiples to form the annular wave winding coil. Then, the annular wave coil is attached to the slot of the stator core to constitute the stator. The same applies to the invention described in Patent Document 2. In addition, the inventions described in Patent Documents 1 and 2 also disclose a method of forming multiple annular wave coils by providing an annular wave coil for each turn of the stator core and connecting the ends thereof. Yes.

JP 2009-11116 A JP 2004-320886 A

  However, in the inventions described in Patent Documents 1 and 2, since the strip-shaped coil is wound in a multiple shape and is wound in an annular shape, the pitch between the coils on the outer peripheral side of the wound annular coil is widened. On the inner peripheral side, the pitch between the coils is narrow. Therefore, in the winding process of the strip-shaped wave winding coil and the mounting process of the annular wave winding coil to the stator core, deformation may occur in the end portion of the axial coil, leading to poor coil formation and insulation deterioration. In addition, the method of providing an annular wave coil for each turn of the stator core and connecting the ends thereof is, for example, when increasing the number of coil conductors in the slot for the purpose of improving the output of the rotating electrical machine. As a result, work efficiency decreases.

  The present invention has been made in view of the above circumstances, and it is possible to improve the working efficiency of coil formation and to suppress the deterioration of the insulation of the wave winding coil by suppressing deformation of the wave winding coil during coil formation. An object of the present invention is to provide a method for manufacturing a stator for a rotating electrical machine.

  A method of manufacturing a stator for a rotating electrical machine according to claim 1 includes a coil side portion inserted alternately into each slot of the stator core, and a coil that is integrally formed with the coil side portion and connects the same side end portion of the coil side portion. A rotating electrical machine stator manufacturing method in which a coil conductor having an end portion is wound so as to have a wave winding configuration and mounted in each slot, wherein the winding frame is provided with a guide inclined with respect to an axis. A winding step of winding a coil conductor along the guide, a pressure forming step of forming a sheet-like coil by press-molding the adjacent coil sides in the thickness direction of the winding frame, and a sheet-like shape A winding process for spirally winding a sheet-shaped coil around the winding core of the winding jig with the coil side direction of the coil aligned with the axial direction of the stator, and the winding core in the circumferential direction of the stator The inner diameter of the stator core while rotating So moved, and having a slot mounting step of inserting the coil sides of the wound sheet-shaped coil helically slot, the.

  According to a second aspect of the present invention, there is provided a method of manufacturing a stator for a rotating electrical machine according to the first aspect, wherein the slot mounting step sets the coil side portion of the sheet-like coil to 1 each time the winding core moves by one winding pitch. Insert one by one into the slot.

  According to a third aspect of the present invention, there is provided a method of manufacturing a stator for a rotating electrical machine according to the first or second aspect, wherein the winding step winds the coil conductor by changing the height of the winding frame every one turn of the stator core.

  According to the method for manufacturing a stator of a rotating electrical machine according to claim 1, a coil conductor is wound along a guide inclined with respect to an axis, and the coil side direction and the axial direction of the stator are made to coincide with each other to form a sheet. Since the coil is wound up in a spiral shape, the sheet-like coil can be taken up with a uniform pitch between the coil sides in the spiral traveling direction without stacking the sheet-like coil on the winding core of the winding jig. Therefore, since excessive tension is not applied to the sheet coil in the winding process of the sheet coil, deformation of the sheet coil can be suppressed. Therefore, it is possible to prevent coil formation failure and insulation deterioration due to deformation of the sheet coil.

  In addition, the winding core of the winding jig is moved to the inner diameter portion of the stator core while rotating in the circumferential direction of the stator, and the coil side portion of the spirally wound sheet-like coil is inserted into the slot. By increasing the number of coil winding turns, the number of coil conductors in the slot can be increased to improve the output of the rotating electrical machine. Therefore, it is not necessary to increase the number of welding points of the coil end portion unlike the method of providing an annular wave winding coil for each turn of the stator core and connecting the end portions thereof.

  According to the method for manufacturing a stator of a rotating electrical machine according to claim 2, each time the core of the winding jig moves by one winding pitch, the coil side portions of the sheet-like coil are inserted into the slot one by one. The pressing force of the coil side portion can be adjusted in accordance with the circumference mounted in the slot. Therefore, the sheet-like coil can be pushed out into the slot with a minimum pressing force required when the sheet-like coil is inserted into the slot, and deformation of the sheet-like coil in the slot mounting process can be suppressed.

  According to the method for manufacturing a stator of a rotating electrical machine according to claim 3, since the coil conductor is wound by changing the height of the winding frame every one turn of the stator core, the coil conductor necessary for each turn mounted in the slot The coil conductor can be wound with a long length, and the height of the coil end can be set to the minimum necessary height. Therefore, increase in winding resistance can be suppressed, and copper loss can be reduced. Further, since the height of the coil end can be made uniform at the minimum necessary height, the size of the rotating electrical machine can be reduced in size.

It is a front view which shows the state which concerns on 1st Embodiment and the coil conductor was wound by the winding frame. FIG. 2 is an enlarged view of a winding frame end portion shown in FIG. 1. It is a side view of a winding frame. It is explanatory drawing which shows the positional relationship of the inclination-angle of a guide and each axis | shaft of a stator. (A) is a top view of a sheet-like coil, (b) is a front view of a sheet-like coil. It is a perspective view which shows the state by which the sheet-like coil was wound up by the winding jig | tool. It is an enlarged view of the stator core part shown in FIG. 6, and is a perspective view which shows the state which inserts a sheet-like coil in a slot. It is a schematic diagram which shows typically the cross section of a winding jig | tool. It is a fragmentary sectional view of the stator in the axial direction showing the positional relationship between the pushing portion, sheet coil and slot of the pushing mechanism. It is a top view of the axial direction of the stator which shows the state with which the sheet-like coil was mounted | worn in the slot. It is a schematic diagram which shows an example of the edge part structure of a sheet-like coil. It is a front view of a reel concerning 2nd Embodiment. It is a front view which shows the state by which the coil conductor was wound by a part of winding frame of FIG. FIG. 6 is a partial cross-sectional view of a stator in the radial direction according to the second embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the overlapping description is abbreviate | omitted by attaching | subjecting a common code | symbol to a common location about each embodiment, and making it respond | correspond. Each figure is a conceptual diagram and does not define the dimensions of the detailed structure.

(1) 1st Embodiment The manufacturing method of the stator of the rotary electric machine which concerns on this embodiment winds the coil conductor 30 so that it may become a wave winding structure, and manufactures the stator 60 of the rotary electric machine which mounts in each slot 62. It is. This embodiment has a winding process, a pressure forming process, a winding process, and a slot mounting process, which are performed in this order.

(Winding process)
The winding process is a process of winding the coil conductor 30 around the winding frame 40. FIG. 1 is a front view showing a state in which the coil conductor 30 is wound around the winding frame 40. FIG. 2 is an enlarged view of the end portion of the reel 40 shown in FIG. FIG. 3 is a side view of the reel 40. The coil conductor 30 includes coil side portions 10 that are alternately inserted into the slots 62 of the stator core 61, and a coil end portion 20 that is formed integrally with the coil side portion 10 and connects the same side end portions of the coil side portion 10. ,have. In the coil conductor 30, the conductor surface of the winding is covered with an insulating layer such as enamel, and a square wire having a polygonal cross section is used. Note that the cross-sectional shape of the winding is not particularly limited, and may be an arbitrary cross-sectional shape. For example, windings having various cross-sectional shapes such as a circular wire having a circular cross-section can be used. The stator core 61 can be formed by stacking a plurality of core sheets made of electromagnetic steel plates in the axial direction Z of the stator 60.

  The winding frame 40 has a main body 41 and side frame portions 42 and 42, and the main body 41 is detachably held by the side frame portions 42 and 42 from the short direction. The winding portions 411 and 411 of the main body portion 41 are provided with guides 43 that are inclined at an inclination angle θ with respect to the axis I-I ′. For example, the guide 43 is configured by a groove capable of guiding the coil conductor 30, and the pitch of the groove is set to the same pitch as the winding pitch S when the coil side portion 10 is mounted in the slot 62. . The guide 43 can be provided only on one winding part 411 of the main body part 41.

FIG. 4 is an explanatory diagram showing the positional relationship between the inclination angle θ of the guide 43 and each axis of the stator 60. The horizontal axis indicates the circumferential direction X of the stator 60, and the vertical axis indicates the axial direction Z of the stator 60. In the figure, the intersection of the coil side 10 at the beginning of winding of the coil conductor 30 and the axis II ′ is point A, and the coil end 10 and the axis I− at the end of winding around one turn of the stator core 61 are wound. Let the intersection with I 'be point B. Further, an intersection of the axis II ′ and the horizontal axis is a point C, a distance from the point A to the horizontal axis is AD, and a distance from the point A to the vertical axis is AE. Here, if the number of slots of the stator 60 is n (48 in the figure), the circumferential X length of the stator core 61 can be expressed by n × S using the winding pitch S. In FIG. It corresponds to the length between. Since ∠BAE is 90 ° −θ, the inclination angle θ can be expressed by the following formula 1 using the distance h between BEs. As will be described later, since the sheet-like coil 31 in which the coil conductor 30 is pressure-molded is spirally wound around the winding core 51 of the winding jig 50, the distance h is equal to the coil side 10 and the coil. A distance obtained by adding the axial Z length of the end 20 and a gap 1G described later can be used.
(Equation 1)
θ = 90 ° -tan ⁻¹ (h / (n × S))

  In this step, the coil conductor 30 is wound along the guide 43 of the winding frame 40. Specifically, the coil conductor 30 may be fixed at an inclination angle θ with respect to the axis II ′, and the winding frame 40 may be rotated and wound around the axis II ′. May be fixed and the coil conductor 30 may be wound spirally. Each winding may be wound around the winding frame 40 or a plurality of windings may be wound simultaneously. For example, as shown in FIG. 2, twelve windings can be wound simultaneously. In this case, in the longitudinal direction of the reel 40, the U phase (forward direction U1), the U phase (forward direction U2), the W phase (reverse direction W1), the W phase (reverse direction W2), and the V phase (forward direction V1). , V phase (forward direction V2), U phase (reverse direction U1), U phase (reverse direction U2), W phase (forward direction W1), W phase (forward direction W2), V phase (reverse direction V1), V Phase coils are formed in the order of the phases (reverse direction V2). Here, the forward direction refers to the coil conductor 30 wound in a direction away from the phase terminal side, and is referred to as a coil unit 1a. The reverse direction refers to the coil conductor 30 wound in the direction approaching the phase terminal side, and is referred to as the coil unit 1b. In the present embodiment, two in-phase coil side portions 10 and 10 are adjacent to each other in the longitudinal direction of the winding frame 40, and together with the coil side portions 10 and 10 facing in the thickness direction of the winding frame 40, The winding unit consists of four wires. The in-phase coil side portions 10, 10, 10, 10 are connected by the coil end portion 20 so that the directions of the currents flowing when the rotating electrical machine is driven match, and constitute a three-phase rotating electrical machine composed of 12 winding units. be able to. Details of the connection order of the coil conductor 30 and the coil end portion will be described later.

(Pressure forming process)
The pressure forming step is a step of forming the sheet-like coil 31 by bringing the coil side portions 10 and 10 adjacent to each other in the thickness direction of the winding frame 40 into close contact and press forming. FIG. 5A is a plan view of the sheet-like coil 31, and FIG. 5B is a front view of the sheet-like coil 31. First, the wound coil conductor 30 is removed from the winding frame 40. The side frame portions 42 and 42 can be removed from the main body portion 41 by moving the side frame portions 42 and 42 in parallel with the axis II ′ while supporting the main body portion 41 of the winding frame 40. Then, the main body 41 is removed from the coil conductor 30. At this time, in order to maintain the adjacent state of the coil side portions 10 and 10 adjacent to each other in the thickness direction of the winding frame 40, for example, a comb-shaped jig can be used. By setting the pitch between the convex portions of the comb-shaped jig to the same pitch as the winding pitch S, the coil side portions 10 and 10 adjacent to each other in the thickness direction of the winding frame 40 are inserted into the respective concave portions of the comb-shaped jig. , The adjacent state can be maintained.

  In this step, a pressure forming jig (not shown) is used for pressure forming the coil side portions 10 and 10. The pressure forming jig has a pair of pressure parts having substantially the same shape as the winding part 411 of the winding frame 40. The coil side portions 10 and 10 are sandwiched from the thickness direction of the winding frame 40 by a pair of pressure units, and are pressure-formed in the thickness direction of the winding frame 40. Thus, the coil side portions 10 and 10 adjacent to each other in the thickness direction of the winding frame 40 are separated by one winding pitch over two layers in the longitudinal direction of the winding frame 40 (axis II ′ direction). Align with. When the coil end portions are connected as described later, a sheet-like coil 31 is formed. In consideration of the case where the winding is damaged during pressure molding, a repair resin coating or the like may be applied after pressure molding.

(Winding process)
The winding process is a process in which the sheet coil 31 is spirally wound around the core 51 of the winding jig 50. FIG. 6 is a perspective view showing a state where the sheet coil 31 is wound by the winding jig 50. In this step, the sheet side coil 31 is spirally wound with the coil side portion 10 direction of the sheet coil 31 and the axial direction Z of the stator 60 aligned.

  As shown in FIG. 4, when the sheet coil 31 is wound spirally, the inclination angle θ of the guide 43 of the winding frame 40 is set so that the direction of the coil side 10 coincides with the axial direction Z of the stator 60. Is set. Further, as shown in FIG. 6, the axial direction of the winding core 51 of the winding jig 50 coincides with the axial direction Z of the stator 60. Therefore, by winding the sheet-like coil 31 around the winding core 51 in a state where the sheet-like coil 31 is inclined by the angle θ with respect to the axis II ′, the direction of the coil side 10 of the sheet-like coil 31 and the stator 60 are increased. The sheet coil 31 can be wound in a spiral manner so as to coincide with the axial direction Z. A spiral winding guide 511 extending in the axial direction can be provided on the winding core 51 of the winding jig 50. The pitch of the winding guide 511 is provided at the same pitch as the winding pitch, and is preferably the same as the winding pitch S. This makes it easy to wind the sheet coil 31 around the core 51 in a state where the sheet coil 31 is inclined at an angle θ with respect to the axis I-I ′.

  In the present embodiment, the sheet-like coil 31 can be routed four times in the circumferential direction X of the stator core 61. Here, the sheet coil 31 disposed on the outermost periphery of the slot 62 is referred to as a first sheet coil 3L1. The sheet coil 31 disposed on the inner peripheral side of the first sheet coil 3L1 is referred to as a second sheet coil 3L2. The sheet coil 31 arranged on the inner peripheral side of the second sheet coil 3L2 is referred to as a third sheet coil 3L3. Then, the sheet-like coil 31 arranged on the inner circumference side of the third sheet-like coil 3L3 and disposed on the innermost circumference of the slot 62 is referred to as a fourth sheet-like coil 3L4. FIG. 6 shows a state in which the sheet-like coil 31 starts to be wound from the coil start end portion 31S and the sheet-like coil 31 is wound up to the coil end portion 31E. Therefore, the sheet-like coil 31 is wound around the core 51 in the order of the first sheet-like coil 3L1, the second sheet-like coil 3L2, the third sheet-like coil 3L3, and the fourth sheet-like coil 3L4 from the coil start end portion 31S side. In addition, as shown in the figure, the sheet-like coil 31 is spirally wound with a gap 1G provided in the axial direction of the winding core 51. By providing the gap 1G, it is possible to prevent the coil end portions 20 of the sheet-like coils 31 having different turns from being stacked. Therefore, the coil side portion 10 can be inserted into the slot 62 without hindrance in a slot mounting step described later.

  In the present embodiment, the coil conductor 30 is wound along the guide 43 inclined with respect to the axis II ′, and the coil side portion 10 direction and the axial direction Z of the stator are made to coincide with each other to form the sheet coil 31. Since the winding is performed in a spiral shape, the sheet-shaped coil 31 can be wound with a uniform pitch between the coil side portions 10 in the spiral traveling direction without stacking the sheet-shaped coil 31 on the core 51 of the winding jig 50. . For this reason, in the winding process of the sheet-shaped coil 31, excessive tension is not applied to the sheet-shaped coil 31, so that deformation of the sheet-shaped coil 31 can be suppressed. Therefore, it is possible to prevent coil formation failure and insulation deterioration due to deformation of the sheet coil 31.

(Slot installation process)
In the slot mounting process, the winding core 51 of the winding jig 50 is moved to the inner diameter portion 63 of the stator core 61 while rotating in the circumferential direction X of the stator 60, and the coil side of the sheet-like coil 31 wound spirally This is a step of inserting the portion 10 into the slot 62. 7 is an enlarged view of the stator core 61 portion shown in FIG. 6, and is a perspective view showing a state in which the sheet-like coil 31 is inserted into the slot 62. FIG. In this figure, each time the winding core 51 of the winding jig 50 moves by one winding pitch, the coil side portions 10 of the sheet coil 31 are pushed one by one in the radial direction Y of the stator 60 and inserted into the slot 62. It shows how to do. FIG. 8 is a schematic view schematically showing a cross section of the winding jig 50.

  The winding jig 50 has a support portion 52 that pivotally supports the winding core 51 on the inner peripheral side of the cylindrical winding core 51. On the inner peripheral side of the support portion 52, a feed mechanism 53 constituted by a ball screw or the like is pivotally supported coaxially with the core 51. The feed mechanism 53 is connected to a servo motor 55 via a speed reducer 54. ing. The axial end of the core 51 is connected to the output side of the speed reducer 54, and when the servo motor 55 rotates, the core 51 is 360 ° / S (S is the winding pitch. .)) In rotation in the circumferential direction X of the stator 60. The winding core 51 has a rack and pinion mechanism 56, and a servo motor 57 is connected to the pinion gear. The pinion gear rotates in conjunction with the rotation of the servo motor 57, the rotational motion is converted into a linear motion by the rack, and the winding core 51 can move in the axial direction Z of the stator 60. Thus, the winding jig 50 can be moved to the inner diameter portion 63 of the stator core 61 while rotating the winding core 51 in the circumferential direction X of the stator 60. The winding core 51 can move S / tan θ in the axial direction Z of the stator 60 every time it rotates 360 ° / S in the circumferential direction X of the stator 60. The inner diameter portion 63 of the stator core 61 refers to a portion in which a rotor (not shown) is accommodated.

  The feed mechanism 53 is provided with an extrusion mechanism 59 via a cam mechanism 58. The driven part (not shown) of the feed mechanism 53 moves in the axial direction Z of the stator 60 by the rotation of the servo motor 55. At this time, the protruding portion 581 provided in the driven portion tilts with respect to the pushing mechanism 59, whereby the pushing portion 591 of the pushing mechanism 59 can be pushed in the radial direction Y of the stator 60. The extruded portion 591 is slightly narrower than the circumferential length X length of the slot 62, and the height 59 h of the extruded portion 591 is substantially the same as the axial Z length of the slot 62. By extruding the pushing portion 591 in the radial direction Y of the stator 60, the coil side portion 10 of the sheet coil 31 can be pushed out in the radial direction Y of the stator 60, and the coil side portion 10 can be inserted into the slot 62. .

  FIG. 8 shows a state immediately after the pushing portion 591 pushes the coil side portion 10. At this time, the protruding portion 581 is at the lowest position, and the pushing portion 591 is pushed out from the outer peripheral surface of the core 51 to a distance 5L1. On the other hand, when the push-out mechanism 59 is in an inoperative state, the protruding portion 581 is in the non-actuated position 580, and the push-out portion 591 is substantially flush with the outer peripheral surface of the core 51. The distance by which the pushing portion 591 is pushed out from the outer peripheral surface of the core 51 can be changed by the rotation of the sheet-like coil 31 arranged in the slot 62. For example, when the fourth sheet-like coil 3L4 arranged on the innermost periphery of the slot 62 is pushed out, the protruding portion 581 is tilted to the adjustment position 582 and the pushing portion 591 is pushed out from the outer peripheral surface of the core 51 to a distance 5L2. be able to. Thereby, the distance from the opening part of the slot 62 to the 4th sheet-like coil 3L4 can be adjusted.

  FIG. 9 is a partial cross-sectional view in the axial direction Z of the stator 60 showing the positional relationship among the pushing portion 591, the sheet coil 31, and the slot 62 of the pushing mechanism 59. In this step, the core 51 is moved in the axial direction Z of the stator 60 by S / tan θ every time the core 51 is rotated 360 ° / S in the circumferential direction X of the stator 60. Then, the coil side portion 10 of the sheet-like coil 31 is opposed to the opening of the slot 62, and the coil side portion 10 is pushed out by the pushing portion 591. When the coil side portion 10 is pushed out, the winding core 51 is similarly rotated and moved to return the pushing portion 591 to the non-operating state, and the coil side portion 10 adjacent in the circumferential direction X is opened to the next slot 62. Opposite the part. Then, the coil side portion 10 is pushed out by the pushing portion 591. By repeating this, the core 51 rotates once, and the first sheet-like coil 3L1 disposed on the outermost periphery of the slot 62 is inserted into the slot 62.

  Similarly, when the winding core 51 makes one more rotation, the second sheet-like coil 3L2 disposed on the inner peripheral side of the first sheet-like coil 3L1 is inserted into the slot 62. At this time, the first sheet coil 3L1 is pushed out in the radial direction Y of the stator 60 by the second sheet coil 3L2. When the winding core 51 makes one more turn, the third sheet-like coil 3L3 disposed on the inner peripheral side of the second sheet-like coil 3L2 is inserted into the slot 62. At this time, the first sheet-like coil 3L1 and the second sheet-like coil 3L2 are pushed out in the radial direction Y of the stator 60 by the third sheet-like coil 3L3. When the winding core 51 is rotated once more, the fourth sheet-like coil 3L4 disposed on the innermost periphery of the slot 62 is inserted into the slot 62. At this time, the first sheet-like coil 3L1, the second sheet-like coil 3L2, and the third sheet-like coil 3L3 are pushed out in the radial direction Y of the stator 60 by the fourth sheet-like coil 3L4. Thus, the first sheet-like coil 3L1 to the fourth sheet-like coil 3L4 are arranged at predetermined positions in the slot 62. FIG. 10 is a plan view in the axial direction Z of the stator 60 showing a state in which the sheet coil 31 is mounted in the slot 62. The figure shows a state in which the sheet-like coil 31 for four turns of the stator core 61 is mounted in the slot 62.

  In this embodiment, each time the winding core 51 of the winding jig 50 moves by one winding pitch, the coil side portions 10 of the sheet coil 31 are inserted into the slot 62 one by one. The pressing force of the coil side portion 10 can be adjusted according to the above. Therefore, the sheet-like coil 31 can be pushed out into the slot 62 with the minimum pressing force required when the sheet-like coil 31 is inserted into the slot 62, and the deformation of the sheet-like coil 31 in the slot mounting process is suppressed. Can do. In the present embodiment, the core 51 of the winding jig 50 is moved to the inner diameter portion 63 of the stator core 61 while rotating in the circumferential direction X of the stator 60, and the sheet-shaped coil 31 wound spirally is moved. Since the coil side portion 10 is inserted into the slot 62, by increasing the number of windings of the sheet coil 31, the number of coil conductors in the slot 62 can be increased and the output of the rotating electrical machine can be improved.

(Coil end of sheet coil)
Next, the example of a structure of the coil end part of the sheet-like coil 31 is shown. FIG. 11 is a schematic diagram illustrating an example of an end configuration of the sheet coil 31. This figure shows a connection state of windings at both ends of the sheet as viewed in the sheet thickness direction. (A)-(c) has shown the connection state for 1 phase of U phase-W phase in order, (d) has shown the connection state for 3 phases. In the present embodiment, a coil unit 1a of X1 phase (X is any of U, V, and W. The same applies hereinafter) and an X2 phase coil unit 1b are connected in series to form a phase unit coil 5X1. . The X2-phase coil unit 1a and the X1-phase coil unit 1b are connected in series to form the phase unit coil 5X2. Phase unit coils 5X1, 5X2 are connected in parallel to form phase coil 6X.

  In the figure, the coil unit 1a is indicated by a solid line, and the coil unit 1b is indicated by a broken line. The circled numbers in the figure indicate the connection order of the windings from the phase terminal 5TX to the neutral point 5N. Since the phase unit coils 5X1 and 5X2 are connected in parallel, for convenience of explanation, the connection order of the windings of the phase unit coil 5X1 is indicated by a circle number starting from 1 and the connection order of the windings of the phase unit coil 5X2 is 100. It is indicated by a circle number starting from the number. Hereinafter, the U phase will be described as an example based on FIG. 5A, but the same applies to the V phase and the W phase.

  A U1 phase coil unit 1a and a U2 phase coil unit 1b are connected in series to form a phase unit coil 5U1. The U1-phase coil unit 1a is wound in the right direction of the drawing with the U-phase terminal 5TU as a starting point (round numerals 1 to 5). The U1-phase coil unit 1a is connected to the U2-phase coil unit 1b at a connection point 5JU1 at the sheet end. The U2-phase coil unit 1b is wound back at the connection point 5JU1 and wound in the left direction of the drawing (circle numbers 6 to 11), and is connected to the neutral point 5N. The U2-phase coil units 1a, 1b are separated from the U1-phase coil units 1a, 1b by one winding pitch in the moving direction of the mover magnetic pole (rightward in the drawing). 1b makes a pair in the sheet thickness direction.

  A U2-phase coil unit 1a and a U1-phase coil unit 1b are connected in series to form a phase unit coil 5U2. The U2-phase coil unit 1a is wound in the right direction on the paper surface starting from the U-phase terminal 5TU (round numerals 100 to 104). The U2-phase coil unit 1a is connected to the U1-phase coil unit 1b at a connection point 5JU2 at the sheet end. The U1-phase coil unit 1b is wound back at the connection point 5JU2 and wound to the left in the drawing (round numerals 105 to 110), and is connected to the U2-phase coil unit 1b at the connection point 5JU3 at the sheet end. And connected to the neutral point 5N. Note that without connecting at the connection point 5JU3, the neutral point 5N may be arranged as it is, and all three phases may be joined at the neutral point 5N.

  After the sheet-like coil 31 is mounted in the slot 62, the joining at the phase terminal 5TX, the drawing process, the joining at the neutral point 5N, and the joining of the windings at the connection points 5JX1 and 5JX2 at the sheet end are performed. After joining the three phases, the joint is insulated and the winding is fixed to the stator core 61 by varnish impregnation, resin molding, or the like. The slot 62 and the sheet coil 31 are preferably insulated by an insulating material. Further, by providing wedges or the like in the stator core 61, it is possible to prevent the sheet coil 31 from falling out of the slot 62.

  In the present embodiment, the coil side portions 10 and 10 are wound so as to have a full-pitch winding structure except for the sheet end portion to which the coil side portions 10 and 10 are connected. The height can be made uniform. In addition, since the coil side portions 10 and 10 can be switched at the sheet end portion, coil manufacture is easy and workability is improved. Further, since the coil end portions 20 of the same phase for switching the coil side portions 10 and 10 are not stacked in the sheet thickness direction, the coil end portion 20 for switching the coil side portions 10 and 10 can be made compact. .

(Deformation)
As the guide 43 of the reel 40, for example, a guide pin extending in the short direction of the reel 40 can be used. In this case, the guide pins are provided on the side frame portions 42 and 42, respectively, and make a pair between the side frame portions 42 and 42. The pair of guide pins are arranged such that a straight line connecting the base ends of the guide pins is inclined at an inclination angle θ with respect to the axis II ′ of the winding frame 40. The pitch of the guide pins adjacent in the direction of the axis II ′ is set to the same pitch as the winding pitch S when the coil side 10 is mounted in the slot 62.

  A plurality of pushing portions 591 of the pushing mechanism 59 may be provided in the circumferential direction X of the stator core 61. Thereby, the plurality of coil side portions 10 can be simultaneously inserted into the slots 62. In this case, since the coil side 10 is inserted into the slot 62 in a state of protruding from the stator core 61, the coil side 10 needs to be appropriately moved in the axial direction Z of the stator 60. The configuration of the push-out mechanism 59 is not limited as long as the coil side portion 10 of the sheet-like coil 31 wound in a spiral shape can be inserted into the slot 62. For example, the pushing mechanism 59 may eject air or the like to the pushing portion 591 to push the pushing portion 591 into the slot 62.

  The number of types of coil side portions 10 in the same phase is not limited to 2 (X1 phase, X2 phase), but 3 or more (X1 phase, X2 phase, X3 phase, ..., Xm phase, where m is Natural number.) Further, the coil end portion of the sheet-like coil 31 is integrally formed with a coil unit 1a wound in a direction away from the phase terminal side and a coil unit 1b wound in a direction approaching the phase terminal side. Thus, the winding can be routed. In this case, it is not necessary to join the windings at the connection points 5JX1 and 5JX2 at the sheet end. The rotating electrical machine is not limited to the Y connection, and may be a Δ connection. Further, the phase unit coils 5X1, 5X2 can be connected in series to form the phase coil 6X.

(2) 2nd Embodiment This embodiment differs in a winding process compared with 1st Embodiment. FIG. 12 is a front view of the reel 40a. FIG. 13 is a front view showing a state in which the coil conductor 30 is wound around a part of the winding frame 40a of FIG. FIG. 14 is a partial cross-sectional view of the stator 60 in the radial direction Y. 14 corresponds to a cross-sectional view taken along a line II-II ′ shown in FIG. The reel 40a used in the present embodiment is characterized by the side frame portions 42a and 42a, compared to the reel 40 used in the first embodiment. The main body portion 41a used in the present embodiment has an inclination angle θ ′ of the guide 43, but the inclination angle of the guide 43 may be θ as in the main body portion 41 used in the first embodiment. it can.

  As shown in FIG. 12, the side frame portion 42a includes, in order in the longitudinal direction, a first winding portion 421, a first gradually changing portion 422, a second winding portion 423, a second gradually changing portion 424, a third winding portion 425, A third gradually changing portion 426 and a fourth winding portion 427 are provided. The first winding portion 421 is a portion around which the coil conductor 30 corresponding to the first sheet coil 3L1 disposed on the outermost periphery of the slot 62 is wound, and the length of the winding frame 40a in the inclination direction is 4L1. . The second winding portion 423 is a portion around which the coil conductor 30 corresponding to the second sheet-like coil 3L2 is wound, and the length of the winding frame 40a in the inclination direction is 4L2. The first gradual change portion 422 is a first sheet riding portion 1T1 between the coil conductor 30 corresponding to the first sheet-like coil 3L1 and the coil conductor 30 corresponding to the second sheet-like coil 3L2, and the winding frame The length of the inclined direction 40a is gradually shortened from 4L1 to 4L2.

  The third winding portion 425 is a portion around which the coil conductor 30 corresponding to the third sheet-like coil 3L3 is wound, and the length of the winding frame 40a in the inclination direction is 4L3. The second gradual change portion 424 is a second seat riding portion 1T2 between the coil conductor 30 corresponding to the second sheet-like coil 3L2 and the coil conductor 30 corresponding to the third sheet-like coil 3L3. The length of the inclined direction 40a is gradually shortened from 4L2 to 4L3. The fourth winding portion 427 is a portion around which the coil conductor 30 corresponding to the fourth sheet-like coil 3L4 disposed on the innermost periphery of the slot 62 is wound, and the length of the winding frame 40a in the inclination direction is 4L4. is there. The third gradual change portion 426 is a third seat riding portion 1T3 between the coil conductor 30 corresponding to the third sheet-like coil 3L3 and the coil conductor 30 corresponding to the fourth sheet-like coil 3L4, and the winding frame The length in the inclination direction of 40a is gradually shortened from 4L3 to 4L4. Note that the first seat riding portion 1T1 to the third seat riding portion 1T3 are regions surrounded by broken lines in FIG.

  Since the inclination angle of the winding frame 40 with respect to the axis II ′ is θ ′, the height in the short direction of the winding frame 40a (hereinafter simply referred to as the height of the winding frame 40a) is, for example, the first winding portion 421. In this case, 4L1 × sin θ ′. The same applies to the second winding portion 423, the third winding portion 425, and the fourth winding portion 427, and the height of the winding frame 40a is 4L2 × sin θ ′, 4L3 × sin θ ′, 4L4 × sin θ ′. In the present embodiment, after the sheet coil 31 is mounted in the slot 62, the first winding is performed such that the heights 20h of the coil end portions 20 of the first sheet coil 3L1 to the fourth sheet coil 3L4 are uniform. The height of the winding frame 40a in the part 421 to the fourth winding part 427 is set.

  In the winding process in the present embodiment, the coil conductor 30 is wound by changing the height of the winding frame 40 a for every one turn of the stator core 61. The coil conductor 30 has a first turn (corresponding to the first sheet-like coil 3L1 disposed on the outermost periphery of the slot 62), a second turn (corresponding to the second sheet-like coil 3L2), and a third turn (third sheet-like). (Equivalent to the coil 3L3) The required coil conductor length becomes shorter as the fourth turn (corresponding to the fourth sheet-like coil 3L4 arranged on the innermost periphery of the slot 62) is reached. In the present embodiment, since the coil conductor 30 is wound by changing the height of the winding frame 40a for every one turn of the stator core 61, it is possible to wind the coil conductor with a necessary coil conductor length for each turn attached to the slot 62. The height 20h of the coil end 20 can be set to the minimum necessary height. Therefore, increase in winding resistance can be suppressed, and copper loss can be reduced. Moreover, as shown in FIG. 14, since the height 20h of the coil end part 20 can be made uniform with the minimum necessary height, the size of the rotating electrical machine can be reduced in size.

(3) Others The present invention is not limited to the embodiment described above and shown in the drawings, and can be implemented with appropriate modifications within a range not departing from the gist. Further, the present invention can be used for various rotating electric machines of the wave winding method, for example, an electric motor used for an electric motor for a vehicle, an electric appliance for home use, or an electric motor for driving a general industrial machine. it can.

10: Coil side 20: Coil end 30: Coil conductor 31: Sheet coil 40: Winding frame 43: Guide 50: Winding jig 51: Core 60: Stator 61: Stator core 62: Slot 63: Inner diameter part

Claims (3)

A coil conductor having a coil side portion alternately inserted into each slot of the stator core and a coil end portion integrally formed with the coil side portion and connected to the same side end portion of the coil side portion A method of manufacturing a stator of a rotating electrical machine that is wound so as to be attached to each slot,
A winding step of winding the coil conductor along the guide on a winding frame provided with a guide inclined with respect to the axis;
A pressure forming step of forming a sheet-like coil by press-molding the coil sides adjacent to each other in the thickness direction of the winding frame; and
A winding step of spirally winding the sheet-shaped coil around the core of the winding jig by matching the coil side direction of the sheet-shaped coil with the axial direction of the stator;
The winding core of the winding jig is moved to the inner diameter portion of the stator core while rotating in the circumferential direction of the stator, and the coil side portion of the sheet-like coil wound spirally is inserted into the slot. Slot mounting process,
A method of manufacturing a stator for a rotating electrical machine, comprising:   2. The rotation according to claim 1, wherein in the slot mounting step, the coil side portions of the sheet-like coil are inserted into the slot one by one every time the winding core of the winding jig moves by one winding pitch. A method for manufacturing an electric stator.   The method of manufacturing a stator for a rotating electrical machine according to claim 1, wherein the winding step winds the coil conductor by changing a height of the winding frame every one turn of the stator core.

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