JP2014209834A - Winding formation apparatus and winding formation method for stator coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate winding formation for a stator coil with a straight-angle conductor wound by a plurality of turns without causing a performance degradation.SOLUTION: A winding formation apparatus for a stator coil 14, having a slot section stored in a slot formed at a stator core 12 and a coil end section projecting from an axial end face of the stator core 12, includes a winding fixture in which a plurality of grooves fitted with straight angle conductors at respective stages of the stator coil 14 in the lamination direction and arranged in a predetermined direction are formed and the straight angle conductors are wound. A portion corresponding to the slot of the winding fixture is formed so that bottom faces of the grooves at the respective stages in the predetermined direction are arranged in the predetermined direction while being dislocated in a first orthogonal direction orthogonal to the predetermined direction, and a portion corresponding to the coil end of the winding fixture is formed so that the bottom faces of the grooves at the respective stages in the predetermined direction are arranged in the predetermined direction in the identical plane without being dislocated in a second orthogonal direction orthogonal to the predetermined direction for a lane change of the straight angle conductor in the lamination direction to be performed.

Description

  The present invention relates to a winding forming apparatus and a winding forming method for a stator coil, and in particular, a slot portion accommodated in a slot formed in a stator core, in which a rectangular conductor having a rectangular cross section is wound a plurality of turns. The present invention relates to a winding forming apparatus and a winding forming method for forming a winding of a stator coil having a coil end portion protruding from an axial end surface of the stator core.

  Conventionally, there is known a stator coil in which coil end portions protruding from the axial end surface of the stator core are formed in a plurality of different non-linear shapes (specifically, a crank shape, an arc shape, and a bent shape) (for example, , See Patent Document 1). This stator coil is a concentric winding coil in which a flat conducting wire having a rectangular cross section is wound several turns.

  Generally, in forming a concentric winding coil, first, a substantially straight wire as a flat wire is wound around a winding jig of a winding forming device, thereby forming a substantially elliptical shape. The formed intermediate formed coil is formed. And after that, said concentric winding coil is shape | molded by shape | molding the coil end part of the intermediate | middle shaping | molding coil into several different non-linear shape using a shaping | molding apparatus.

JP 2012-125043 A

  By the way, when forming a substantially elliptical intermediate formed coil in which a plurality of turns of a rectangular conductor wire are wound from a single substantially straight wire using the winding jig of the above winding forming apparatus, It is necessary to change the lane between the stages by connecting the rectangular conductors of the stages adjacent in the direction between the stages. If the lane change is provided in the slot portion accommodated in the slot formed in the stator core, the linearity in the slot portion is hindered, which may lead to a decrease in performance of the stator coil. In this regard, it is appropriate to provide the above-described lane change in the coil end portion.

  On the other hand, the length of the coil end portion of the stator coil that is wound around a plurality of turns and attached to the stator core is longer at the radially outer portion. For this reason, when the gaps between the slots on both sides of each step in the lamination direction of the flat wire of the intermediate formed coil are made uniform, the coil end portions of the intermediate formed coil are orthogonal to each other so that the flat wire of each step in the lamination direction is orthogonal to the lamination direction. It is necessary to form it so as to be aligned in the stacking direction while being greatly displaced in the direction. In this case, it is necessary to change the lane between stages while the rectangular conductors at each stage in the stacking direction are displaced in the orthogonal direction at the coil end portion. If the configuration is complicated and if it is intended to be realized with a winding jig having a simple configuration, it is difficult to change the lane between the stages when the flat wire is wound around the winding jig.

  The present invention has been made in view of the above-described points, and winding of a stator coil that can easily realize winding formation of a stator coil in which a plurality of turns of a rectangular conductor wire are wound without causing performance degradation. An object is to provide a wire forming apparatus and a winding forming method.

  The above-mentioned object is accommodated in a slot formed in a stator core in which a plurality of turns of a rectangular conductor wire having a substantially rectangular cross section is wound, and a gap is formed between adjacent rectangular conductors at each stage in the stacking direction. And a coil end portion projecting from an axial end surface of the stator core, wherein the rectangular conductor wire at each stage in the stacking direction of the stator coil includes: A plurality of grooves arranged in a predetermined direction to be fitted are formed, and a winding jig around which the flat wire is wound is provided, and a slot corresponding portion of the winding jig corresponding to the slot portion is in the predetermined direction The bottom surface of the groove of each stage is formed to be aligned in the predetermined direction while being displaced in a first orthogonal direction orthogonal to the predetermined direction, and the coil end portion of the winding jig Top Corresponding coil end corresponding portions are arranged in the predetermined direction in the same plane without the bottom surface of the groove of each step in the predetermined direction being displaced in the second orthogonal direction orthogonal to the predetermined direction. This is achieved by the stator coil winding forming device formed so that the lane change in the stacking direction is performed.

  In addition, the above-described object is to provide a slot formed in the stator core in which a rectangular conductor having a substantially rectangular cross section is wound around a plurality of turns, and a gap is formed between adjacent rectangular conductors at each stage in the stacking direction. A method of forming a winding of a concentric winding stator coil having a slot portion to be accommodated and a coil end portion protruding from an axial end surface of the stator core, wherein the flat angle of each stage in the stacking direction of the stator coil A plurality of grooves arranged in a predetermined direction in which the conducting wire is fitted are formed, so that the bottom surfaces of the grooves of each step in the predetermined direction are aligned in the predetermined direction while being displaced in a first orthogonal direction orthogonal to the predetermined direction. The slot-corresponding portion corresponding to the slot portion to be formed and the bottom surface of the groove at each step in the predetermined direction are in the same plane without being displaced in the second orthogonal direction orthogonal to the predetermined direction. A coil jig having a coil end corresponding portion corresponding to a top portion of the coil end portion formed so as to be changed in a lane in the laminating direction of the flat conductor wire in the predetermined direction. By winding a conducting wire, the slot portion is formed so that the flat conducting wires at each stage in the laminating direction are aligned in the laminating direction while being displaced in the first orthogonal direction perpendicular to the laminating direction, and The top of the coil end portion is aligned in the laminating direction in the same plane without the flat conducting wires of each step in the laminating direction being displaced in the second orthogonal direction perpendicular to the laminating direction, and the lamination of the rectangular conducting wires is performed. This is achieved by a stator coil winding forming method in which the lane change in the direction is performed.

  According to the present invention, it is possible to easily realize the formation of a winding of a stator coil in which a plurality of turns of a rectangular conducting wire are made without causing a performance degradation.

It is a perspective view of a stator provided with the stator coil which is one Example of this invention. It is a block diagram of the stator coil shape | molded using the coil | winding formation apparatus of a present Example. It is a block diagram after shape | molding the coil end part of the stator coil of a present Example in several different non-linear shape. It is a block diagram of the coil | winding formation apparatus which forms the coil | winding of the stator coil of a present Example. It is a block diagram of the winding jig | tool with which the winding formation apparatus of a present Example is provided. It is a figure showing the operation | movement procedure of the coil | winding formation apparatus of a present Example. It is a block diagram showing the state by which the stator coil was wound by the winding jig with which the winding formation apparatus of a present Example is provided. It is a block diagram of the stator coil shape | molded using the coil | winding formation apparatus which is a modification of this invention. It is a partial block diagram of the winding jig | tool with which the coil | winding formation apparatus which is a modification of this invention is provided. It is a block diagram of the winding jig | tool with which the winding formation apparatus which is a modification of this invention is provided. It is a block diagram showing the state by which the stator coil is wound by the winding jig with which the coil | winding formation apparatus which is a modification of this invention is provided.

  Hereinafter, specific embodiments of a winding forming apparatus and a winding forming method for a stator coil according to the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view of a stator having a stator coil according to an embodiment of the present invention. FIG. 2 shows a configuration diagram of a stator coil formed by using the winding forming apparatus of the present embodiment. Moreover, FIG. 3 shows the block diagram after shape | molding the coil end part of the stator coil of a present Example in several different non-linear shape. 2 (A) and 3 (A) are perspective views, FIG. 2 (B) and FIG. 3 (B) are top views, side views from four directions, AA sectional views, A BB sectional view, a CC sectional view, and a DD sectional view are respectively shown.

  In the present embodiment, the stator 10 is a stator used in a rotating electrical machine such as a three-phase AC motor. The stator 10 is disposed radially outside the rotor as a rotor via a predetermined air gap, and generates a magnetic field that rotates the rotor when energized. The stator 10 includes a stator core 12 and a stator coil 14. The stator core 12 is a member formed in a hollow cylindrical shape, and is formed by laminating a plurality of insulation-coated electromagnetic steel plates in the axial direction. A cylindrical yoke made of a material obtained by compression-molding a soft magnetic powder coated with an insulating coating may be attached to the radially outer surface of the stator core 12.

  The stator core 12 includes a yoke 16 formed in an annular shape, and teeth 18 that protrude from the radially inner side surface of the yoke 16 toward the radially inner side (axial center side). A plurality of teeth 18 are provided in the circumferential direction on the radially inner side surface of the yoke 16 (for example, 96 pieces as shown in FIG. 1), and are provided at regular intervals along the circumferential direction. A slot is formed between two teeth 18 adjacent in the circumferential direction.

  Each of the teeth 18 is wound with the stator coil 14 described above. A plurality of stator coils 14 (for example, 96 as shown in FIG. 1) are arranged in the circumferential direction on the radially inner side of the stator core 12. A plurality of stator coils 14 are arranged in the circumferential direction to constitute a coil assembly 20. The coil assembly 20 is formed in an annular shape along the circumferential direction by the plurality of stator coils 14. In the coil assembly 20, a plurality of stator coils 14 are arranged while shifting the accommodation slots one by one in the circumferential direction, and the stator coils 14 adjacent in the circumferential direction overlap in the stacking direction in which the lead wires of the stator coils 14 circulate. It is constituted by.

  Each stator coil 14 constitutes one of a U-phase coil, a V-phase coil, and a W-phase coil when the rotating electrical machine is applied to, for example, a three-phase AC motor. In this case, the U-phase coil, the V-phase coil, and the W-phase coil that are the stator coils 14 are wound around the teeth 18 in that order in the circumferential direction.

  The stator core 12 includes a plurality of (for example, 48 as shown in FIG. 1) divided cores divided in the circumferential direction. That is, the stator core 12 is divided into a plurality of divided cores in the circumferential direction. All the split cores have the same shape as each other. Specifically, each of the split cores has a shape including the yoke 16 and the two teeth 18 corresponding to the same circumferential angle. An insulating member that secures insulation between the stator core 12 and the stator coil 14 is attached to each divided core.

  The split core with the insulating member is inserted into the coil assembly 20 from the outside in the radial direction so that the stator coil 14 of the coil assembly 20 is disposed in the slot between the two teeth 18. When all the divided cores are assembled to the coil assembly 20, the stator 10 in which the stator core 12 and the stator coil 14 are assembled is configured.

  The stator coil 14 is constituted by a rectangular conducting wire 22 having a rectangular cross section (specifically, a rectangular shape). A plurality of stator coils 14 arranged in the circumferential direction of the stator 10 are concentric winding coils formed by bending a rectangular conductive wire 22 that has been wound by a predetermined number of turns (for example, 5 turns). Hereinafter, for the sake of convenience, the rectangular wire 22 that has been wound by a predetermined number of turns before bending is formed with the intermediate formed coil 24, and the stator coil 14 formed by bending the intermediate formed coil 22 is formed with the concentric wound coil 26. Respectively.

  As shown in FIG. 2, the intermediate formed coil 24 is wound around a winding jig provided in a winding forming device, which will be described in detail later, as a flat conductive wire 22 as a single linearly formed element wire. It is formed in a substantially elliptical shape while being circulated by a predetermined number of turns. In addition, the corner | angular part of the flat conducting wire 22 is good to carry out R process. Moreover, the flat conducting wire 22 should just be comprised with metals, such as copper and aluminum, with high electroconductivity. Further, the concentric winding coil 26 is formed by bending a substantially elliptical intermediate forming coil 24 using a predetermined forming device, and as shown in FIG. The end portion is formed in a substantially hexagonal shape having a convex tip.

  The concentric winding coil 26 includes slot portions 30 and 32 housed in slots formed in the stator core 12, coil end portions 34 and 36 protruding outward in the axial direction from both axial end portions of the stator core 12, and have. The slot portions 30 and 32 extend substantially linearly so as to penetrate the slots of the stator core 12 in the axial direction. The coil end portions 34 and 36 are curved so as to connect the slot portions 30 and 32 on the outer side in the axial direction with respect to both axial end portions of the stator core 12.

  Further, the intermediate formed coil 24 includes slot portions 40 and 42 corresponding to the slot portions 30 and 32 of the concentric winding coil 26 and coil end portions 44 and 46 corresponding to the coil end portions 34 and 36 of the concentric winding coil 26. And have. The slot portions 40 and 42 are formed in a substantially linear shape. The coil end portions 44 and 46 are formed in a substantially arc shape and are curved so as to connect the slot portions 40 and 42 on both sides.

  The intermediate formed coil 24 is configured such that the rectangular conductive wires 22 of each step aligned in the stacking direction are aligned in parallel. In the intermediate molded coil 24, the flat conductors 22 at each stage in the stacking direction of the slot portions 40 and 42 have a length corresponding to the axial length of the slot formed in the stator core 12, and are the same length in the longitudinal direction. have. Further, the rectangular conducting wires 22 at each stage in the stacking direction are arranged in parallel to each other at the same position at both ends in the axial direction of the slot.

  Of the rectangular conductor wires 22 arranged in the stacking direction of the intermediate molded coil 24, the slot portions 40 and 42 and the coil end portion 46 at each stage are formed on the same plane. On the other hand, the coil end portion 44 of each stage changes one lane for each of the rectangular conductive wires 22 arranged in the stacking direction of the intermediate molded coil 24 by obliquely connecting between the slot portions 40 and 42 on both sides. Shaped to do.

  Both ends of the concentric winding coil 26 and thus both ends of the intermediate formed coil 24 are connected to the same axial direction side (hereinafter referred to as the other ends) of the stator core 12 in order to connect to the other concentric wound coil 26 or intermediate formed coil 24 and terminals. , Referred to as the axial lead side). The coil end portions 34 and 44 are provided on the axial lead side, and the coil end portions 36 and 46 are provided on the axially opposite lead side opposite to the axial lead side. Hereinafter, the coil end portions 34 and 44 are referred to as lead side coil end portions 34 and 44, and the coil end portions 36 and 46 are referred to as anti-lead side coil end portions 36 and 46, respectively. The slot portions 30 and 40 are provided on one side in the circumferential direction, and the slot portions 32 and 42 are provided on the other side in the circumferential direction, respectively. Hereinafter, the slot portions 30 and 40 are referred to as one-side slot portions 30 and 40, and the slot portions 32 and 42 are referred to as the other-side slot portions 32 and 42, respectively.

  The slot portions 40 and 42 of each intermediate formed coil 24 are separated from each other by a predetermined distance in the axial direction connecting the coil end portions 44 and 46 and the orthogonal direction perpendicular to the laminating direction in which the flat conducting wires 22 are laminated. Further, the slot portions 30 and 32 of each concentric coil 26 are separated from each other by a predetermined angle in the circumferential direction. Further, the intermediate formed coil 24 and the concentric coil 26 are configured such that a plurality of flat conductors 22 are laminated in the short side direction of the flat conductor 22.

  The intermediate formed coil 24 and the concentric coil 26 are configured such that a predetermined gap is formed between the flat rectangular conductors 22 of the adjacent stages in the stacking direction. The intermediate formed coil 24 and the concentric winding coil 26 are arranged so that the distance between the slot portions 30 and 32 or the distance between the slot portions 40 and 42 changes according to the position in the stacking direction, that is, each slot portion 30, 32, 40 and 42 are formed in a trapezoidal cross section so that the flat conductive wires 22 at each stage in the stacking direction are aligned in the stacking direction while being displaced in a direction perpendicular to the stacking direction. The trapezoidal cross section is formed in order to properly accommodate the slot portions 30 and 32 of the concentric winding coil 26 in the slots of the stator core. The concentric winding coil 26 is assembled to the stator core 12 such that the lamination direction of the rectangular conducting wires 22 coincides with the radial direction orthogonal to the axial direction of the stator core 12.

  In the intermediate formed coil 24 and the concentric coil 26 described above, when the number of turns of the flat conducting wire 22 is, for example, “5”, the non-lead side coil end portions 36, 46, the one side slot portions 30, 40, and the other side In the slot portions 32 and 42, the number of laminated conductors is five, while in the lead-side coil end portions 34 and 44, the number of conductors is four.

  The coil end portions 34 and 36 of the concentric winding coil 26 are each formed in a plurality of different non-linear shapes. Specifically, each of the coil end portions 34 and 36 is formed in three types of non-linear shapes, and is formed into a crank shape that is bent stepwise toward the radial direction of the stator core 12 (crank forming). ) And is formed into an arc shape that is curved in accordance with the arc of the annular stator core 12 (arc forming), and is also formed into a bent shape that is bent in the longitudinal direction of the cross section of the flat conducting wire 22 (edgewise forming).

  Crank forming and arc forming are bending in the radial direction toward the lamination direction of the flat wire 22, and edgewise forming is bending in the orthogonal direction orthogonal to the lamination direction of the flat wire 22. . Crank forming is bending performed at the tops of the coil end portions 34 and 36 in order to change the lane between the flat rectangular conductors 22 at each stage in the stacking direction. Arc forming is a bending process performed in order to efficiently accommodate the concentric winding coil 26 in a slot. The edgewise molding is a bending process that is performed to efficiently arrange a plurality of concentric coils 26 when the coil assembly 20 is configured.

  Next, with reference to FIGS. 4 to 7, the winding formation of the intermediate formed coil 24 of the present embodiment will be described.

  FIG. 4 shows a plan view of a winding forming apparatus for forming the winding of the intermediate formed coil 24 of this embodiment. FIG. 5 shows a configuration diagram of a winding jig provided in the winding forming apparatus of the present embodiment. 5A shows a perspective view, and FIG. 5B shows a plan view. FIG. 6 is a diagram showing an operation procedure of the winding forming apparatus of this embodiment. Moreover, FIG. 7 shows the block diagram showing the state by which the intermediate | middle shaping | molding coil 24 was wound by the winding jig with which the winding formation apparatus of a present Example is provided. FIG. 7A shows a perspective view, and FIG. 5B shows a plan view.

  In the present embodiment, an intermediate molding formed into a substantially elliptical shape while being wound around a predetermined number of turns by winding a rectangular conductor wire 22 as a single linearly formed wire around the winding forming device 50. The coil 24 is formed. The winding forming device 50 includes a rotary seat 52 that can rotate with respect to a base, and a winding jig 54 around which the flat wire 22 is wound. The winding jig 54 is integrated and fixed to the rotary seat 52. The winding jig 54 and the rotary seat 52 are rotated with respect to the base by rotating the handle 56.

  The winding jig 54 is a box-shaped member formed in accordance with a desired three-dimensional shape of the intermediate molded coil 24. The winding jig 54 is formed in a substantially elliptical cross section so that the substantially elliptical intermediate molded coil 24 can be held on the side surface, and the lamination direction in which the flat rectangular conductors 22 at each stage of the intermediate molded coil 24 are stacked. It is formed in a column shape extending toward

  Hereinafter, portions of the winding jig 54 corresponding to the slot portions 40 and 42 of the intermediate formed coil 24 are referred to as slot corresponding portions 60 and 62, and portions corresponding to the coil end portions 44 and 46 of the intermediate formed coil 24 are referred to. They are referred to as coil end corresponding portions 64 and 66, respectively. Further, in the winding jig 54, the direction in which the slot-corresponding portions 60, 62 face each other is the first direction X, the direction in which the coil end-corresponding portions 64, 66 face each other is the second direction Y, and A direction perpendicular to both the first direction X and the second direction Y is referred to as a third direction Z. The third direction Z coincides with the stacking direction in which the steps of the set flat wire 22 are stacked.

  A plurality of grooves 70 arranged in the third direction Z are formed on the side surface of the winding jig 54. The groove 70 is a groove into which the flat conducting wire 22 at each stage in the stacking direction is fitted when the intermediate formed coil 24 is formed. The winding jig 54 is configured by laminating a plurality of plate-like members 72 and 74 formed in a substantially elliptical shape in accordance with the substantially elliptical intermediate molded coil 24 in the third direction Z. The winding jig 54 is configured by fastening a plurality of plate-like members 72 and 74 stacked in the third direction Z with bolts or the like.

  The flat plate member 72 and the flat plate member 74 have different sizes (areas). The size of the flat plate member 72 is smaller than the size of the flat plate member 74. The flat members 72 and 74 are provided in the same number as the number of turns of the intermediate formed coil 24 corresponding to the intermediate formed coil 24, respectively. The winding jig 54 is configured by alternately arranging flat plate members 72 and flat plate members 74 having different sizes on the seat surface of the rotary seat 52 in that order. The alternate arrangement of the flat plate member 72 and the flat plate member 74 produces a recess (that is, the groove 70 described above) that opens in the XY in-plane direction.

  The shape of the flat plate member 74 farthest from the seating surface of the rotary seat 52 may be the same as the shape of the other flat plate members 74, but other shapes such as a thickness as shown in FIG. The shape of the flat plate member 74 may be different. Further, the flat plate members 74 having the same shape are provided by a number smaller by “1” than the number of the flat plate members 72, adjacent to the flat plate member 72 farthest from the seating surface of the rotary seat 52, A flat plate member having the same size (area) as the flat plate member 74 and having a thickness larger than that of the flat plate member 74 may be disposed.

  The flat plate member 72 is formed so that the thickness in the third direction Z is the same as or slightly larger than the thickness in the short side direction of the flat conductor wire 22. Further, the flat plate member 74 is formed so that the thickness in the third direction Z is substantially the same as the gap between the flat conductors 22 of the adjacent stages in the stacking direction of the intermediate molded coil 24.

  The groove 70 is formed between the rotary seat 52 and the flat plate member 74 or between the two flat plate members 74, and is formed on the radially outer side of the flat plate member 72. The side wall of the groove 70 is a wall surface facing the third direction Z formed at a portion of the rotary seat 52 or the flat plate member 74 protruding from the end of the flat plate member 72. The bottom surface of the groove 70 is a side surface of the flat plate member 72 and faces the direction orthogonal to the third direction Z. Each step groove 70 is formed in the same XY plane.

  The plurality of flat plate-like members 72 arranged in the third direction Z are formed such that the width between the slot corresponding portion 60 and the slot corresponding portion 62 decreases as the distance from the seating surface of the rotary seat 52 increases. . Further, the plurality of flat plate-like members 74 arranged in the third direction Z are formed such that the width between the slot corresponding portion 60 and the slot corresponding portion 62 decreases as the distance from the seating surface of the rotary seat 52 increases. ing. In other words, the slot-corresponding portions 60 and 62 of the winding jig 54 are moved in the first direction X while the bottom surfaces of the grooves 70 in each step aligned in the third direction Z are displaced in the first direction X perpendicular to the third direction Z. It is formed so as to line up in three directions Z. Further, the slot-corresponding portions 60 and 62 are arranged in the third direction Z while the side surfaces of the flat plate members 74 of the respective stages arranged in the third direction Z are displaced in the first direction X orthogonal to the third direction Z. It is formed to line up.

  Each slot corresponding to each slot 60, 62 has a substantially equal length in the longitudinal direction, that is, the second direction Y, and is aligned in the third direction Z while being displaced in the first direction X. They are parallel to each other between the same positions in the direction.

  The coil end corresponding portions 64 and 66 of the winding jig 54 are formed in a shape having a plurality of arcs having different curvature radii (arc radii). The lead side coil end corresponding portion 64 of the winding jig 54 includes shoulder portions 76 and 78, a top portion 80, and large R portions 82 and 84. The shoulder portions 76 and 78 are portions that are connected to the slot corresponding portions 60 and 62 and are curved with respect to the slot corresponding portions 60 and 62. The top portion 80 is a portion corresponding to the top portion of the lead-side coil end portion 44 of the intermediate molded coil 24 and is a portion having a relatively small radius of curvature. Further, the large R portions 82 and 84 are portions that connect the shoulder portions 76 and 78 and the top portion 80 and are smoothly curved portions that have a relatively large radius of curvature as compared with the shoulder portions 76 and 78 and the top portion 80. .

  Further, the anti-lead side coil end corresponding portion 66 of the winding jig 54 includes shoulder portions 86 and 88, a top portion 90, and large R portions 92 and 94. The shoulder portions 86 and 88 are portions that are connected to the slot corresponding portions 60 and 62 and are curved with respect to the slot corresponding portions 60 and 62. The top portion 90 is a portion corresponding to the top portion of the counter lead side coil end portion 46 of the intermediate molded coil 24 and is a portion having a relatively small radius of curvature. The large R portions 92 and 94 are portions that connect the shoulder portions 86 and 88 and the top portion 90, and are smoothly curved portions that have a relatively large radius of curvature as compared with the shoulder portions 86 and 88 and the top portion 90. .

  As the plurality of flat plate-like members 72 arranged in the third direction Z are farther away from the seating surface of the rotary seat 52, the size and large R of the shoulder portions 76, 78, 86, 88 at the coil end corresponding portions 64, 66, respectively. The portions 82, 84, 92, and 94 are formed so as to be slightly smaller in size. In addition, as the plurality of flat plate members 74 arranged in the third direction Z move away from the seating surface of the rotary seat 52, the size of the shoulder portions 76, 78, 86, 88 in the coil end corresponding portions 64, 66 and The large R portions 82, 84, 92, and 94 are formed to be slightly smaller in size.

  That is, the shoulder portions 76, 78, 86, 88 and the large R portions 82, 84, 92, 94 of the coil end corresponding portions 64, 66 of the winding jig 54 are arranged in the third direction Z, respectively. The bottom surfaces of the grooves 70 are formed so as to be aligned in the third direction Z while being displaced in an orthogonal direction (XY in-plane direction) orthogonal to the third direction Z. Further, the shoulder portions 76, 78, 86, 88 and the large R portions 82, 84, 92, 94 of the respective coil end corresponding portions 64, 66 are respectively arranged in flat plate members 74 at respective stages arranged in the third direction Z. Are arranged so as to be aligned in the third direction Z while being displaced in an orthogonal direction (XY in-plane direction) orthogonal to the third direction Z.

  On the other hand, the plurality of flat plate-like members 72 arranged in the third direction Z are formed so that the sizes of the top portions 80 and 90 are the same in the coil end corresponding portions 64 and 66, respectively. The plurality of flat plate members 74 arranged in the third direction Z are formed such that the sizes of the top portions 80 and 90 are the same in the coil end corresponding portions 64 and 66, respectively. That is, the top portions 80 and 90 of the coil end corresponding portions 64 and 66 of the winding jig 54 are arranged in the second direction Y in which the bottom surfaces of the grooves 70 in each step aligned in the third direction Z are orthogonal to the third direction Z. Are formed so as to be aligned in the third direction Z in the same plane without being displaced. Further, the top portions 80 and 90 of the coil end corresponding portions 64 and 66 are displaced in the second direction Y in which the side surfaces of the flat plate-like members 74 arranged in the third direction Z are orthogonal to the third direction Z. It forms so that it may line up in the 3rd direction Z within the same plane.

  Further, the flat plate member 72 and the flat plate member 74 arranged in the third direction Z are formed so that the sizes of the top portions 80 are the same in the lead-side coil end corresponding portion 64. That is, at the top 80 of the lead-side coil end corresponding portion 64 of the winding jig 54, the flat plate member 72 and the flat plate member 74 are alternately arranged so as not to have a dent or a step in the first direction X. Has been. The top portion 80 is formed such that the bottom surfaces of the grooves 70 arranged in the third direction Z are in contact with each other without a side wall interposed therebetween.

  Incidentally, the lead-side coil end corresponding portion 64 of the winding jig 54 has a depth of the groove 70 of each step aligned in the third direction Z from the vicinity of the top portion 80 via the large R portions 82 and 84. It is formed so as to gradually increase over the portions 76 and 78.

  On the other hand, the flat plate member 72 and the flat plate member 74 arranged in the third direction Z are formed so that the size of the top 90 is changed in the anti-lead side coil end corresponding portion 66. That is, at the top 90 of the anti-lead side coil end corresponding portion 66 of the winding jig 54, the flat plate member 72 and the flat plate member 74 are alternately arranged so that a dent or a step in the first direction X is generated. Has been. In the top portion 90, the bottom surfaces of the grooves 70 arranged in the third direction Z are separated from each other via a side wall (specifically, a portion of the flat plate member 74 protruding from the end of the flat plate member 72). It is formed as follows.

  The winding forming device 50 also includes an outer diameter varying device (not shown) that varies the outer diameter of the winding jig 54. The winding jig 54 is divided into a plurality of parts in the first direction X and the second direction Y (that is, the XY plane). A gap is formed between these parts. The above outer diameter varying device is a device that varies the separation distance of each part of the winding jig 54, and the molding from the rectangular conductor wire 22 as a single linearly formed wire has been completed. This is an apparatus for facilitating the removal of the substantially elliptical intermediate molded coil 24 that has been wound by a predetermined number of turns from the winding jig 54. In the outer diameter variable device, the separation distance between the parts of the winding jig 54 is usually suitable for forming the intermediate formed coil 24 from the flat wire 22, while the intermediate formed coil 24 has been formed. Is actuated to be smaller than the normal distance.

  In the present embodiment, when the flat wire 22 as a straight wire formed on the winding forming apparatus 50 having the above structure is set, the spacing between the parts of the winding jig 54 is separated. The distance is set to be suitable for forming the intermediate formed coil 24 from the flat wire 22. In such a state, first, the rectangular conductive wire 22 as a single strand formed in a straight line is set in the winding forming device 50. At this time, the flat conducting wire 22 is set so as to fit into a groove 70 formed on the side surface of the lowermost flat plate member 72 between the rotary seat 52 and the lowermost flat plate member 74 of the winding jig 54. Is done.

  When the above setting is performed, the rectangular wire 22 is then wound around the winding jig 54 by rotating the handle 56. The flat conductive wire 22 is wound around the winding jig 54 so that the flat conductive wire 22 wraps around the winding jig 54 while fitting into the groove 70 along the side surface of the winding jig 54.

  In the winding jig 54, the slot-corresponding portions 60 and 62 are displaced in the first direction X in which the bottom surfaces of the respective grooves 70 arranged in the third direction Z are orthogonal to the third direction Z as described above. However, they are formed so as to be aligned in the third direction Z. Further, the top portions 80 and 90 of the coil end corresponding portions 64 and 66 are not displaced in the second direction Y perpendicular to the third direction Z from the bottom surfaces of the grooves 70 arranged in the third direction Z, respectively. It is formed so as to be aligned in the third direction Z within the same plane.

  Therefore, according to the winding forming apparatus 50 of the present embodiment, the slot portions 40 formed so that the flat conductors 22 at each stage in the stacking direction are aligned in the stacking direction while being shifted in the orthogonal direction orthogonal to the stacking direction. 42 and coil end portions 44 and 46 (particularly, the top portions thereof) formed so that the flat conductors 22 at each step in the stacking direction are aligned in the stacking direction in the same plane without being displaced in the orthogonal direction orthogonal to the stacking direction. ) Can be formed.

  The formed intermediate formed coil 24 is formed such that the interval between the slot portions 40, 42 on both sides of the flat conducting wire 22 at each stage in the stacking direction changes according to the position in the stacking direction. More specifically, the portion located on the radially outer side when mounted on the stator core 12 is formed such that the distance between the slot portions 40 and 42 on both sides is increased. For this reason, since adjustment of the length of the coil end part according to the site | part of the lamination direction in the stator coil 14 can be implement | achieved by the change of the space | interval of both side slot parts, each stage of the lamination direction of the top part of a coil end part The length adjustment of the coil end part according to the site | part of the lamination direction is realizable, without shifting the position of the flat conducting wire 22 in the direction orthogonal to the lamination direction.

  Further, in the winding jig 54, the slot corresponding portions 60 and 62 and the coil end corresponding portions 64 and 66 excluding the top portion 80 are arranged in the XY plane direction by alternately arranging the flat plate member 72 and the flat plate member 74. It is formed so as to have a recess that is open toward the end (that is, a groove 70 separated through a side wall). On the other hand, the top portion 80 of the lead-side coil end corresponding portion 64 does not have the above-described dent even if the flat plate members 72 and the flat plate members 74 are alternately arranged, and the bottom surface of the groove 70 of each step is the same surface. It is formed to constitute. The same surface is formed so that the normal line substantially coincides with the first direction X.

  According to the structure of the winding jig 54, the winding of the rectangular conductive wire 22 described above corresponds to the lead-side coil end corresponding portion 64 (respectively) of the groove 70 of each step aligned in the third direction Z of the winding jig 54. In particular, in the portion excluding the top portion 80), the flat wire 22 extends so as to extend in the same XY plane, while the lead-side coil end corresponding portion 64 (particularly, the top portion 80) of each of the grooves 70 of each step. Is performed so that the rectangular conductive wires 22 of adjacent steps extend diagonally. In this case, the intermediate formed coil 24 formed by the round turn of the flat conducting wire 22 has a lane change at the top of the lead side coil end portion 44 so that the flat conducting wires 22 of adjacent steps in the stacking direction are obliquely connected to each other. Become.

  The portion of the intermediate formed coil 24 where the lane change between adjacent stages in the stacking direction is performed is the top of the lead-side coil end portion 44, and the rectangular wire 22 at each stage in the stacking direction is orthogonal to the stacking direction. It is a site | part formed so that it may align in the lamination direction within the same plane, without shifting in position. That is, the lane change between the flat conductors 22 at each stage in the stacking direction is not performed at a position where the flat conductors 22 at each stage in the stacking direction are displaced in the orthogonal direction perpendicular to the stacking direction.

  For this reason, in the present embodiment, in the process of forming the winding of the intermediate formed coil 24 in the winding forming device 50, the flat conductors 22 at each stage in the stacking direction are aligned in the stacking direction along the side surface of the winding jig 54. Can be prevented from being easily shifted. In this regard, when the winding of the intermediate formed coil 24 is formed using the winding forming device 50, the lane change between the stages can be appropriately performed when the flat conductor 22 is wound around the winding jig 54. .

  Further, in this embodiment, the winding of the intermediate formed coil 24 is realized by using a winding jig 54 in which a plurality of substantially elliptical flat plate members 72 and 74 are laminated in the third direction Z. For this reason, it is not necessary to use a winding jig whose side surface is formed in a complicated shape in order to appropriately change the lane between the stages when forming the winding of the intermediate formed coil 24, and has a simple and simple structure. It is sufficient to use the winding jig 54. In this respect, the winding of the intermediate formed coil 24 can be easily realized.

  Further, in this embodiment, the lane change between adjacent steps in the stacking direction in the intermediate formed coil 24 is performed at the top of the lead side coil end portion 44. For this reason, it is not necessary to change the lane between adjacent steps in the stacking direction in the intermediate formed coil 24 at the slot portions 40 and 42 which are linear portions. In this respect, it is possible to prevent the linearity and parallelism of the flat conducting wire 22 in both the slot portions 40 and 42 from being inhibited, and it is possible to suppress the performance degradation as the stator coil.

  Therefore, according to the present embodiment, it is possible to easily realize the winding formation of the intermediate formed coil 24 in which the flat conducting wire 22 is wound a plurality of turns without incurring performance deterioration as a stator coil.

  In the present embodiment, in the next step, the intermediate molded coil 24 is formed in a plurality of different non-linear shapes (specifically, a crank shape, an arc shape, and a bent shape) in the next step. It is bent toward the concentric winding coil 26. When the coil end portions 34 and 36 of the concentric winding coil 26 are formed into a crank shape, in particular, the coil end portions 44 and 46 of the intermediate forming coil 24 are laminated with the flat conducting wire 22 laminated using a jig of a forming apparatus. It is necessary to bend in the direction.

  On the other hand, in this embodiment, the lane change between adjacent stages in the stacking direction in the intermediate formed coil 24 is performed at the top of the lead side coil end portion 44 as described above, and the rectangular conductors of the adjacent stages are arranged. It is performed so that 22 may extend diagonally. If the lane change between steps in the intermediate formed coil 24 is performed at the top of the lead side coil end portion 44, the shape of the lead side coil end portion 44 of the intermediate formed coil 24 becomes the final lead of the concentric winding coil 26. It becomes closer to the shape of the side coil end portion 34.

  For this reason, when the lead side coil end portion 44 of the intermediate formed coil 24 is bent particularly in a crank shape, the proximity of the lead side coil end portion 44 to the jig of the molding apparatus in the next process is improved. Therefore, according to the present embodiment, the lead-side coil end portion 44 of the intermediate formed coil 24 is bent to form the coil end portion 34 of the concentric winding coil 26 into a desired shape (particularly crank shape). Can be ensured.

  Furthermore, in this embodiment, the coil end corresponding portions 64 and 66 of the winding jig 54 are formed in a shape having a plurality of arcs having different curvature radii (arc radii) as described above. Specifically, the top portions 80 and 90 of the coil end corresponding portions 64 and 66 have a smaller radius of curvature than the large R portions 82, 84, 92 and 94 on both sides. In the structure of the winding jig 54, the coil end portions 44 and 46 of the intermediate formed coil 24 are formed in a shape having a relatively small curvature radius at the top.

  For this reason, the top shape of the lead side coil end portions 44 and 46 of the intermediate formed coil 24 is changed to the top shape of the lead side coil end portions 34 and 36 of the final concentric winding coil 26 (particularly, edgewise bent). Shape). Therefore, according to the present embodiment, the lead-side coil end portions 44 and 46 of the intermediate formed coil 24 are bent and bent back when the coil end portions 34 and 36 of the concentric winding coil 26 are formed into a desired shape. Therefore, good moldability can be ensured.

  In this embodiment, when the forming of the intermediate forming coil 24 is completed, the outer diameter variable mechanism of the winding forming device 50 is operated so that the distance between the parts of the winding jig 43 is smaller than the normal distance. In this case, since the outer diameter of the winding jig 54 is reduced, the intermediate molded coil 24 that has been molded can be easily taken out from the winding jig 54.

  In the above embodiment, the intermediate formed coil 24 is formed in a substantially elliptical shape as shown in FIG. 2 by the winding jig 54 of the winding forming device 50. However, the present invention is not limited to this, and using the winding jig 100, the intermediate formed coil 24 is formed by bending the formed intermediate formed coil 22 as shown in FIG. As an approximate hexagonal shape that approximates the desired shape (final shape) of the concentric winding coil 26 (for example, unlike the final shape of the concentric winding coil 26, the tip is not formed in a convex shape). Also good. Hereinafter, the intermediate formed coil 24 formed in a substantially hexagonal shape using the winding jig 100 is referred to as an intermediate formed coil 101.

  According to the above-described modification, the amount of bending deformation of the coil at the time of forming from the intermediate forming coil 101 formed by the winding jig 100 to the concentric winding coil 26 is reduced, so that the bending deformation of the coil (particularly edgewise). It is possible to prevent the coil end portions 34 and 36 (particularly the top portions) from being forcibly pulled along with the molding and peeling off the film at the pulled portions.

  FIG. 8 shows a configuration diagram of a stator coil formed by using a winding forming apparatus which is a modification of the present invention. FIG. 9 shows a configuration diagram of a part of a winding jig 100 provided in the winding forming apparatus of the present modification. FIG. 10 shows a configuration diagram of a winding jig 100 provided in the winding forming apparatus of the present modification. FIG. 11 is a configuration diagram showing a state in which the intermediate formed coil 101 is wound around the winding jig 100 provided in the winding forming apparatus of the present modification.

  In the above modification, the winding jig 100 is a box-shaped member formed in accordance with a desired three-dimensional shape of the intermediate molded coil 101 and can hold the substantially hexagonal intermediate molded coil 101 on the side surface. In this way, it is formed in a substantially hexagonal shape, and is formed in a column shape extending in the stacking direction in which the flat conductive wires 22 of each step of the intermediate formed coil 101 are stacked.

  Hereinafter, portions of the winding jig 100 corresponding to the slot portions 40 and 42 of the intermediate molded coil 101 are referred to as slot corresponding portions 102 and 104, and portions corresponding to the coil end portions 44 and 46 of the intermediate molded coil 101 are referred to. They are referred to as coil end corresponding portions 106 and 108, respectively. Further, in the winding jig 100, the direction in which the slot-corresponding portions 102, 104 face each other is the first direction X, the direction in which the coil end-corresponding portions 106, 108 face each other is the second direction Y, and A direction perpendicular to both the first direction X and the second direction Y is referred to as a third direction Z. The third direction Z coincides with the stacking direction in which the steps of the set flat wire 22 are stacked.

  A plurality of grooves 110 arranged in the third direction Z are formed on the side surface of the winding jig 100. The groove 110 is a groove into which the flat conducting wire 22 of each step in the stacking direction is fitted when the winding of the intermediate formed coil 101 is formed. The winding jig 100 is configured by laminating a plurality of flat plate members 112 and 114 formed in a substantially hexagonal shape in accordance with the substantially hexagonal intermediate molded coil 101 in the third direction Z. The winding jig 100 is configured by fastening a plurality of plate-like members 112 and 114 stacked in the third direction Z with bolts or the like.

  The flat plate member 112 and the flat plate member 114 have different sizes (areas). The size of the flat plate member 112 is smaller than the size of the flat plate member 114. The flat members 112 and 114 are provided in the same number as the number of turns of the intermediate formed coil 101 corresponding to the intermediate formed coil 101, respectively. The shape of the flat plate member 114 (not shown) farthest from the seat surface of the rotary seat 52 may be the same as the shape of the other flat plate members 114, but may be other, for example, thicker. The shape of the flat plate member 114 may be different.

  The winding jig 100 is configured by alternately arranging flat members 112 and 114 having different sizes on the seat surface of the rotary seat in that order. The alternate arrangement of the plate-like member 112 and the plate-like member 114 produces a recess (that is, the groove 110 described above) that opens in the XY plane direction.

  The flat plate member 112 is formed such that the thickness in the third direction Z is the same as or slightly larger than the thickness in the short side direction of the flat conductor wire 22. Further, the flat plate member 114 is formed so that the thickness in the third direction Z is substantially the same as the gap between the flat conductors 22 of the step adjacent in the stacking direction of the intermediate formed coil 101.

  The groove 110 is formed between the rotary seat 52 and the flat plate member 114 or between the two flat plate members 114, and is formed on the radially outer side of the flat plate member 112. The side wall of the groove 110 is a wall surface facing the third direction Z formed at a portion of the rotary seat 52 or the flat plate member 114 protruding from the end of the flat plate member 112. In addition, the bottom surface of the groove 110 is a side surface of the flat plate-like member 112 and faces in a direction orthogonal to the third direction Z. Each step of the groove 110 is formed in the same XY plane.

  The plurality of flat plate-like members 112 arranged in the third direction Z are formed such that the width between the slot corresponding portion 102 and the slot corresponding portion 104 decreases as the distance from the seating surface of the rotary seat 52 increases. . Further, the plurality of flat plate members 114 arranged in the third direction Z are formed such that the width between the slot corresponding portion 102 and the slot corresponding portion 104 becomes smaller as the distance from the seating surface of the rotary seat 52 increases. ing. In other words, the slot corresponding portions 102 and 104 of the winding jig 100 are shifted while the bottom surfaces of the respective grooves 110 arranged in the third direction Z are displaced in the first direction X perpendicular to the third direction Z. It is formed so as to line up in three directions Z. In addition, the slot corresponding portions 102 and 104 are arranged in the third direction Z while the side surfaces of the respective flat plate members 114 arranged in the third direction Z are displaced in the first direction X perpendicular to the third direction Z. It is formed to line up.

  Each slot corresponding portion 102, 104 is displaced in the first direction X while being aligned in the third direction Z, and each step of the groove 110 has substantially the same length in the longitudinal direction, that is, the second direction Y. They are parallel to each other between the same positions in the direction.

  The coil end corresponding portions 106 and 108 of the winding jig 100 are formed in a shape imitating a desired shape of the coil end portions 44 and 46 of the intermediate formed coil 101. The lead-side coil end corresponding portion 106 of the winding jig 100 is formed in a mountain shape including shoulder portions 120 and 122, corresponding top portions 124, and straight portions 126 and 128. The shoulder portions 120 and 122 are portions that are connected to the slot corresponding portions 102 and 104 and are curved with respect to the slot corresponding portions 102 and 104. The corresponding top portion 124 is a portion corresponding to the top portion of the lead-side coil end portion 44 of the intermediate molded coil 101 and a portion having a relatively small radius of curvature. The straight portions 126 and 128 are portions that connect the shoulder portions 120 and 122 and the corresponding top portions 124, and are portions that are formed in a substantially linear shape.

  Further, the anti-lead side coil end corresponding portion 108 of the winding jig 100 is formed in a mountain shape including shoulder portions 130 and 132, a corresponding top portion 134, and straight portions 136 and 138. The shoulder portions 130 and 132 are portions that are connected to the slot corresponding portions 102 and 104 and are curved with respect to the slot corresponding portions 102 and 104. The corresponding top part 134 is a part corresponding to the top part of the non-lead-side coil end part 46 of the intermediate molded coil 101 and a part having a relatively small radius of curvature. Further, the straight portions 136 and 138 are portions that connect the shoulder portions 130 and 132 and the corresponding top portions 134 and are formed in a substantially linear shape.

  In the plurality of flat plate members 112 arranged in the third direction Z, the shoulder portions 120, 122, 130, and 132 are slightly smaller in the coil end corresponding portions 106 and 108, respectively, as they are separated from the seating surface of the rotary seat 52. It is formed to be smaller. In addition, as the plurality of flat plate members 114 arranged in the third direction Z move away from the seating surface of the rotary seat 52, the sizes of the shoulder portions 120, 122, 130, 132 in the coil end corresponding portions 106, 108 respectively become larger. Each is formed to be slightly smaller.

  That is, the shoulders 120, 122, 130, 132 of the coil end corresponding portions 106, 108 of the winding jig 100 are respectively in the third direction Z so that the bottom surfaces of the grooves 110 in each step aligned in the third direction Z are in the third direction Z. They are formed so as to be aligned in the third direction Z while being displaced in the orthogonal direction (XY in-plane direction) perpendicular to each other. Further, the shoulder portions 120, 122, 130, 132 of the respective coil end corresponding portions 106, 108 are orthogonal to each other so that the side surfaces of the respective flat plate members 114 arranged in the third direction Z are orthogonal to the third direction Z. It is formed to be aligned in the third direction Z while being displaced in the direction (XY in-plane direction).

  On the other hand, the plurality of flat plate-like members 112 arranged in the third direction Z are formed so that the sizes of the corresponding top portions 124 and 134 are the same in the coil end corresponding portions 106 and 108, respectively. The plurality of flat plate members 114 arranged in the third direction Z are formed so that the sizes of the corresponding top portions 124 and 134 are the same in the coil end corresponding portions 106 and 108, respectively. That is, the corresponding top portions 124 and 134 of the coil end corresponding portions 106 and 108 of the winding jig 100 are in the second direction in which the bottom surfaces of the grooves 110 in each step aligned in the third direction Z are orthogonal to the third direction Z. They are formed so as to be aligned in the third direction Z in the same plane without being displaced in Y. Further, the corresponding top portions 124 and 134 of the respective coil end corresponding portions 106 and 108 are positioned in the second direction Y in which the side surfaces of the flat plate members 114 arranged in the third direction Z are orthogonal to the third direction Z. They are formed so as to be aligned in the third direction Z within the same plane without shifting.

  Further, the flat plate member 112 and the flat plate member 114 arranged in the third direction Z are formed such that the sizes of the corresponding top portions 124 are the same in the lead side coil end corresponding portion 106. That is, at the corresponding top portion 124 of the lead-side coil end corresponding portion 106 of the winding jig 100, the flat plate member 112 and the flat plate member 114 are alternately arranged so as not to have a dent or a step in the first direction X. Has been placed. The corresponding top portion 124 is formed such that the bottom surfaces of the grooves 110 arranged in the third direction Z are in contact with each other without a side wall interposed therebetween.

  The lead-side coil end corresponding portion 106 of the winding jig 100 has a depth of the groove 110 of each step aligned in the third direction Z from the vicinity of the corresponding top portion 124 via the straight portions 126 and 128 and the shoulder. It is formed so as to gradually increase over the portions 120 and 122.

  In addition, the lead-side coil end corresponding portion 106 of the winding jig 100 is provided with a regulation guide 140 for performing one-stage lane change for each of the flat conducting wires 22 at each stage in the stacking direction. The regulation guide 140 is formed on both sides of the flat plate member 114 with the corresponding top portion 124 therebetween, and is formed in a shape that extends obliquely toward the adjacent flat plate member 112. The lead-side coil end corresponding portion 106 has a planar shape in which convex portions are formed by the regulation guide 140 on each of the straight portions 126 and 128 on both sides of the corresponding top portion 124.

  On the other hand, the plate-like member 112 and the plate-like member 114 arranged in the third direction Z are formed so that the size of the corresponding top portion 134 is changed in the anti-lead side coil end corresponding portion 108. That is, the flat plate member 112 and the flat plate member 114 are alternately arranged so that a dent or a step in the first direction X is generated at the corresponding top portion 134 of the anti-lead side coil end corresponding portion 108 of the winding jig 100. Is arranged. The corresponding top portion 134 is spaced apart from the bottom surfaces of the grooves 110 arranged in the third direction Z through side walls (specifically, portions of the flat plate member 114 protruding from the end of the flat plate member 112). It is formed to be slashed.

  In the modified example having the above-described structure, a single rectangular wire 22 as a straight wire is set on the winding jig 100 of the winding forming apparatus. At this time, the flat conducting wire 22 is set so as to fit in the groove 110 formed on the side surface of the lowermost flat plate member 112 between the rotary seat 52 and the lowermost flat plate member 114 of the winding jig 100. Is done. Next, the rectangular conducting wire 22 is wound around the winding jig 100 by rotating the handle 56. The winding of the flat conducting wire 22 around the winding jig 100 is performed so that the flat conducting wire 22 wraps around the winding jig 100 while fitting into the groove 110 along the side surface of the winding jig 100.

  Therefore, according to the winding forming apparatus of this modification, the slot portions 40 and 42 are formed so that the flat conductors 22 at each stage in the stacking direction are aligned in the stacking direction while being displaced in the orthogonal direction orthogonal to the stacking direction. And the coil end portions 44 and 46 (particularly, the top portions) formed so that the flat conductors 22 at each stage in the stacking direction are aligned in the stacking direction within the same plane without being displaced in the orthogonal direction orthogonal to the stacking direction. And the intermediate formed coil 101 can be formed. Further, the intermediate formed coil 101 can be formed in a substantially hexagonal shape that approximates the desired shape of the concentric winding coil 26 that is formed by bending the formed intermediate formed coil 22.

  Also in the above modification, as shown in FIG. 6 in the above embodiment, the winding jig 100 is divided into a plurality of parts in the first direction X and the second direction Y (that is, the XY plane). Each part is projected from the center to the outer diameter side during the molding of the intermediate molded coil 101, and after the molding of the intermediate molded coil 101 is completed, each part is returned to the center side and after the molding is completed. The intermediate formed coil 101 may be easily removed from the winding jig 100.

  In the above-described embodiment, the top 80 of the lead-side coil end corresponding portion 64 of the winding jig 54 of the winding forming device 50 is located between the bottom surfaces of the grooves 70 of each step aligned in the third direction Z. The top portion 90 is formed so that the bottom surfaces of the grooves 70 arranged in the third direction Z are separated from each other via the side wall. And only the top part of the lead side coil end part 44 of the intermediate formed coil 24 is changed in lane so that the flat conductive wires 22 of adjacent steps in the stacking direction are obliquely connected to each other. In such a configuration, the lane change between the adjacent rectangular conductors 22 in the stacking direction is performed one step at the top of the coil end portion 44 on one axial side.

  However, the present invention is not limited to this, and the top portions 80 and 90 of the coil end corresponding portions 64 and 66 of the winding jig 54 of the winding forming device 50 are arranged in the third direction Z. The bottom surfaces of the stepped grooves 70 are formed so as to be in contact with each other without a side wall, and the top portions of the coil end portions 44 and 46 of the intermediate molded coil 24 are adjacent to each other in the stepwise direction of the rectangular conductor wires 22 in the stacked direction It is good also as changing a lane so that may be connected diagonally.

  In such a modification, the lane change between the adjacent flat conductors 22 in the stacking direction is performed by 0.5 steps at both the top portions of the coil end portions 44 and 46 on both axial sides. In this case, the shapes of the coil end portions 44 and 46 of the intermediate formed coil 24 are both closer to the shape of the coil end portions 34 and 36 of the final concentric winding coil 26. For this reason, when the coil end portions 44 and 46 of the intermediate forming coil 24 are bent particularly in a crank shape, the proximity of the coil end portions 44 and 46 to the jig of the forming apparatus in the next process is improved. When the coil end portions 44 and 46 of the intermediate forming coil 24 are bent to form both the coil end portions 34 and 36 of the concentric winding coil 26 into a desired shape (particularly crank shape), good formability is obtained. It can be secured.

DESCRIPTION OF SYMBOLS 10 Stator 12 Stator core 14 Stator coil 22 Flat conductor 24 Intermediate forming coil 26 Concentric winding coil 40, 42 Slot part 44, 46 Coil end part 50 Winding formation apparatus 54, 100 Winding jig 60, 62, 102, 104 Slot Corresponding part 64, 66, 106, 108 Coil end corresponding part 70, 110 Groove

Claims (11)

A slot portion housed in a slot formed in the stator core, in which a plurality of turns of the rectangular conductor wire having a substantially rectangular cross section is wound, and a gap is formed between the adjacent rectangular conductor wires in each step in the stacking direction, A coil end portion protruding from an axial end surface of the stator core, and a device for forming a winding of a concentric winding stator coil,
A plurality of grooves arranged in a predetermined direction in which the flat conductors of each stage in the stacking direction of the stator coil are fitted, and a winding jig around which the flat conductors are wound,
Slot-corresponding portions corresponding to the slot portions of the winding jig are arranged in the predetermined direction while the bottom surfaces of the grooves in the respective steps in the predetermined direction are displaced in a first orthogonal direction orthogonal to the predetermined direction. As is formed,
The coil end corresponding portion of the winding jig corresponding to the top of the coil end portion is not displaced in the second orthogonal direction in which the bottom surface of the groove at each step in the predetermined direction is orthogonal to the predetermined direction. A stator coil winding forming device, wherein the winding is formed so that the lane change in the laminating direction of the rectangular conductor wire is performed side by side in the predetermined direction in the same plane.   2. The stator coil according to claim 1, wherein at least one of the coil end corresponding portions on both sides is formed such that bottom surfaces of the grooves of each step in the predetermined direction are in contact with each other without a side wall interposed therebetween. Winding forming device.   3. The stator coil according to claim 1, wherein the grooves of each step in the predetermined direction that are displaced in the first orthogonal direction at the slot corresponding portions have substantially the same length in the longitudinal direction. Winding forming device.   4. The stator according to claim 3, wherein the grooves of each step in the predetermined direction that are displaced in the first orthogonal direction of the slot corresponding portions are arranged in parallel with each other between the same positions in the longitudinal direction. Coil winding device.   The coil end corresponding portion corresponds to each of the top portions of the coil end portions on both sides in the axial direction of the stator coil, and the bottom surface of the groove of each step in the predetermined direction is not displaced in the second orthogonal direction. The stator coil winding forming device according to any one of claims 1 to 4, wherein the stator coil winding forming device is formed so as to be aligned in the predetermined direction in the same plane.   6. The stator coil winding forming apparatus according to claim 1, wherein the coil end corresponding portion is formed in a shape having a plurality of arcs having different curvature radii.   The winding of the stator coil according to any one of claims 1 to 6, wherein the coil end portion forms an intermediate formed coil having a substantially elliptical shape before being bent into a plurality of different non-linear shapes. Forming equipment.   The coil end corresponding part includes a shoulder part connected to the slot corresponding part, a corresponding top part corresponding to the top part of the coil end part, and a linear part formed in a substantially straight line connecting the shoulder part and the corresponding top part. 6. The stator coil winding forming device according to claim 1, wherein the stator coil winding forming device has a shape including   The stator coil according to any one of claims 1 to 5 and 8, wherein the coil end portion forms an intermediate formed coil having a substantially hexagonal shape before being bent into a plurality of different non-linear shapes. Winding forming device. A slot portion housed in a slot formed in the stator core, in which a plurality of turns of the rectangular conductor wire having a substantially rectangular cross section is wound, and a gap is formed between the adjacent rectangular conductor wires in each step in the stacking direction, A coil end portion protruding from an axial end surface of the stator core, and forming a winding of a concentric winding stator coil,
A plurality of grooves arranged in a predetermined direction in which the flat conductors of each stage in the stacking direction of the stator coil are fitted are formed, and a bottom surface of the groove of each stage in the predetermined direction is in a first orthogonal direction orthogonal to the predetermined direction. The slot-corresponding portion corresponding to the slot portion formed so as to be aligned in the predetermined direction while being displaced, and the bottom surface of the groove in each step in the predetermined direction are displaced in the second orthogonal direction perpendicular to the predetermined direction. A coil end corresponding portion corresponding to a top portion of the coil end portion, which is formed so that the lane change in the laminating direction of the flat conductor wire is performed in the same plane without being performed. By winding the flat conducting wire around a winding jig, the slot portion is displaced while the position of the flat conducting wire at each stage in the stacking direction is shifted in the first orthogonal direction perpendicular to the stacking direction. The top ends of the coil end portions are arranged in the same direction, and the flat conductors at each step in the stacking direction are not displaced in the second orthogonal direction perpendicular to the stacking direction, and the stacking direction is within the same plane. A method for forming a winding of a stator coil, wherein the lane change in the laminating direction of the flat wire is performed. Among the coil end corresponding portions on both sides, the coil end portions are adjacent to each other in the stacking direction by using the portions formed so that the bottom surfaces of the grooves in each step in the predetermined direction are in contact with each other without a side wall. The method of forming a winding of a stator coil according to claim 10, wherein the rectangular conductive wires of the matching steps are formed so as to be obliquely connected to each other.

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