JP2014161176A - Manufacturing method for stator of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a stator of a rotary electric machine, whereby an axial dimension of a stator can be shortened and, on the other hand, the leading end parts of the legs of a coil segment can securely be joined.SOLUTION: A manufacturing method for the stator of a rotary electric machine comprises the steps of: inserting a pair of legs of a coil segment into the slot of a stator core 13; bending the projecting portions 25 of the pair of legs projecting opposite the side where a connection part is arranged, in a circumferential direction such that the bending directions of the legs adjacent in a radial direction in the slot are opposite to each other, and forming an axially extending straight part 27 on the leading end part 26A of the leg 21A bent to one side in a circumferential direction; and superposing the leading end part 26A of the leg 21A with a straight part 27 and the leading end part 26B of the leg 21B with no straight part for a corresponding coil segment, fusing the straight part 27, and joining the leading end parts 26A and 26B of the legs 21A and 21B respectively.

Description

  The present invention relates to a method for manufacturing a stator for a rotating electrical machine, and more particularly to a method for manufacturing a stator for a segment coil type rotating electrical machine.

  Conventionally, as a stator 100 of a segment coil type rotating electrical machine, as shown in FIG. 9, after inserting a U-shaped coil segment 103 into a plurality of slots (not shown) formed in a stator core 101, With the tip 104a of the arm 104 restrained, the leg 104 of the coil segment 103 is inclined by rotating and bending in the circumferential direction, and then the tips 104a extending in the axial direction adjacent to each other are joined together. Thus, the coil 105 is formed.

  Further, in the stator described in Patent Document 1, in order to solve the problem that the axial dimension of the stator becomes long due to the tip portion extending in the axial direction, the tip portions of the two leg portions are crossed at a predetermined angle. It is described that the length of the stator in the axial direction is shortened without using a tip portion extending in the axial direction as a joint portion.

JP 2003-259583 A

  By the way, in the stator described in Patent Document 1, as shown in FIG. 10A, the tip portions 104a and 104a of the two leg portions 104 and 104 are melted by the welding electrode 110, but in FIG. As shown in FIG. 10C, the melted portion 106 that has become liquid melts and breaks, or even if it does not melt, as shown in FIG. 10C, it joins to the adjacent conductor (leg portion 104 '). May be short-circuited. On the other hand, as shown in FIG. 10 (d), there is a problem that the bonding strength is insufficient when bonding is performed with a small amount of melting as shown in FIG.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to reduce the axial dimension of the stator, and to reliably join the distal ends of the leg portions of the coil segments. It is providing the manufacturing method of the stator of a rotary electric machine.

In order to achieve the above object, the invention according to claim 1
A plurality of slots penetrating in the axial direction (for example, slots 14 in the embodiments described later) are accommodated in the slots, and a stator core (for example, a stator core 13 in the embodiments described later) arranged in the circumferential direction at a predetermined interval. A plurality of parts each having a pair of leg parts (for example, leg parts 21, 21A, and 21B in an embodiment described later) and a connecting part (for example, a connecting part 22 in an embodiment described later) connecting the pair of leg parts. A substantially U-shaped coil segment (for example, a coil segment 23 in an embodiment described later), and a method of manufacturing a stator for a rotating electrical machine,
Inserting a pair of leg portions of the coil segment into corresponding slots of the stator core;
Bending of the protruding portions of a pair of leg portions (for example, protruding portions 25 in the embodiments described later) that protrude in the opposite direction to the side where the connecting portion is disposed, between the legs adjacent in the radial direction within the slot The stator core is bent in the circumferential direction so that the directions are opposite to each other, and only the leg bent to one side in the circumferential direction is axially directed to the tip (for example, tip 26A in the embodiment described later). Forming an extending straight part (for example, a straight part 27 in an embodiment described later);
A distal end portion of the leg portion having the straight portion that is bent to the one side in the circumferential direction, and a leg portion that has the straight portion of the corresponding coil segment that is bent to the opposite side to the one side in the circumferential direction. A step of superimposing a distal end portion (for example, a distal end portion 26B in an embodiment described later), melting the straight portion, and joining the distal end portions of the leg portions;
A method of manufacturing a stator for a rotating electrical machine, comprising:

The invention according to claim 2 is the invention of claim 1,
In the bending step, the distal end portion of the leg portion that does not have the straight portion includes a radial side surface of the leg portion having the straight portion (for example, a radial side surface 28 in an embodiment described later), and both circumferential directions thereof. It is piled up so that it may contact over an edge (for example, circumferential direction both edges 28a and 28b in the below-mentioned embodiment),
The joining step is characterized by melting from an axial edge portion (for example, an axial edge portion 28c in an embodiment described later) of a radial side surface of the leg portion having the straight portion.

The invention according to claim 3 is the invention according to claim 1 or 2,
The bending step includes a bending jig (e.g., a plurality of recesses (e.g., recesses 41 in the embodiments described later)) that respectively hold the circumferential side surfaces of the plurality of legs having the same radial position in the slot. , Using a bending jig 40) in the embodiment described later,
An opening (for example, an opening 41a in an embodiment described later) of each of the bending jigs is chamfered (for example, a chamfer 42 in an embodiment described later) on one end side in the circumferential direction. And

  According to the first aspect of the present invention, the axial dimension of the stator can be shortened, while the tip end portions of the leg portions of the coil segments can be reliably joined.

  According to the invention of claim 2, the metal in which the straight portion is melted can be received by the tip portion of the leg portion that does not have the straight portion, and the tip portion of the leg portion of the coil segment can be reliably joined.

  According to the invention of claim 3, the plurality of leg portions at the same radial position in the slot are bent at a time to the tip end portion of the leg portion having the straight portion or the tip end portion of the leg portion not having the straight portion. And the bending process can be simplified.

It is a front view of the stator which concerns on this invention. It is a perspective view of the coil segment which comprises a stator coil. It is a partial front view of the stator of the side by which the leg part of a coil segment is joined. (A) is a figure for demonstrating the process of bending the protrusion part of a long leg part with a bending tool, (b) demonstrates the process of bending the protrusion part of a short leg part with a bending tool. (C) is a figure which shows the state which accumulated both the leg parts. It is a principal part enlarged view of a bending tool. (A) is a figure which shows the positional relationship of the two leg parts after a bending process, (b) is a figure for showing the aim position of a welding electrode, (c) is a figure which shows a joining process. (D) is a figure which shows the state by which the insulation coating was carried out. It is the figure which compared the length of the front-end | tip part of the leg part after the conventional joining, and the length of the front-end | tip part of the leg part after joining of this invention. (A) is a figure for calculating the length of a straight part, (b) is a graph for demonstrating the relationship between the volume to melt and joining strength. (A) is a front view of a conventional stator, and (b) is a partially enlarged view. It is a figure for demonstrating the conventional welding process.

  Hereinafter, a stator for a rotating electrical machine and a method for manufacturing the same according to an embodiment of the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  As shown in FIG. 1, the stator 10 of the present embodiment includes a stator core 13 in which a plurality of slots 14 penetrating in the axial direction are arranged at a predetermined interval in the circumferential direction, and a plurality of phases (for example, U-phase, V-phase, and W-phase) stator coils 15. Each stator coil 15 is connected to a power supply unit 16 and supplied with electric power from an external power source. A rotor (not shown) is rotatably disposed inside the stator 10 and is housed in a casing (not shown) to constitute a rotating electric machine.

  As shown in FIG. 2, the stator coil 15 includes a pair of leg portions 21 extending in parallel with each other and a connecting portion 22 that connects both the leg portions 21 at one end, and has a rectangular cross section. A plurality of substantially U-shaped coil segments 23 composed of the wires 30 are arranged in a row for every predetermined number (four in the present embodiment) to form a bundle of coil segment groups 20.

  A curved portion 24 that is curved in an S shape along the alignment direction of the coil segments 23 is formed at the center of the coupling portion 22, and as shown in FIG. One leg 21 is inserted into a radially inner portion of one slot 14, and the other leg 21 is radially outward of the other slot 14 at a predetermined number of slots away from one slot 14. It is comprised so that it may insert in each part. Therefore, in this embodiment, eight coil segments 23 are arranged in one slot 14.

  Moreover, as shown in FIG.2 and FIG.3, as for the coil segment group 20, in the both leg parts 21, the length of what adjoins alternately differs. That is, the odd-numbered leg portions 21A counted from the outside in the slot 14 are set to have short leg lengths, and the even-numbered leg portions 21B have leg lengths of 21A. It is set longer than the leg 21A.

  In the coil segment group 20 configured as described above, the pair of leg portions 21 of the coil segment 23 are inserted into the corresponding slots 14 of the stator core 13 as shown in FIG. Then, the protruding portions 25 of the pair of leg portions protruding to the side opposite to the side where the connecting portion 22 is arranged are arranged so that the bending directions of the leg portions 21 adjacent in the radial direction in the slot 14 are opposite to each other. The stator core 13 is bent in the circumferential direction.

  As shown in FIGS. 4 and 5, the bending step is performed by using a bending jig 40 having a plurality of concave portions 41 that respectively hold the circumferential side surfaces of the plurality of leg portions 21 having the same radial position in the slot 14. Done with. The opening 41a of each concave portion 41 of the bending jig 40 is chamfered at one end in the circumferential direction, and is formed at a right angle without chamfering at the other end in the circumferential direction.

  Therefore, for example, the long leg portion 21A, which is even-numbered from the outside in the radial direction in the slot 14, is in a state where the tip end portion 26A is held by the bending jig 40 as shown in FIG. The straight portion 27 extending in the axial direction is formed at the distal end portion 26A by being bent by one side in the circumferential direction and being held by the concave portion 41 until the bending is completed. On the other hand, the short leg portion 21B, which is positioned oddly from the outside in the radial direction in the slot 14, has a distal end portion 26B held by the bending jig 40 as shown in FIG. It is bent in the direction opposite to one side. In this case, the distal end portion 26B is released from the recessed portion 41 by the chamfer 42 of the bending jig 40 in the bending process, and thus the leg portion 21B has a configuration in which the distal end portion 26B does not have a straight portion.

  Therefore, as shown in FIG. 4C and FIG. 6A, the distal end portion 26A of the leg portion 21A having the straight portion 27, which is bent to one side in the circumferential direction, and the other end portion in the circumferential direction are bent. The front end portion 26B of the leg portion 21B not having the straight portion of the corresponding coil segment 23 is overlapped with the straight portion 27 extending in the axial direction from the front end portion 26B. Specifically, as shown in FIG. 6B, the distal end portion 26B of the leg portion 21B that does not have the straight portion includes the radial side surface 28 of the leg portion 21B that has the straight portion 27 and both circumferential edges thereof. 28a and 28b are stacked so as to be in contact with each other.

  In this state, the melting electrode 32 melts the straight portion 27 with the intermediate portion of the axial edge portion 28c of the radial side surface 28 of the straight portion 27 as a target position P, and the molten metal is used as a leg portion having no straight portion. It is received by the tip 26B of 21B. Thereby, as shown in FIG.6 (c), the front-end | tip parts 26A and 26B of the leg parts 21A and 21B are joined by the fusion | melting part 29 which fuse | melted the straight part 27. FIG. Thereafter, as shown in FIG. 6 (d), an insulating coat 31 is applied from above the melting portion 29.

  As shown in FIG. 7, the tip portions 26A and 26B of the pair of leg portions 21A and 21B joined in this way are higher in height than the case where the tip portions 104a extending in the conventional axial direction are joined together. Can be reduced.

As shown in FIG. 8B, the volume V ₂ of the melting portion 29 needs to be a volume V ₂ ′ for satisfying a predetermined bonding strength, and the leg portion 21 constituting the straight portion 27 is a rectangular wire. Therefore, the length h of the straight portion 27 shown in FIG. 8A is set to a value obtained by dividing the required volume V ₂ ′ by the conductor cross-sectional area A.

  As described above, according to the method for manufacturing the stator 10 of the rotating electrical machine according to the present embodiment, the step of inserting the pair of leg portions 21 of the coil segment 23 into the corresponding slot 14 of the stator core 13, The protruding portions 25 of the pair of leg portions 21 protruding to the side opposite to the side where they are arranged are arranged so that the bending directions of the leg portions 21 adjacent in the radial direction in the slot 14 are opposite to each other. A step of forming a straight portion 27 extending in the axial direction at the tip end portion 26A, and a straight portion 27 bent in the circumferential direction, and a leg portion 21A that is bent in the circumferential direction and having only the leg portion 21A bent in the circumferential direction. 26A of leg part 21A and leg part 21B which does not have the straight part of the corresponding coil segment 23 bent on the opposite side to the circumferential direction one side Overlapping an end portion 26B, it has been the straight portion 27 is melted and bonding legs 21A, 21B of tip portion 26A, and 26B to each other, the. Thereby, while the axial direction dimension of the stator 10 can be shortened, the front-end | tip parts 26A and 26B of the leg parts 21A and 21B of the coil segment 23 can be joined reliably.

  Further, in the bending step, the distal end portion 26B of the leg portion 21B having no straight portion is in contact with the radial side surface 28 of the leg portion 21A having the straight portion 27 and the circumferential edges 28a and 28b. In the joining step, melting is performed from the axial edge portion 28c of the radial side surface 28 of the leg portion 21A having the straight portion 27. Thereby, the metal in which the straight portion 27 is melted can be received by the distal end portion 26B of the leg portion 21B having no straight portion, and the distal end portions 26A and 26B of the leg portions 21A and 21B of the coil segment 23 are reliably joined. be able to.

  Further, the bending step is performed using a bending jig 40 including a plurality of concave portions 41 each holding the circumferential side surfaces of the plurality of leg portions 21 having the same radial position in the slot 14. The opening 41a of each recess 41 is chamfered 42 on one end side in the circumferential direction. As a result, the plurality of leg portions 21 located at the same radial position in the slot 14 are bent at a time to the distal end portion 26A of the leg portion 21A having the straight portion 27 or the distal end portion 26B of the leg portion 21B not having the straight portion. And the folding process can be simplified.

  In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.

DESCRIPTION OF SYMBOLS 10 Stator 13 Stator core 14 Slot 15 Stator coil 20 Coil segment group 21,21A, 21B Leg part 22 Connection part 23 Coil segment 25 Protruding part 26A, 26B Tip part 27 Straight part 28 Radial side surface 28a, 28b Circumferential edge part 28c Axis Directional edge 40 Bending jig 41 Recess 42 Chamfer

Claims (3)

A plurality of stator cores each having a plurality of slots penetrating in the axial direction at predetermined intervals in the circumferential direction, a pair of leg portions accommodated in the slots, and a connecting portion connecting the pair of leg portions. A substantially U-shaped coil segment, and a method of manufacturing a stator of a rotating electrical machine comprising:
Inserting a pair of leg portions of the coil segment into corresponding slots of the stator core;
The stator core is configured such that the protruding portions of the pair of leg portions projecting to the side opposite to the side where the connecting portion is disposed are arranged such that the bending directions of the leg portions adjacent in the radial direction in the slot are opposite to each other. A step of forming a straight portion extending in the axial direction at the distal end portion only with the leg portion bent in the circumferential direction, and
A distal end portion of the leg portion having the straight portion that is bent to the one side in the circumferential direction, and a leg portion that has the straight portion of the corresponding coil segment that is bent to the opposite side to the one side in the circumferential direction. A step of overlapping the tip portion, melting the straight portion, and joining the tip portions of the leg portions;
A method of manufacturing a stator for a rotating electrical machine, comprising: In the bending step, the tip portion of the leg portion not having the straight portion is overlapped so as to be in contact with the radial side surface of the leg portion having the straight portion, and across both circumferential edges thereof,
2. The method of manufacturing a stator for a rotating electrical machine according to claim 1, wherein in the joining step, melting is performed from an axial edge portion of the radial side surface of the leg portion having the straight portion. The bending step is performed using a bending jig provided with a plurality of recesses that respectively hold the circumferential side surfaces of the plurality of legs having the same radial position in the slot;
The method for manufacturing a stator for a rotating electrical machine according to claim 1 or 2, wherein the opening of each of the recesses of the bending jig is chamfered at one end in the circumferential direction.

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