JP2015033192A - Method for manufacturing rotary electric machine stator and rotary electric machine stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress damage to a coil while firmly fixing the coil to a stator core to improve insulation reliability in a rotary electric machine stator.SOLUTION: A method for manufacturing a rotary electric machine stator includes the steps of: inserting a coil into a slot of a stator core; inserting a fixing member made of resin between adjoining coils from the periphery of the end surface of the stator core; performing flexure forming for forming a coil end part while pressing the coil against the stator core via the fixing member; and applying pressure and restricting the fixing member from the periphery. In the step of inserting the fixing member, the fixing member that corresponds to the tooth end face of the stator core but has a planar shaped tooth adhesion part whose width is wider than a tooth width is inserted between the coils and the coils are separated from the stator core.

Description

  The present invention relates to a rotating electrical machine stator manufacturing method and a rotating electrical machine stator, and more particularly to a rotating electrical machine stator manufacturing method and a rotating electrical machine stator using a fixing member for fixing a coil.

  A stator used in a rotating electrical machine includes a stator core provided with a plurality of slots extending radially in the radial direction and penetrating in the axial direction, and a coil inserted into the slot. Concentrated winding, distributed winding, wave winding, and the like are used as a method of inserting and winding a coil in a plurality of slots, but a gap may be provided between the coil on the axial end surface of the stator core and the stator core. is there. This gap is provided in order to relieve stress applied to the coil to be wound, to ensure insulation performance, and to prevent the stator core from biting into the coil when winding or assembling the coil and the stator core.

  Patent Document 1 discloses a coil fixing member that is inserted into a gap provided between a stator core and a coil in a stator of a rotating electrical machine. The coil fixing member is inserted from the radial outer side of the stator core, and the wedge-shaped first fixing member that restricts the circumferential displacement of the coil on one side in the circumferential direction, and the other side in the circumferential direction of the first fixing member And a second fixing member inserted from the inside in the radial direction.

JP 2009-207334 A

  Since the coil fixing member of Patent Document 1 is inserted into the gap between the coil and the stator core after the coil end portion is formed in the stator, the coil may be damaged depending on the gap, and the insulation reliability may be reduced. Moreover, since it consists of two parts, assembly workability | operativity is low and parts cost and assembly cost increase. Further, depending on the dimensional accuracy between the two parts, the play may occur, the coil cannot be completely fixed to the stator core, and the coil fixing member may drop off due to vibration or the like.

  An object of the present invention is to provide a method of manufacturing a rotating electrical machine stator capable of suppressing the damage of the coil and improving insulation reliability while firmly fixing the coil to the stator core, and a rotating electrical machine stator obtained by the manufacturing method. It is to be.

  A method of manufacturing a rotating electrical machine stator according to the present invention includes a step of inserting a coil into a slot of a stator core, a step of inserting a resin-made fixing member between adjacent coils from an outer peripheral portion of an end surface of the stator core, and a fixing member A step of bending to form the coil end portion while pressing the coil against the stator core via the step, and a step of pressing and restraining the fixing member from the outer peripheral portion after or before the step of bending. It is characterized by.

  In the method for manufacturing a rotating electrical machine stator according to the present invention, the step of inserting the fixing member includes a fixing member having a planar tooth contact portion corresponding to the tooth end surface of the stator core but having a width larger than the tooth width between the coils. It is preferable to insert and separate the coil from the stator core.

  In the method for manufacturing a rotating electrical machine stator according to the present invention, a plurality of fixing members are used, and the step of pressing and fixing the fixing members is preferably performed by connecting the outer peripheral sides of the plurality of fixing members to each other by heat melting.

  The rotating electrical machine stator according to the present invention includes a stator core having a plurality of teeth arranged along the inner periphery, a coil inserted in a slot between adjacent teeth, and an outer periphery of an end face of the stator core between adjacent coils. A fixed member made of resin inserted from the portion, and a coil end portion formed by bending a coil protruding from the slot at the end surface of the stator core via the fixed member and connected to each other. A tooth contact portion having a planar shape corresponding to the tooth end surface but having a width larger than the tooth width is provided, and the coil is separated from the stator core.

  In the rotating electrical machine stator according to the present invention, it is preferable that a plurality of fixing members are used, and the plurality of fixing members are connected and restrained by heat melting on the outer peripheral side.

  In the rotating electrical machine stator according to the present invention, it is preferable that the plurality of fixing members have an annular shape as a whole when connected to each other, and each fixing member is divided into slots of the stator core.

  In the rotating electrical machine stator according to the present invention, the coil is preferably formed of a conductor segment.

  In the rotating electrical machine stator according to the present invention, the coil is preferably a distributed winding coil arranged over a plurality of slots spaced at a predetermined slot interval.

  According to the method of manufacturing a rotating electrical machine stator and the rotating electrical machine stator according to the present invention, the fixing member is inserted between the coils inserted into the slots of the stator core before the coil end portion is formed. Therefore, damage to the coil can be suppressed while firmly fixing the coil to the stator core, and insulation reliability is improved.

It is a perspective view which shows a part of rotary electric machine stator of embodiment of this invention. It is a top view in FIG. It is a flowchart which shows the procedure of the manufacturing method of the rotary electric machine stator in embodiment of this invention. FIG. 4 is a top view of a stator core prepared in FIG. 3. 3A and 3B are diagrams showing a stator core having a coil inserted therein, where FIG. 3A is a top view and FIG. 3B is a cross-sectional view of one slot. It is a top view of the fixing member prepared in FIG. 4A and 4B are diagrams showing a state in which a fixing member is disposed on a stator core in which a coil is inserted in FIG. 3, in which FIG. 3A is a top view and FIG. 3B is a cross-sectional view in one slot. 3A and 3B are views showing a state where the coil is bent after FIG. 7, in which FIG. 3A is a top view and FIG. 3B is a cross-sectional view of one slot.

  Embodiments according to the present invention will be described below in detail with reference to the drawings. In the following, a plurality of fixing members divided for each slot of the annular stator will be described as fixing members for fixing the coil, but the dividing method may not be for each slot. Moreover, although the part corresponding to the teeth of the stator in the fixing member will be described as a tapered portion, it is sufficient if it has a shape wider than the teeth and has a surface that is in close contact with the end surface of the teeth.

  Further, although the coil is constituted of a conductor segment, the shape thereof may be any shape as long as it can be inserted into the slot in a straight state or can be protruded from the slot in a straight state. For example, as shown below, a conductor segment formed in a V shape in advance may be used, but a straight conductor wire may be used as a conductor segment as it is. Although distributed winding is described as a winding method of the coil, any winding method may be used as long as the conductor wire is inserted into the slot and then bent and formed into a coil.

  The dimensions, shapes, number of coils, materials, and the like described below are examples for explanation, and can be appropriately changed according to the specifications of the rotating electrical machine stator. Below, the same code | symbol is attached | subjected to the same element in all the drawings, and the overlapping description is abbreviate | omitted.

  FIG. 1 is a perspective view showing a part of the rotating electrical machine stator 10. FIG. 2 is a top view of FIG. The rotating electrical machine stator 10 is a stator used in a three-phase synchronous motor / generator mounted on a vehicle. Below, unless otherwise indicated, the rotary electric machine stator 10 is called the stator 10. FIG. FIG. 1 is a view of the coil end portion on the other end side in the axial direction of the stator 10 from the inner peripheral side of the stator 10. The stator 10 includes a stator core 12, a coil 20, and a plurality of fixing members 30. The plurality of fixing members 30 are connected to each other at the connecting portion 36 on the outer peripheral side thereof, and have an annular shape as a whole. In FIGS. 1 and 2, the illustration of the coil 20 is partially omitted so that the structure of the plurality of fixing members 30 can be understood.

  The stator core 12 is an annular magnetic part including a plurality of base portions 13 on the outer peripheral side, a plurality of teeth 14 arranged on the inner peripheral side, and a plurality of slots 16 that are gaps between adjacent teeth 14. The stator core 12 is formed by laminating a plurality of annular magnetic thin plates 18 formed into a predetermined shape including the teeth 14 and the slots 16. As the magnetic thin plate 18, an electromagnetic steel plate can be used. Instead of the laminated body of the magnetic thin plates 18, a magnetic powder integrally formed into a predetermined shape can be used. In FIG. 2, five teeth 14a, 14b, 14c, 14d, and 14e and four slots 16ab, 16bc, 16cd, and 16de are shown.

  The coil 20 is formed by bending a conductor wire having an appropriate insulation coating into a predetermined shape, which is formed by a predetermined arrangement method and separated by a predetermined slot interval along the circumferential direction. The three-phase windings in the stator 10 are formed. In FIG. 1, distributed winding is shown as a predetermined arrangement method. FIG. 1 shows an axial direction, a radial direction, and a circumferential direction in the stator 10. Regarding the axial direction, one end side and the other end side are shown.

  As the conductor wire with insulation coating used for the coil 20, a rectangular wire having a rectangular cross section is used. By using the flat wire, the coil space factor in the slot 16 can be improved. Instead of a flat wire, one having a circular or elliptical cross section may be used. As the coil 20, a segment coil composed of a plurality of conductor segments is used. The conductor segment is obtained by bending a conductor wire having a predetermined length into a predetermined shape as necessary. As the conductor segment, a U-shaped conductor segment or V-shape in which one conductor wire is previously formed into a U-shape in order to be arranged between a plurality of slots 16 separated by a predetermined slot interval along the circumferential direction. A V-shaped conductor segment formed into the shape can be used. In addition, in FIG.5 (b) mentioned later, the V-shaped conductor segment was shown.

  In the case of the V-shaped conductor segment, straight conductor portions serving as both V-shaped leg portions are respectively inserted into two slots 16 that are spaced apart by a predetermined slot interval in the circumferential direction in the stator core 12. A V-shaped top portion connecting both the leg portions protrudes to one end side in the axial direction of the stator core 12 and becomes a coil end portion on one end side. The two straight conductor portions 21 corresponding to the leg portions respectively inserted into the two slots 16 protrude to the other end side of the stator core 12 in the axial direction. The end. Similarly, the other conductor segments are appropriately bent on the other end side in the axial direction of the stator core 12 to form connection end portions. The connection end portion or the like is a coil end portion on the other end side of the stator core 12. Therefore, the distributed winding coil 20 can be formed by sequentially electrically connecting the connection end portions of the plurality of conductor segments constituting the in-phase coil by an appropriate connection method such as welding.

In the example of FIGS. 1 and 2, four straight conductor portions 21 of the coil 20 are disposed in one slot 16 in total along the radial direction. Since the opening width W along the circumferential direction of the slot 16 is set larger than the outer dimension W _SC along the circumferential direction of the conductor portion 21 in the slot 16, the inner wall surface of the slot 16 and the outer shape of the conductor portion 21 A gap is formed between them. The relationship between W and W _SC is shown in FIGS. 4 and 5 described later. In FIG. 2, four coils 20a, 20b, 20c, and 20d inserted into the slot 16ab are shown.

  The plurality of fixing members 30 are a plurality of members obtained by dividing an annular resin member having substantially the same shape as the stator core 12 corresponding to each of the slots 16 of the stator core 12. Therefore, the number of fixing members 30 is the same as the number of slots 16 of the stator core 12, that is, the number of teeth 14. The dividing part is performed at a part where the slot 16 is divided into two, and each fixing member 30 has a tapered part 32 corresponding to the teeth 14 of the stator core 12 and a base dividing part 34 corresponding to the base part 13. The plurality of divided fixing members 30 are formed into an integrated annular shape by combining the base dividing portions 34 with each other and connecting them with a connecting portion 36.

  The tapered portion 32 of the fixing member 30 has a tapered shape with a width that becomes narrower from the outer diameter side toward the inner diameter side at the same taper angle as the teeth 14, and the slot 16 corresponding to the stator core 12 and the bottom portion on the outer diameter side are formed. When combined, the width dimension is larger than the width dimension of the corresponding teeth 14 of the stator core 12. That is, the planar shape of the tapered portion 32 of the fixing member 30 is slightly larger than the planar shape of the teeth 14. Details of the tapered portion 32 of the fixing member 30 are shown in FIG.

  As the resin constituting the fixing member 30, a thermoplastic resin that is softened and plasticized by heating and solidified by stopping the heating and cooling is used. Thermoplastic resins include ABS resin, PP (polypropylene), PE (polyethylene), PS (polystyrene), PMMA (acrylic), PET (polyethylene terephthalate), PPE (polyphenylene ether), PA (nylon / polyamide), PC ( Polycarbonate, POM (polyacetal), PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), LCP (liquid crystal polymer), fluororesin, urethane resin, elastomer, and the like can be used.

  The connecting portion 36 shown in FIG. 1 is a connecting portion that connects the plurality of fixing members 30 to each other. In order to connect the adjacent fixing members 30, a thermal melting process is used. That is, it is possible to use a process in which the thermoplastic resin constituting the fixing member 30 is heated, softened and fluidized to integrate the adjacent fixing members 30 and then cooled. You may pressurize with heating. In FIG. 2, five fixing members 30a, 30b, 30c, 30d, and 30e and four connecting portions 36ab, 36bc, 36cd, and 36de that connect them to each other are shown.

The rotating electrical machine stator 10 having the above configuration will be described in more detail through the manufacturing process. FIG. 3 is a flowchart showing a procedure of a method for manufacturing the rotating electrical machine stator 10. 4 to 8 are diagrams for explaining the contents of the corresponding manufacturing process. As shown in FIG. 3, at the beginning of the procedure for manufacturing the stator 10, the stator core 12 is prepared (S10). Here, a stator core 12 formed by laminating a plurality of annular magnetic thin plates 18 formed in a predetermined shape including the teeth 14 and the slots 16 is prepared. FIG. 4 shows five teeth 14 a to 14 e as the teeth 14 and four slots 16 ab to 16 de as the slots 16. The teeth 14 have a tapered shape whose width becomes narrower from the outer diameter side toward the inner diameter side. The taper angle of the taper is 2θ, the length in the radial direction of the taper is L _S , the width dimension along the circumferential direction of the distal end portion on the inner diameter side is SW ₁ , and the width along the circumferential direction on the outer diameter side connected to the base portion 13. dimensions are shown in the SW _2. Here, SW ₂ > SW ₁ is satisfied. The width dimension of the slot 16 is a constant value W.

  Returning to FIG. 3 again, next, the coil 20 is inserted into the slot 16 (S12). Here, the coil 20 is a conductor segment before bending. FIGS. 5A and 5B are diagrams when four coils 20 are inserted into the slots 16 of the stator core 12, respectively. FIG. 5A is a plan view and FIG. 5B is a cross-sectional view of one slot 16ab. Here, the teeth 14a and 14b on both sides forming the slot 16ab are shown, and the teeth 14a and 14b are shown to be a laminate of the magnetic thin plates 18. The coil 20d is a V-shaped conductor segment before bending molding, and a V-shaped portion is disposed on one end side in the axial direction of the stator core 12, and one leg portion of the two leg portions not bent. Is inserted as a straight conductor portion 21 from the one end side of the slot 16ab toward the other end side.

As shown in FIG. 5B, if the dimension of the opening width of the slot 16 is W and the outer dimension of the coil 20 is W _SC , W> W _SC . Therefore, a gap is generated between the inner wall surface of the slot 16 and the outer shape of the coil 20. The outer dimension W _SC of the coil 20 is a dimension that becomes the circumferential direction when inserted into the slot 16. In the case of a flat wire, the length of the side in the circumferential direction when inserted into the slot 16 out of the length of the two sides forming the rectangular cross section.

  Returning to FIG. 3 again, next, a plurality of fixing members 30 are prepared, and the prepared fixing members 30 are arranged (S14). FIG. 6 is a diagram showing a plurality of prepared fixing members 30. Here, five fixing members 30a to 30e are shown. These correspond to the five teeth 14a to 14e described in FIG.

The fixing member 30 has a base dividing portion 34 corresponding to the base portion 13 of the stator core 12 and a tapered shape portion 32 corresponding to the teeth 14. The tapered portion 32 has a tapered shape whose width becomes narrower from the outer diameter side toward the inner diameter side. The taper angle of the taper is 2θ, the length in the radial direction of the taper is L _F , the width dimension along the circumferential direction of the distal end portion on the inner diameter side is FW ₁ , and the circumferential direction on the outer diameter side connected to the base dividing portion 34 is aligned. The width dimension is indicated by FW ₂ . Here, FW ₂ > FW ₁ is satisfied. In comparison with the teeth 14 described in FIG. 4, L _F but is substantially the same as L _S, a _{FW 2> SW 2, FW 1} > SW 1.

  FIG. 7 is a view showing a state in which the fixing member 30 is arranged on the stator core 12 in which the coil 20 is inserted. 7A is a plan view, FIG. 7B is a cross-sectional view of one slot 16ab, and FIG. 7C is a cross-sectional view of the tapered portion 32 of the fixing member 30.

  The fixing member 30 is positioned on the axial end surface of the stator core 12 while aligning the tapered portion 32 with the teeth 14 of the stator core 12. As shown in FIG. 7A, the tapered shape portion 32 of the fixing member 30a is positioned on the teeth 14a, the tapered shape portion 32 of the fixing member 30b is positioned on the teeth 14b, and so on. , 14d, and 14e, the tapered portions 32 of the fixing members 30c, 30d, and 30e are positioned and arranged.

  Here, since the planar shape of the tapered shape portion 32 is slightly larger than the planar shape of the tapered shape of the tooth 14, the fixing member 30 is attached to the stator core 12 into which the coil 20 is inserted from the outer peripheral side toward the inner peripheral side. When inserted, the side wall surface of the fixing member contacts the side wall surface of the outer shape of the coil 20, and the insertion stops there. FIG. 7B shows a state in which the side wall surface of the conductor portion 21 of the coil 20d is in contact with the side wall surfaces of the tapered portions 32 of the two fixing members 30a and 30b. In this state, the fixing member 30 is arranged with respect to the stator core 12 in which the coil 20 is inserted.

As described above, the relationship between the opening width dimension W of the slot 16 and the outer dimension W _SC of the coil 20 is W> W _SC , and there is a gap between the inner wall surface of the slot 16 and the outer shape of the coil 20. Yes. The relationship between the width dimensions FW ₂ and FW ₁ of the tapered portion 32 of the fixing member 30 and the width dimensions SW ₂ and SW ₁ of the teeth 14 is FW ₂ > SW ₂ and FW ₁ > SW ₁ . Here, since the side wall surface of the tapered portion 32 of the fixing member 30 contacts the side wall surface of the coil 20, the coil 20 is separated from the inner wall surface of the teeth 14 of the stator core 12. Thereby, the insulation reliability of the stator 12 is improved.

  The size of the base dividing portion 34 of the fixing member 30 is such that when the fixing member 30 is arranged corresponding to each tooth 14, the base dividing portion 34 between the opposing surfaces 31 facing each other in the base dividing portion 34 of the adjacent fixing member 30. It is determined so that an appropriate gap is left. In FIG. 7, four opposing surfaces 31ab, 31bc, 31cd, and 31de are shown as the opposing surface 31.

  As shown in FIG. 7C, the tapered portion 32 of the fixing member 30 has a flat surface facing the end surface in the axial direction of the stator core 12, and the opposite surface is a suitable rounded portion (R) over the side wall surface. ) Is provided. This flat surface is a tooth contact portion that is in close contact with the end surface of the tooth 14. The rounded portion (R) is provided to bend the coil 20 into a smooth shape when the coil 20 is bent next.

  Returning to FIG. 3 again, the coil is then bent (S16). This bending is performed to form a coil end portion. Here, the coil 20 is made to follow the side wall surface of the tapered portion 32 of the fixing member 30, and the stator core 12 side through the upper surface of the fixing member 30. It is bent while being pressed. FIG. 8 is a diagram showing a state in which the four coils 20a to 20d inserted into one slot 16ab are bent along the upper surface of the fixing member 30b. FIG. 8A is a plan view, and FIG. 8B is a cross-sectional view of the slot 16ab. In FIG. 8B, the coil 20 d follows the side wall surface of the tapered portion 32 of the fixing member 30 b along the rounded portion (R) and passes through the upper surface of the tapered portion 32 to the teeth 14 b of the stator core 12. It is shown that the bend 22 is formed and bent by pressing.

  Returning to FIG. 3 again, when all the coils 20 are bent and formed, the fixing members 30 are pressed from the outer peripheral side, positioned firmly in the radial direction, and the fixing members 30 are restrained (S18). ). The restraining process is performed by connecting the opposing surfaces 31 of the adjacent fixing members 30 by a thermal melting process. That is, the thermoplastic resin that constitutes the fixing member 30 is heated and optionally softened and fluidized, and the adjacent fixing members 30 are integrated with each other, and then cooled. In this way, the connecting portion 36 shown in FIGS. 1 and 2 is formed, and the plurality of fixing members 30 are integrated into an annular shape. In this state, the plurality of fixing members 30 are fixed to the stator core 12 in the radial direction by integration, and the axial position is fixed by pressing and bending the coil 20. In addition, process S16 and S18 may replace order and may implement S18 previously.

  Next, the plurality of bent coils 20 are wound around the plurality of slots 16 according to a predetermined arrangement method, and then the ends of the coils 20 are connected to each other (S20). Thus, a coil end portion is formed, and the stator 10 including the plurality of coils 20 and the plurality of fixing members 30 is obtained (S22).

  The stator 10 having the above configuration has the following effects. That is, a varnish and a resin mold for fixing the coil 20 are not necessary, and the productivity of manufacturing the stator 10 is improved, and the cost can be reduced. In addition, since the coil 20 is firmly fixed to the integrated fixing member 30 and does not move, even if an external stress such as vibration or cold heat is applied, the insulating coating of the coil and the electrical junction are not damaged. In addition, the insulation gap between the stator core and the coil is reliably maintained. Further, when the fixing member 30 is arranged, the coil 20 is not damaged because it starts from a state where there is a gap between the fixing member 30 and the coil 20. As a result, the insulation reliability of the stator 10 is improved. Therefore, even when an insulating material is used, the specification can be relaxed.

  10 (rotary electric machine) stator, 12 stator core, 13 base part, 14, 14a, 14b, 14c, 14d, 14e teeth, 16, 16ab, 16bc, 16cd, 16de slot, 18 magnetic thin plate, 20, 20a, 20b, 20c , 20d coil, 21 conductor portion, 22 bent portion, 30, 30a, 30b, 30c, 30d, 30e fixing member, 31, 31ab, 31bc, 31cd, 31de facing surface, 32 tapered shape portion, 34 base divided portion, 36, 36ab, 36bc, 36cd, 36de connecting part.

Claims (8)

Inserting the coil into the slot of the stator core;
Inserting a resin fixing member between adjacent coils from the outer peripheral portion of the end face of the stator core; and
A step of bending to form a coil end portion while pressing the coil against the stator core via a fixing member;
After or before the step of bending, the step of pressing and restraining the fixing member from the outer periphery,
The manufacturing method of the rotary electric machine stator characterized by including. In the manufacturing method of the rotary electric machine stator according to claim 1,
The step of inserting the fixing member is
A method of manufacturing a rotating electrical machine stator, characterized in that a fixing member having a flat tooth contact portion corresponding to a tooth end surface of a stator core but having a width larger than a tooth width is inserted between coils, and the coil is separated from the stator core. . In the manufacturing method of the rotary electric machine stator according to claim 1,
A plurality of fixing members are used,
The step of pressing and restraining the fixing member includes
A method of manufacturing a rotating electrical machine stator, wherein outer peripheral sides of a plurality of fixing members are connected and restrained by heat melting. An annular stator core having a plurality of teeth disposed along the inner circumference;
A coil inserted in a slot between adjacent teeth;
A resin-made fixing member inserted from the outer peripheral portion of the end face of the stator core between adjacent coils;
A coil end portion formed by bending a coil protruding from the slot at the end face of the stator core via a fixing member and connecting the coils;
With
The fixing member is
A rotating electrical machine stator having a planar tooth contact portion corresponding to a tooth end surface of a stator core but having a width larger than a tooth width, and having a coil separated from the stator core. The rotating electrical machine stator according to claim 4,
A plurality of fixing members are used,
The rotating electrical machine stator, wherein the plurality of fixing members are connected and restrained by heat melting on the outer peripheral side. In the rotating electrical machine stator according to claim 5,
The plurality of fixing members are
A rotating electrical machine stator having a single annular shape as a whole when connected to each other, and each fixing member being divided for each slot of the stator core. The rotating electrical machine stator according to claim 4,
The rotating electrical machine stator, wherein the coil is composed of a conductor segment. The rotating electrical machine stator according to claim 4,
The rotating electrical machine stator according to claim 1, wherein the coil is a distributed winding coil arranged over a plurality of slots having a predetermined slot interval.

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