JP2013192303A - Stator coil shaping method and stator coil shaping device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator coil shaping technique which does not require correction of the lead-out position of a lead-out line or re-routing after coil end shaping, and has no risk of damage on the lead-out line or the like.SOLUTION: Lead-out lines 4a, 4b, and 5U, 5V, 5W incidental to a coil end 3a are positioned at the final routing position thereof in the circumferential direction. Furthermore, the terminal side of each lead-out line 4a, 4b, 5U, 5V, 5W is bent so as to direct the counter-coil end 3a side in the axial direction of a stator core 2, and the part thus bent is held so as to be confined in the annular projection area of the coil end 3a. Under this state, primary shaping is carried out by compression shaping the coil end 3a from the inner and outer peripheral surface side. Subsequently, secondary shaping is carried out by compression shaping the coil end 3a in the axial direction.

Description

  The present invention relates to a method and apparatus for shaping a coil end of a stator coil in a motor.

  For example, when assembling a distributed winding type motor, as described in Patent Document 1, for example, in order to reduce the occupied area of the coil end of the stator coil wound around the stator core as much as possible and to reduce the size thereof The coil end is compression-molded and shaped into a predetermined cross-sectional shape.

  On the other hand, the coil end of the stator coil is generally accompanied by a plurality of lead wires connected to external power supply terminals (for example, U, V, W three-phase output terminals from the inverter) and neutral point terminals. Thus, these lead wires are drawn out to the outside in the radial direction of the stator. The final lead position of the lead wire from these coil ends is set according to the position of the external terminal as described above, and in many cases, a specific position in the circumferential direction of the coil end (regular routing) Position or final routing position).

  When the coil ends are compression-molded and shaped into a predetermined cross-sectional shape, the processing of the lead wires becomes a problem, and before the coil ends are shaped, the lead wires are moved from the final routing position to the radially outer side of the stator. If pulled out, it becomes difficult to compress and mold the coil end itself in the axial direction at the portion corresponding to the final wiring position. In the coil end shaping technique described in Patent Document 1, no consideration is given to the processing of the lead wire attached to the coil end.

  Therefore, in many cases, when the coil end is compressed and shaped into a predetermined cross-sectional shape, the respective lead wires are wound around the coil end so as to be within the projected area of the coil end. In addition to compressing and forming the lead wires once, each lead wire is dispersed in the circumferential direction without being concentrated at a specific position, and is also drawn out radially on the radially outer side of the coil end. The coil end is compression-molded so as to avoid the lead wire.

JP 2006-5999 A

  However, in any of the above methods for processing the lead wires attached to the coil end, in each case, after shaping the coil end, each lead wire is collected at a specific position in the coil end circumferential direction, which is the final routing position. Therefore, it is necessary to manually correct or re-route the lead-out position of the lead-out line. Therefore, the area occupied by the coil end once subjected to compression molding becomes large, and there is a limit to downsizing the coil end.

  In addition, when the coil ends are shaped by compression molding in a state where the respective lead wires are radially drawn out to the outer peripheral side in the radial direction of the coil end, the lead wires are bitten between the molds that perform compression molding. This is not preferable because there is a risk of breakage of the lead wire.

  The present invention has been made paying attention to such problems, and does not require modification or re-routing of the lead-out position of the lead wire after the coil end shaping, and there is no risk of breakage of the lead wire. Provide technology.

  The present invention provides a lead wire processing method for shaping the coil end of a stator coil, positioning the lead wire from the coil end at the final wiring position in the circumferential direction of the coil end, and The terminal side is directed to the side opposite to the coil end in the axial direction of the stator core so that the lead wire is held within the annular projection area of the coil end, and in this state, the coil end is radially and axially centered. The construction method is to compress and shape sequentially.

  And this construction method includes an inner peripheral type that constrains the inner peripheral surface of the coil end, and an outer peripheral type that constrains the outer peripheral surface of the coil end and compresses the coil end in the radial direction in cooperation with the inner peripheral mold. And a stator coil shaping device provided with an end surface molding die that enters the region surrounded by the inner peripheral die and the outer peripheral die from the axial direction of the coil end and compresses the coil end in the axial direction. This can be realized by providing a lead wire holding means having a lead wire holding function as described above in a part of the end face mold.

  According to the present invention, the lead wire attached to the coil end is directed to the side opposite to the coil end in the axial direction of the stator core, and the lead wire is held so as to be within the annular projection area of the coil end. Since the coil end is shaped by compression molding, there is no need to correct or re-route each lead-out line after the coil end is molded. Therefore, the area occupied by the coil end can be reduced to reduce the size thereof, and damage or the like due to biting of the lead wire can be prevented.

Cross-sectional explanatory drawing which shows the schematic structure of the stator provided for implementation of this invention. FIG. 2 is an enlarged plan view of a main part of FIG. 1. It is a figure which shows the behavior of the press molding apparatus for shaping the coil end of the stator coil shown in FIG. 1, and is explanatory drawing which shows the state which the inner side jig | tool fell. Explanatory drawing which shows the state which the outer side jig | tool fell from the state of FIG. Explanatory drawing which shows the state which the inner periphery type | mold expanded from the state of FIG. 4, and the outer periphery type | mold reduced diameter. Explanatory drawing which shows the state which the end surface shaping | molding die fell from the state of FIG. The expansion perspective view of the principal part of FIG. The principal part enlarged view of FIG. The perspective view which shows the state which the end surface shaping | molding die fell from the state of FIG.

  1 to 9 show a more specific form for carrying out the coil end shaping method according to the present invention. In particular, FIG. 1 is a schematic explanatory view of the stator 1, and FIG. 2 is a view of the stator 1 shown in FIG. The principal part enlarged plan view is shown, respectively. 3 to 6 show the structure of a press forming apparatus for coil end shaping and its operation.

  As shown in FIGS. 1 and 2, for example, a distributed winding type stator 1 in a three-phase synchronous motor has an annular stator core 2 in which a large number of electromagnetic steel plates are laminated and fixed integrally by mechanical or adhesion. A number of slots (not shown) are formed, and stator coils (windings) 3 for three phases, for example, U phase, V phase, and W phase, are wound around these slots together with a neutral wire coil. Is forming. Coil ends 3a and 3b of the stator coil 3 protrude in an annular shape from both axial end surfaces of the stator core 2, and a specific position in the circumferential direction (regular routing position or final position) The lead wires 4a and 4b of the neutral wire are led out close to each other together with the lead wires 5U, 5V and 5W for the three phases of the U phase, the V phase and the W phase. . It should be noted that terminals 6U, 6V, 6W and 7a, 7b are individually connected to the lead wires 5U, 5V, 5W and the lead wires 4a, 4b by caulking afterwards.

  In such a stator 1, when a necessary amount of the stator coil 3 is wound around the stator core 2, the stator coil 3 that protrudes to both end surfaces of the stator core 2 is wound on the end surfaces thereof to coil ends 3 a, Although it finishes as 3b, the closeness of the strands which should become the coil ends 3a and 3b is not raised at this stage, and the coil ends 3a and 3b are greatly unnaturally swollen.

  Therefore, the coil ends 3a and 3b are shaped after the necessary amount of the stator coil 3 is wound around the stator core 2 and before racing (binding with a string or the like). As will be described later, the coil ends 3a and 3b are shaped by a primary shaping process in which the coil ends 3a and 3b are compression-molded in the radial direction from the inner and outer peripheral sides, and the coil ends 3a and 3b are moved to the stator core 2 following the primary shaping. And a secondary shaping step of compression molding toward the end face side.

  3 to 6 schematically show a press forming apparatus for forming the coil ends 3a and 3b in the stator 1. FIG. 3 to 6, the symbol Q indicates the shape of the coil end 3a before shaping.

  The press molding apparatus shown in FIG. 3 is roughly divided into a support body 8 for supporting the stator 1 as a work, an inner jig 11 that can be moved up and down, and includes an inner peripheral mold 9 and an end face molding mold 10 described later. An outer jig 13 which is arranged outside the inner jig 11 and has an outer peripheral mold 12 which will be described later, and an inner pusher 14 and an outer pusher 15 for driving each part of the inner jig 11. Consists of The stator 1 is fixedly supported on the support body 8 in an upright posture so that its axis is vertical.

  The inner jig 11 stacks the cylindrical mandrel 34, the inner peripheral mold 9 and the extension 15 concentrically in order from the lower side, and the end face mold 10 can be moved up and down with respect to the extension 15. It is inserted. When the inner jig 11 is lowered with respect to the stator 1 supported by the support 8, the mandrel 34 is inscribed in the inner peripheral surface of the stator core 2, and the upper part of the mandrel 34 is locked to the upper end surface of the stator core 2. . Thereby, relative positioning and centering (centering) between the stator 1 and the inner jig 11 in the axial direction are performed.

  A cam sleeve 16 penetrating them is disposed at the center of the inner peripheral die 9 and the extension 15. The cam sleeve 16 is supported by a guide rod 17 erected from a mandrel 34 so as to be movable up and down, and is always urged upward by a compression coil spring 18 interposed between the cam sleeve 16 and the mandrel 34. A drive cam surface 16a for driving the inner peripheral mold 9 is formed on the outer peripheral surface of the cam sleeve 16 as will be described later.

  The inner peripheral mold 9 is generally cylindrical, and is divided into a plurality of mold pieces that are mutually independent in the circumferential direction. Each mold element is slidable in the radial direction, and the inner peripheral mold 9 as a whole can be reduced in diameter. Each die piece is given a biasing force in the direction of diameter reduction by a spring means (not shown). A drive cam surface 16a on the cam sleeve 16 side and a slidable driven cam surface 9a are formed on the inner surface of the inner peripheral mold 9, and the cam sleeve 16 is lowered with respect to the inner peripheral mold 9 as will be described later. The inner peripheral die 9 is expanded on the basis of sliding between the drive cam surface 16a and the driven cam surface 9a.

  Even though the end surface mold 10 inserted on the extension 15 can be moved up and down with respect to the extension 15, the relative rotation is impossible due to the engagement between the pin 19 and the guide groove 20. Further, even if the end surface forming die 10 is a hollow cylinder as a whole, as shown in FIG. 7, the final lead wires 4a, 4b and 5U, 5V, 5W from the coil end 3a are collected. A lead wire receiving recess 21 is formed at a position corresponding to the routing position so as to be cut out in a fan shape over a predetermined length in the circumferential direction. As a result, at the position corresponding to the lead wire receiving recess 21 in the end surface mold 10, only the flange portion 22 having the same outer diameter as the end surface mold 10 itself and a relatively small thickness t is left. Will be. On the upper surface of the flange portion 22, a lead wire holding mechanism 29 is provided as a lead wire holding means described later.

  On the other hand, the outer jig 13 has a holder 23 that can be moved up and down as a base and a plurality of (for example, eight) outer peripheral molds 12 arranged on the lower surface of the holder 23. The outer peripheral molds 12 are arranged at the same pitch on the same circumference having the same axis as that of the stator 1, and are driven by a driving mechanism (not shown) so that the respective outer peripheral molds 12 are simultaneously synchronized with each other. The stator 1 is slidable in the radial direction. In other words, the plurality of outer peripheral dies 12 can be contracted and expanded in the radial direction of the stator 1 by sliding all at once in synchronization with each other.

  Here, details of the lead wire holding mechanism attached to the end face mold 10 described above will be described with reference to FIGS.

  As shown in FIGS. 7 and 8, the flange portion 22 left by forming the lead wire receiving recess 21 in the end surface mold 10 has lead wires 4a and 4b drawn to the final wiring position in FIG. The slots 24 corresponding to the total number of 5U, 5V, and 5W (here, 5) are notched so as to be close to each other. Each slot 24 is opened to the outer peripheral surface side of the flange portion 22 itself, and the slot width is expanded in a taper shape in the vicinity of the open end.

  7 and 8, a pair of clips 25 formed by bending leaf springs are opposed to each other in the three slots 24 at the center, and each clip 25 is screwed to the flange portion 22. It is supported by the holder block 26. On the other hand, each of the slots 24 at both ends in the arrangement direction of FIGS. 7 and 8 faces a single clip 27 formed by bending a leaf spring. Similarly, each clip 27 is screwed to the flange portion 22. The holder block 28 is supported.

  The two types of clips 25 and 27 having different shapes have a protruding portion 25a or 27a that protrudes inside the slot 24, thereby forming a narrowed portion that locally narrows the slot width of each slot 24. Will be. Therefore, as shown in FIGS. 7 and 8, the lead wires 4a, 4b and 5U, 5V, 5W from the coil end 3a are wound at the final wiring position in FIG. 2, and then the lead wires 4a, 4b. In addition, the terminal sides of 5U, 5V, and 5W are bent substantially at right angles so as to be directed to the side opposite to the coil end 3a in the axial direction of the stator 1 and pushed into the deep portions of the respective slots 14. By doing so, the lead wires 4a, 4b and 5U, 5V, 5W are prevented from being removed from the corresponding slots 24 by the protrusions 25a, 27a of the clips 25, 27 described above, and the respective slots. It is elastically held by the portion 24, and the state can be self-held. In addition, in the state where the terminal side of each lead wire 4a, 4b and 5U, 5V, 5W held in each slot 24 is oriented in the axial direction of the stator 1, each lead wire 4a, 4b and 5U, 5V and 5W are held so as to be within the annular projection area of the coil end 3a.

  In FIG. 7, if the left two lead lines 4b and 5W are correctly drawn, the previous clips 25 and 27 are hidden and cannot be seen. In FIG. 7, some of the left two lead lines 4b and 5W are partially hidden. It is indicated by a virtual line.

  As apparent from the above description, the slots 24 formed in the flange portion 22 and the clips 25 and 27 facing the respective slot portions 24 are connected to the lead wires 4a and 4b and 5U, 5V and 5W as coil ends. 3a is positioned at the final wiring position in the circumferential direction, and the terminal sides of the lead wires 4a, 4b and 5U, 5V, 5W are directed to the side opposite to the coil end 3a in the axial direction of the stator 1 The lead wire holding mechanism 29 is formed as lead wire holding means for positioning and holding the lead wires 4a, 4b and 5U, 5V, 5W within the annular projection area of the coil end 3a.

  Next, a procedure for shaping the coil end 3a using the press molding apparatus configured as described above will be described.

  First, as shown in FIG. 3, the inner jig 11 is lowered with respect to the stator 1 supported by the support 8, and relative positioning and centering in the axial direction between the stator 1 and the inner jig 1 ( Centering). In this case, the inner peripheral mold 9 is inserted inside the coil end 3a, but the inner peripheral mold 9 is in a reduced diameter state and does not positively contact the coil end 3a before shaping. . Further, the end surface mold 10 that is extrapolated to the extension 15 is in a state of being raised with respect to the extension 15.

  7 is an enlarged perspective view of the main part of FIG. 3, and in the state of FIGS. 3 and 7, the lead wires 4a, 4b and 5U, 5V, 5W attached to the coil end 3a of the stator coil 2 are arranged on the inner circumference. The wire is wound around the mold 9, and the terminal sides of the lead wires 4a, 4b and 5U, 5V, 5W are gathered at the final wiring position in FIG. Then, the terminal side of each of the lead wires 4a, 4b and 5U, 5V, 5W is bent at a substantially right angle so as to be directed to the side opposite to the coil end 3a in the axial direction of the stator 1, thereby forming a lead wire holding mechanism 29. Each slot 24 is pushed into the back of each slot 24 and held. In this state, of the lead wires 4a, 4b and 5U, 5V, 5W, the portion on the terminal side of the portion held by the lead wire holding mechanism 29 is the annular projection area of the coil end 3a before shaping. It will be contained within.

  When the positioning of the lead wires 4a, 4b and 5U, 5V, 5W and the holding by the lead wire holding mechanism 29 are thus completed, the outer jig 13 is lowered as shown in FIG. When the outer jig 13 is lowered, each outer peripheral mold 12 is in a diameter-expanded state and does not positively contact the coil end 3a before shaping. As a result, the coil end 3 a is located in the gap between the inner peripheral die 9 and the outer peripheral die 12.

  Next, the inner pusher 14 is lowered from the state of FIG. 4, and the cam sleep 16 is pushed down by the inner pusher 14 as shown in FIG. When the cam sleeve 16 is pushed down, the inner peripheral die 9 expands due to the sliding of the drive cam surface 16a on the cam sleeve 16 side and the driven cam surface 9a on the inner peripheral die 9 side. Simultaneously or substantially simultaneously with the diameter expanding operation of the inner peripheral mold 9, the outer peripheral mold 12 is contracted by a driving means (not shown). As a result, the inner peripheral mold 9 and the outer peripheral mold 12 cooperate with each other to perform compression molding so as to pressurize and restrain the coil end 3a in the radial direction, and as a primary shaping, the radial thickness dimension of the coil end 3a is a predetermined dimension. It will be shaped to finish.

  In this case, the respective lead wires 4a, 4b and 5U, 5V, 5W attached to the coil end 3a remain held by the lead wire holding mechanism 29 as shown in FIG. It does not bite between the outer peripheral mold 12.

  Subsequently, the outer pusher 15 is lowered while maintaining the state in which the inner peripheral mold 9 and the outer peripheral mold 12 are compression-molding the coil end 3a as shown in FIG. 5, and as shown in FIG. Press 10 down. The lowered end face forming die 10 enters the facing gap between the inner peripheral die 9 and the outer peripheral die 12, and presses the coil end 3a compression-molded by the inner peripheral die 9 and the outer peripheral die 12 against the stator core 2 side. Further, compression molding is performed to shape the height dimension of the coil end 3a from the stator core 2 to a predetermined dimension as secondary shaping.

  In the process in which the end surface mold 10 is lowered, the state of FIG. 7 is shifted to the state of FIG. 9, and the lead wire holding mechanism 29 and the lead wire holding mechanism 29 are held as shown in FIGS. The respective lead wires 4a, 4b and 5U, 5V, 5W directed in the axial direction of the stator 1 are moved relative to each other, and the lead wires 4a, 4b and 5U of the coil end 3a are respectively moved. Even at the position corresponding to the final wiring position of 5V and 5W, the flange portion 22 of the end surface mold 10 compresses and forms the coil end 3a. Note that FIG. 9 shows a state in which the primary shaping and the secondary shaping of the coil end 3a are not completely completed in the drawing.

  Here, the lead wire holding mechanism 29 only elastically holds the terminal sides of the lead wires 4a, 4b and 5U, 5V, 5W as described above, and the lead wire 4a, 4b and 5U, 5V, and 5W are bundles of coil wires and have a predetermined rigidity. Therefore, in the process in which the lead wire holding mechanism 29 is lowered together with the end surface mold 10, the lead wire holding mechanism 29 is the stator 1. The respective lead wires 4a, 4b and 5U, 5V, 5W which are directed in the axial direction of each of the lead lines 4a, The terminal side of 4b and 5U, 5V, 5W is not buckled.

  Then, the shaping by compression molding in the radial direction and the axial direction of the coil end 3a is completed in the state of FIG. 6, and the coil end 3a has a higher density or close contact of the coil wire than before the shaping. The cross-sectional area is reduced and the cross-sectional shape is finished as a rectangular shape.

  When the primary shaping and the secondary shaping of the coil end 3a are completed, the end surface mold 10 is first returned to the state shown in FIG. 5 in the reverse procedure to the above, and further the outer peripheral die so as to be in the state shown in FIG. 12 is operated to expand the diameter, and the inner peripheral mold 9 is operated to reduce the diameter, and the entire outer jig 13 is raised and returned to the state shown in FIG.

  And if it will be in the state of FIG. 3, the operation | movement of a press molding apparatus shall be once stopped. In this state, the terminal sides of the lead wires 4a, 4b and 5U, 5V, 5W attached to the shaped coil end 3a are still held by the lead wire holding mechanism 29 as shown in FIG. Therefore, the terminal side of each of the lead wires 4a, 4b and 5U, 5V, 5W is extracted from the slot 24 of the lead wire holding mechanism 29 and released from being held by the lead wire holding mechanism 29.

  Thus, when the respective lead wires 4a, 4b and 5U, 5V, 5W are released from being held by the lead wire holding mechanism 29, the press molding apparatus is started again, and the entire inner jig 11 is raised and returned. Thereafter, the stator 1 after the shaping of the coil end 3a is taken out from the support 8. The stator 1 having finished shaping the coil end 3a in the stator coil 3 is press-fitted into a predetermined case after undergoing processes such as racing and terminal connection.

  As described above, according to the present embodiment, the lead wires 4a, 4b and 5U, 5V, 5W attached to the coil end 3a are positioned at the final routing positions, and the lead wires 4a, 4b are placed. And the terminal sides of 5U, 5V, and 5W are directed to the side opposite to the coil end 3a in the axial direction of the stator 1, and the lead wires 4a and 4b and 5U, 5V, and 5W are substantially formed in an annular shape of the coil end 3a. The coil end 3a is shaped by compression molding in the radial direction and axial direction of the coil end 3a while being held so as to be within the projected area. For this reason, it is not necessary to correct or reroute the lead positions of the respective lead wires 4a, 4b and 5U, 5V, 5W after shaping, so that the area occupied by the coil end 3a can be reduced and the size thereof can be reduced. In addition, it is possible to prevent damage caused by the biting of the lead wires 4a, 4b and 5U, 5V, 5W.

  Here, in FIG. 3 to FIG. 6, the case where the upper coil end 3 a of the stator 1 positioned and supported by the support body 8 is shaped has been described. However, the press forming apparatus in FIG. Thus, not only the upper coil end 3a but also the lower coil end 3b are simultaneously shaped.

  The behavior of the press molding apparatus is merely an example, and it goes without saying that various changes can be made as necessary without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 1 ... Stator 2 ... Stator core 3 ... Stator coil 3a, 3b ... Coil end 4a, 4b ... Lead wire 5U, 5V, 5W ... Lead wire 9 ... Inner circumference type 10 ... End surface molding die 12 ... Outer die type 22 ... Flange part 24 ... Slot 25 ... Clip 27 ... Clip 29 ... Lead wire holding mechanism (lead wire holding means)

Claims (5)

A method of shaping an annular coil end that extends from the end face of the stator core and extends in the circumferential direction by being wound around the stator core,
The lead wire from the coil end is positioned at the final wiring position in the circumferential direction of the coil end, and the lead wire end is directed to the opposite coil end side in the axial direction of the stator core. A positioning step for holding the wire so that it falls within the annular projection area of the coil end;
A primary shaping step of shaping the coil end in a radial direction while constraining the inner and outer peripheral surfaces of the coil end;
A secondary shaping step of compressing and shaping the coil end other than the lead wire in the axial direction in a state in which the inner and outer peripheral surfaces of the coil end are constrained;
A stator coil shaping method comprising: A device for shaping an annular coil end that extends from the end face of the stator core and extends in the circumferential direction by being wound around the stator core,
An inner peripheral type that restrains the inner peripheral surface of the coil end;
An outer peripheral mold that restrains the outer peripheral surface of the coil end and compresses the coil end in the radial direction in cooperation with the inner peripheral mold;
It is extrapolated so as to be movable relative to the inner peripheral mold in the axial direction of the coil end, and enters the area surrounded by the inner peripheral mold and the outer peripheral mold from the axial direction of the coil end. An end face mold that compresses the coil end in the axial direction;
Lead wire holding means that is provided in a part of the end surface mold and holds the lead wire from the coil end;
With
The lead wire holding means is a final routing position of the lead wire in the circumferential direction of the coil end in a state where the end surface forming die does not enter the region surrounded by the inner peripheral die and the outer peripheral die. And the terminal side of the lead wire is directed to the side opposite to the coil end in the axial direction of the stator core so as to hold the lead wire within the annular projection area of the coil end. A stator coil shaping device.   The lead wire holding means elastically holds the lead wire so as to allow relative movement between the end surface die and the lead wire when the end surface die compresses the coil end in the axial direction. The stator coil shaping device according to claim 2, wherein the stator coil shaping device is provided.   The stator coil shaping device according to claim 2 or 3, wherein the inner circumferential type is configured to pressurize and restrain the coil end in a direction in which the diameter of the coil end is increased from the inner circumferential surface side of the coil end.   The stator coil shaping device according to any one of claims 2 to 4, wherein the outer peripheral die is pressure-restrained from the outer peripheral surface side of the coil end in a direction of reducing the diameter of the coil end. .

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