JP2015035929A - Manufacturing method of rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a rotary electric machine capable of relatively easily holding position of a coil with respect to a core.SOLUTION: The manufacturing method of a rotary electric machine includes: a deformation step, a coil winding step, and a deformation releasing step. The deformation step is a step in which, defining an interval between a pair of coil sides 30 connected to each other via a crossover part as a target interval A; and defining the target interval A in a state that a coil 3 is wound on a core 2 as a reference interval B, in a coil 3 which is formed so that the target interval A is different from the reference interval B, to deform a crossover part so that the target interval A matches the reference interval B using an external force. The coil winding step is a step in which while holding the state the crossover part is deformed in the deformation step, the coil 3 is wounded the core 2. The deformation releasing step is a step in which, after completing the coil winding step, the external force deforming the crossover part is removed, to bring each of the pair of coil sides 30 in contact with a side faces 50 of a slot 40, each facing to opposite side of a circumferential direction C.

Description

  The present invention provides a core in which a plurality of slots extending in the axial direction and the radial direction of a cylindrical core reference surface are arranged in a distributed manner in the circumferential direction of the core reference surface, and arranged in the slot while being wound around the core. The present invention relates to a method of manufacturing a rotating electrical machine including a coil side portion and a coil having a transition portion that connects a pair of coil side portions on the outer side in the axial direction of a core.

  As the rotating electric machine as described above, one described in Japanese Patent Application Laid-Open No. 2012-125043 (Patent Document 1) is known. Patent Document 1 describes a configuration for welding a joint portion between concentrically wound coils constituting a coil after inserting a coil formed in an annular shape into a stator core with respect to a method of manufacturing a rotating electrical machine.

  By the way, when the coil moves in the axial direction with respect to the stator core, the coil end portion may interfere with other members, and the distance between the coil end portion and the case housing the rotating electrical machine is shortened. Therefore, it may be difficult to appropriately ensure electrical insulation between them. Further, when the coil moves in the radial direction with respect to the stator core, the distance between the coil and the rotor is shortened, which may increase eddy current loss generated in the coil. However, in Patent Document 1, no particular recognition has been made on these points.

JP 2012-125043 (paragraphs 0051 and 0070)

  Therefore, it is desired to realize a method of manufacturing a rotating electrical machine that can hold the position of the coil with respect to the core relatively easily.

  According to the present invention, a plurality of slots extending in the axial direction and the radial direction of a cylindrical core reference surface are distributed in the circumferential direction of the core reference surface, and the slot is wound around the core. A coil having a coil side portion arranged inside and a pair of the coil side portions connecting the outer side in the axial direction of the core, and a characteristic configuration of a method of manufacturing a rotating electrical machine includes: The interval between the pair of coil sides connected by the target interval, and the target interval in the state where the coil is wound around the core in the pair of coil sides is set as the reference interval. Using the coil formed to be different from the reference interval, a deforming step of deforming the transition portion by an external force so that the target interval matches the reference interval, and the transfer step by the deforming step. While maintaining the deformed state of the part, the coil is connected to the coil so that each of the pair of coil sides connected by the crossing part is disposed at a predetermined set position in the different slot. After the winding process of winding around the core and the execution of the winding process, the external force is removed, and each of the pair of coil sides connected by the crossing part faces the opposite side of the circumferential direction. And a deformation releasing step for contacting the side surface of the slot.

According to the above characteristic configuration, each of the pair of coil sides connected by the crossover part in the winding process is disposed in the slot in a state where the crossover part is deformed by an external force so that the target interval matches the reference interval. Is done. Here, the reference interval is a target interval in a state where the coil is wound around the core. Therefore, in the winding process, each of the pair of coil sides can be arranged relatively easily in the slot. Furthermore, according to said characteristic structure, by performing a deformation | transformation cancellation | release process, each of a pair of coil side part connected by a crossing part is contact | abutted to the side part of the slot which faces the other side of the circumferential direction mutually be able to. Here, a restoring force is generally generated in the transition portion that is deformed by an external force so that the target interval matches the reference interval. In addition, not only when the deformation of the transition portion is elastic deformation, but also when the deformation of the transition portion is plastic deformation, a restoring force corresponding to the elastic deformation can be generated at the transition portion. Therefore, in the deformation release step, by removing the external force (load) for deforming the transition portion, the restoring force generated in the transition portion is used to make each of the pair of coil sides opposite to each other in the circumferential direction. Can be brought into contact with the side surface portion of the slot facing. As a result, the frictional force generated between each of the pair of coil side portions and the side surface portion of the slot can be used as a force for maintaining the position of the coil with respect to the core. Accordingly, the position of the coil relative to the core can be maintained by the frictional force, or the configuration for maintaining the position of the coil relative to the core can be simplified to the extent that the frictional force can be utilized.
As described above, according to the above-described characteristic configuration, it is possible to realize a method of manufacturing a rotating electrical machine that can hold the position of the coil with respect to the core relatively easily. As a result, for example, it is possible to reduce the number of man-hours for manufacturing the rotating electrical machine and simplify the manufacturing equipment for the rotating electrical machine.

  Here, in the deformation step, the coils arranged in a cylindrical shape having the axial direction as an axial center are pressurized in the radial direction over the entire circumference, and a plurality of the transitions arranged in the circumferential direction are distributed. It is preferable that the part is deformed.

  According to this configuration, the winding process of arranging each of the pair of coil sides connected by the crossover part in the slot can be a common process for each of the plurality of crossover parts. The number of manufacturing steps can be reduced.

  As described above, in the deformation step, the coil arranged in a cylindrical shape having the axial direction as an axial center is pressed in the radial direction over the entire circumference. In the winding step, the adjacent slots Using a plurality of core pieces having teeth formed therebetween, moving the plurality of core pieces arranged on the outer side in the radial direction with respect to the coil toward the inner side in the radial direction; It is preferable that each of the above is arranged at the set position.

  According to this configuration, the winding process can be simplified as compared with the case where the core is integrally formed in the circumferential direction. Moreover, it can also suppress that a shape arises in the shape of a coil end part compared with the case where a core is integrally formed in the circumferential direction.

  In the manufacturing method of the rotating electrical machine having each configuration described above, the coil side portion on the circumferential first direction side, which is one side in the circumferential direction, of the pair of coil side portions connected by the crossing portion is the first coil. The coil side on the second circumferential direction side that is the side opposite to the first circumferential direction is the second coil side and the circumference of the slot in which the first coil side is disposed In the side part facing the second direction side, the first coil side part arranged at the set position and the part facing the circumferential direction, and the first circumference of the slot in which the second coil side part is arranged In the deformation step, the distance between the second coil side portion arranged at the set position and the portion facing in the circumferential direction on the side surface portion facing the direction side is a first reference slot interval. A side portion facing the circumferential first direction side of the portion; Serial interval between the second coil side portions the peripheral surface part facing the second direction side of, it is preferable that a configuration using the coil shaped to be larger than the first reference slot interval.

  According to this configuration, when the external force (load) for deforming the crossover portion is removed, the restoring force generated in the crossover portion causes the first coil side portion to be on the side surface portion facing the circumferential second direction side of the slot. In addition to the contact, the second coil side can be in contact with the side surface facing the circumferential first direction of the slot. Moreover, according to said structure, it becomes possible to use the coil of a shape with a comparatively small shaping | molding load (for example, shape with a comparatively large curvature radius of a bending part) as a coil used at a deformation | transformation process, for example. In this case, it is easy to suppress the stress applied to the insulating film at the time of forming the coil used in the deformation process and to appropriately ensure the electrical insulation of the coil.

  In the manufacturing method of the rotating electrical machine having each configuration described above, the coil side portion on the circumferential first direction side, which is one side in the circumferential direction, of the pair of coil side portions connected by the crossing portion is the first coil. The coil side on the second circumferential direction side that is the side opposite to the first circumferential direction is the second coil side and the circumference of the slot in which the first coil side is disposed In the side part facing the first direction side, the first coil side part arranged at the set position and the part facing the circumferential direction, and the second circumference of the slot in which the second coil side part is arranged In the deforming step, the first coil side is defined as an interval between the second coil side portion arranged at the set position and a portion facing the circumferential direction in the side surface portion facing the direction side. A side part facing the second circumferential direction side of the part, Serial interval between the second coil side portions side portions facing said circumferential first direction side of an also preferable to use the second reference slot the coil shaped to be smaller than the interval.

  According to this configuration, when the external force (load) for deforming the crossover portion is removed, the restoring force generated in the crossover portion causes the first coil side portion to be on the side surface portion facing the circumferential first direction side of the slot. It can be set as the structure which contact | abuts to the side part which the 2nd coil side part faces the circumferential second direction side of a slot while contacting. Moreover, according to said structure, for example, when a transition part has an arc-shaped part extended along the circumferential direction seeing in an axial direction, it is set as the structure which pressurizes a transition part from the radial inside. It becomes possible. In this case, for example, when the winding step includes a step of moving the plurality of core pieces inward in the radial direction as described above, the winding step can be simplified.

It is a partial sectional view of a stator concerning an embodiment of the present invention. It is a radial view of the coil unit which concerns on embodiment of this invention. It is an axial view of the coil unit according to the embodiment of the present invention. It is a figure which shows the arrangement | positioning state to the stator core of the coil unit which concerns on embodiment of this invention. It is a figure which shows the arrangement | positioning state of the coil after execution of the arrangement | positioning process which concerns on embodiment of this invention. It is sectional drawing of the coil unit used at the pressurization process which concerns on embodiment of this invention. It is a figure which shows the arrangement | positioning state of each part after execution of the pressurization process which concerns on embodiment of this invention. It is a figure which shows the arrangement | positioning state of each part at the time of performing the winding process which concerns on embodiment of this invention. It is a figure which shows the arrangement | positioning state of each part after execution of the pressure release process which concerns on embodiment of this invention. It is a flowchart which shows the manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is sectional drawing of the coil unit used at the pressurization process which concerns on other embodiment of this invention.

  An embodiment of a method for manufacturing a rotating electrical machine according to the present invention will be described with reference to the drawings. Here, the case where the manufacturing method of the rotating electrical machine according to the present invention is applied to the manufacturing method of the inner rotor type rotating electrical machine 100 (see FIG. 1) will be described as an example. In this embodiment, the rotating electrical machine 100 is a rotating field type rotating electrical machine, and the core to be wound with the coil 3 is the core of the stator 1 (stator core 2). That is, in the present embodiment, the stator core 2 corresponds to the “core” in the present invention. In this specification, the “rotary electric machine” is used as a concept including any of a motor (electric motor), a generator (generator), and a motor / generator functioning as both a motor and a generator as necessary.

  In the following description, the “axial direction L”, “circumferential direction C”, and “radial direction R” are based on the cylindrical core reference plane S (see FIG. 1) unless otherwise specified. It is defined as The “circumferential first direction C1” represents a direction toward one side in the circumferential direction C, and the “circumferential second direction C2” represents a direction toward the other side in the circumferential direction C (a direction opposite to the circumferential first direction C1). Represents. Further, in the following description, it is assumed that the coil 3 is wound around the stator core 2 (see FIG. 1 and FIG. 9) and the coil 3 is not wound around the stator core 2. Description will be made using each direction of the direction L, the circumferential direction C, and the radial direction R. In the present specification, terms relating to dimensions, arrangement direction, arrangement position, and the like are used as a concept including a state having a difference due to an error (an error that is acceptable in manufacturing).

1. Overall Configuration of Rotating Electric Machine The rotating electric machine 100 includes a stator 1 as shown in FIG. The stator 1 includes a stator core 2 and a coil 3 wound around the stator core 2. The stator 1 functions as an armature. Inside the radial direction R of the stator core 2, a rotor (not shown) as a magnetic field including a permanent magnet or an electromagnet is disposed, and the rotor is rotated by a rotating magnetic field generated from the stator 1. In the present embodiment, the rotating electrical machine 100 is a rotating electrical machine that is driven by three-phase alternating current (an example of multi-phase alternating current), and a coil that includes three phase coils: a U-phase coil, a V-phase coil, and a W-phase coil. 3 is wound around the stator core 2.

  In the stator core 2, a plurality of slots 40 extending in the axial direction L and the radial direction R are distributed in the circumferential direction C. The plurality of slots 40 are arranged at regular intervals along the circumferential direction C. In the present embodiment, the number of slots per phase per pole is “2”, and two slots 40 for each phase are repeatedly arranged along the circumferential direction C in the stator core 2. . A tooth 23 is formed between two slots 40 adjacent to each other in the circumferential direction C. The above-described “cylindrical core reference surface” is a virtual surface that serves as a reference for the arrangement and configuration of the slots 40. In the present embodiment, as shown in FIG. A cylindrical virtual surface (core inner peripheral surface) including the inner end surface is defined as a core reference surface S. The outer surface (core outer peripheral surface) in the radial direction R of the stator core 2 may be used as the core reference surface S.

  Each of the slots 40 is formed so as to penetrate the stator core 2 in the axial direction L. Each of the slots 40 has an opening 40a that opens inward in the radial direction R. In the present embodiment, each of the slots 40 is formed such that an imaginary line (that is, a center line in the width direction) connecting the central part in the circumferential direction C extends in parallel to the radial direction R. Further, in the present embodiment, each of the slots 40 is an open slot, and a protruding portion that protrudes in the circumferential direction C as provided in the case of a semi-open slot is provided at the inner end portion of the tooth 23 in the radial direction R. Not formed. That is, the side surface portions 50 (two side surface portions 50 facing the circumferential direction C) on both sides in the circumferential direction C of the slot 40 are formed so as to be a plane that continues to the inner end portion in the radial direction R. Here, as shown in FIG. 4, among the side surface portions 50 on both sides in the circumferential direction C, the side surface portion 50 on the circumferential first direction C1 side (that is, the side surface portion 50 facing the circumferential second direction C2 side) is the first. The side surface portion 51 and the side surface portion 50 on the circumferential second direction C2 side (that is, the side surface portion 50 facing the circumferential first direction C1 side) are defined as the second side surface portion 52. In the present embodiment, the width of the slot 40 in the circumferential direction C is uniformly formed along the radial direction R. That is, in this embodiment, the slot 40 is a parallel slot, and the side surface portions 50 on both sides of the slot 40 are formed in parallel to each other. That is, the slot 40 is formed in a rectangular shape when viewed in the axial direction L.

  In the present embodiment, the stator core 2 is configured by arranging a plurality of core pieces 20 in a ring shape along the circumferential direction C. Each of the core pieces 20 includes a main body portion 20a (yoke portion) extending in the circumferential direction C and a tooth 23 extending inward in the radial direction R from the main body portion 20a. The side surface portions on both sides in the circumferential direction C of the main body portion 20a serve as the joint surfaces 21 with the adjacent core pieces 20. In this example, the joint surface 21 is formed with a fitting portion 20b for positioning adjacent core pieces 20 to each other. In the present embodiment, the joint surface 21 is formed at a position in the circumferential direction C corresponding to the slot 40 (here, the central portion of the slot 40 in the circumferential direction C). The plurality of core pieces 20 arranged in an annular shape are fixed to each other so as not to move using, for example, a cylindrical fixing member fitted to the outer surface (outer peripheral surface) in the radial direction R. The core piece 20 is configured by, for example, laminating a plurality of magnetic plates (for example, electromagnetic steel plates such as silicon steel plates), or is mainly made of a powder material formed by press-molding magnetic material powder. Configured as a component.

  In the present embodiment, the plurality of core pieces 20 have the same shape. In the present embodiment, each of the core pieces 20 includes two teeth 23. When the stator 1 is manufactured, as will be described later, a plurality of core pieces 20 are inserted from the outside in the radial direction R into the coil 3 formed in the same cylindrical shape as that wound around the stator core 2. . At this time, since all the slots 40 including the slots 40 formed between the two teeth 23 of one core piece 20 are parallel slots, the core piece 20 can be easily formed from the outside in the radial direction R with respect to the coil 3. Can be worn.

  As shown in FIGS. 1 and 2, the coil 3 is configured by using a linear conductor 34 having a rectangular cross section that is a cross section orthogonal to the extending direction. That is, the coil 3 is configured using a rectangular wire. Here, the “rectangular shape” includes a rectangle whose corners are arc-shaped, or a rectangle whose absolute value of the difference between the size of the inner angle and 90 degrees is less than a predetermined angle (for example, 5 degrees or 10 degrees). including. The linear conductor 34 is formed using a material capable of plastic deformation in addition to elastic deformation. Further, the linear conductor 34 is formed using a conductive material (for example, a metal such as copper or aluminum), and the surface of the linear conductor 34 excludes a part of a connection portion with another conductor. And an insulating film made of resin (for example, enamel). That is, the linear conductor 34 is a rectangular wire with an insulating film, and in this embodiment, the insulating film is formed over the entire circumference of the orthogonal cross section of the linear conductor 34.

  The coil 3 includes a coil side portion 30 and a crossover portion 38. The coil side portion 30 is a portion arranged inside the slot 40 in a state where the coil 3 is wound around the stator core 2. The coil side portion 30 is formed in a straight line so as to extend along the axial direction L (in parallel with the axial direction L by design). As shown in FIG. 4, the coil side portion 30 includes a first side surface portion 61 that is a side surface portion facing the circumferential first direction C1 side, and a second side surface portion 62 that is a side surface portion facing the circumferential second direction C2 side. Is provided. The transition portion 38 is a portion that connects the pair of coil side portions 30 outside the stator core 2 in the axial direction L in a state where the coil 3 is wound around the stator core 2. The crossover portion 38 forms a coil end portion that is a portion of the coil 3 protruding in the axial direction L from the stator core 2. As shown in FIG. 1, a plurality of coil side portions 30 are arranged inside the slot 40. In each of the coil side portions 30, an arrangement position in the slot 40 is set in advance as a set position. In the present embodiment, a plurality of coil side portions 30 are arranged in a line along the radial direction R in the slot 40. That is, assuming that the arrangement region in the radial direction R of one coil side portion 30 is one layer, a plurality of coil side portions 30 are divided into a plurality of layers (10 layers in this example) in each slot 40. . Thus, in the present embodiment, the position of the layer (number of the layer) is set in advance as the set position for each of the coil side portions 30.

  In the present embodiment, the coil 3 is formed using a plurality of coil units 10 (see FIGS. 2 and 3). Each of the coil units 10 includes a first coil side portion 31 disposed on the circumferential first direction C1 side and a second coil side portion 32 disposed on the circumferential second direction C2 side as the coil side portion 30. . In the present embodiment, each of the coil units 10 includes a plurality of first coil side portions 31 and a plurality of second coil side portions 32. Specifically, in the present embodiment, the coil unit 10 is a single coil portion (overlapping portion) that is wound a plurality of times between a pair of slots 40. The coil unit 10 is a cassette coil that is spirally formed before being wound around the stator core 2. That is, in this embodiment, the coil 3 is wound around the stator core 2 by lap winding. In the example shown in FIG. 2, the coil unit 10 is formed by winding a single linear conductor 34 a plurality of times in a spiral shape.

  The coil unit 10 includes connection portions 39 at both ends in the extending direction of the linear conductor 34, in other words, at both ends in the current flow direction. In the present embodiment, the connection portion 39 includes a circumferential bent portion that bends the extending direction to one side of the circumferential direction C, and a radial bent portion that bends the extending direction to the inside of the radial direction R. In FIG. 2, the shape of the connecting portion 39 is a straight line along the axial direction L for simplification. By providing the radial bending portion, the tip end portion of the connection portion 39 is formed to extend along the radial direction R as shown in FIG. The connecting portion 39 is joined to the connecting portion 39 of the other coil unit 10 to constitute the crossover portion 38, or is connected to a power supply terminal, a neutral point, or the like. In the following description, unless otherwise specified, the transition portion 38 refers to the transition portion 38 included in one coil unit 10, and includes the transition portion 38 configured by joining the connection portions 39 of different coil units 10. Make it not exist.

  The plurality of coil units 10 constituting the coil 3 are configured in the same manner except for the arrangement position in the circumferential direction C except for the shape of the connecting portion 39 in this example. In the present embodiment, the first coil side 31 and the second coil side 32 of one coil unit 10 are spaced apart by 6 times the arrangement pitch of the slots 40 as shown in FIG. A pair of slots 40 are arranged separately. Each of the first coil side portion 31 and the second coil side portion 32 extends along the radial direction R such that a gap G for one layer is formed between two coil side portions 30 adjacent to each other in the radial direction R. Are arranged in a row at intervals. Specifically, the innermost layer in the radial direction R in the slot 40 is defined as the first layer, and then the second layer, the third layer,. Then, the 1st coil side part 31 is arrange | positioned at the even-numbered layer, and the 2nd coil side part 32 is arrange | positioned at the odd-numbered layer. Then, the same number of coil units 10 as the slots 40 are arranged on the one side in the circumferential direction C while being shifted by the arrangement pitch of the slots 40 to constitute the coil 3. Each slot 40 has one first coil side 31 and the other second coil side 32 of the two coil units 10 that are spaced apart by 6 times the arrangement pitch of the slots 40. They are alternately arranged along the radial direction R one by one.

  In the present embodiment, the crossover portion 38 connects a pair of coil side portions 30 respectively disposed in mutually adjacent layers in different slots 40. For this reason, as shown in FIGS. 2 and 3, the crossover portion 38 is formed with an offset portion 37 for offsetting the linear conductor 34 by one layer in the radial direction R. In this example, as shown in FIG. 2, the offset portion 37 is formed at a portion (top portion) that is farthest in the axial direction L from the stator core 2 in the transition portion 38. Further, a portion of the crossover portion 38 excluding the offset portion 37 (specifically, a portion of the crossover portion 38 that is closer to the first circumferential direction C1 than the offset portion 37 and a second portion of the crossover portion 38 that is more circumferential than the offset portion 37) The portion on the C2 side) is formed in an arc shape extending in the circumferential direction C when viewed in the axial direction L. Thereby, it is possible to arrange a plurality of coil units 10 for each arrangement pitch of the slots 40 without causing the crossover portions 38 of different coil units 10 to interfere with each other.

2. Next, a method for manufacturing the rotating electrical machine 100 according to the present embodiment will be described. As shown in FIG. 10, the process of manufacturing the rotating electrical machine 100 includes processes (P1 to P5) of manufacturing the stator 1, and specifically includes a preparation process P1, an arrangement process P2, a pressurization process P3, A winding process P4 and a pressure release process P5 are included. In the present embodiment, the pressurization step P3 corresponds to the “deformation step” in the present invention, and the pressurization release step P5 corresponds to the “deformation release step” in the present invention.

  The preparation step P1 is a step of preparing an annular coil formed by winding the linear conductor 34 in a spiral shape around the winding axis as the coil unit 10 (see FIG. 2). In the present embodiment, the same number of coil units 10 as the slots 40 are prepared in the preparation step P1. In the preparation process P1, the coil unit 10 formed so that the target interval A is different from the reference interval B is prepared. Specifically, the coil unit 10 is prepared so that the target interval A is larger than the reference interval B. Here, as shown in FIG. 2, the target interval A is the interval between a pair of coil side portions 30 connected by the crossover portion 38 (the interval between the first coil side portion 31 and the second coil side portion 32). As shown in FIG. 4, the reference interval B is a target interval A in a state where the coil 3 is wound around the stator core 2 in the pair of coil side portions 30. 2 and 4, for simplification, only the target interval A and the reference interval B for the first coil side portion 31 arranged in the second layer and the second coil side portion 32 arranged in the first layer are shown. However, each of the target interval A and the reference interval B is individually defined for all the combinations of the pair of coil side portions 30 connected by the crossover portion 38.

  Below, paying attention to the crossover part 38 which connects the 1st coil side part 31 arrange | positioned in a 2nd layer, and the 2nd coil side part 32 arrange | positioned in a 1st layer, the said crossover part 38 and connection by it The configuration of the first coil side portion 31 and the second coil side portion 32 will be specifically described. That is, in the following, the first coil side 31 arranged in the second layer is simply referred to as the first coil side 31 and the second coil side 32 arranged in the first layer is simply the second coil side. 32, the first coil side 31 and the second coil side 32 are simply described as a pair of coil sides 30, and the first coil side 31 and the second coil side 32 are connected. The transition part 38 may be simply referred to as the transition part 38 in some cases. The other transition portions 38 and the pair of coil side portions 30 connected thereby are the same except that the size of the interval such as the target interval A is different, and a specific description thereof will be omitted.

  In the present embodiment, the target interval A is the distance between the first coil side part 31 and the second coil side part 32 connected by the crossover part 38 (linear distance, the same applies hereinafter), specifically, the first The distance between the center line 30a of the coil side portion 31 and the center line 30a of the second coil side portion 32 is set. Here, the center line 30a is a line continuously connecting the center or the center of gravity of the coil side portion 30 in the orthogonal cross section along the extending direction. In addition, the object space | interval A is the 1st coil side part 31 and the 2nd coil side part 32 in the cross section orthogonal to the axial direction L (for example, the cross section orthogonal to the axial direction L in the center part of the axial direction L, and so on). (For example, the distance between the centers or the centroids in the orthogonal cross section).

  In the present embodiment, a coil unit 10 as shown in FIG. 6 is used as the coil unit 10 formed so that the target interval A is larger than the reference interval B. The coil unit 10 is configured so that the first coil side 31 and the second coil side 32 of the first coil side 31 are connected to each other with respect to the first coil side 31 and the second coil side 32 connected by the crossing part 38. The coil unit is formed such that the distance between the two side surface parts 62 is larger than the first reference slot distance D1. Here, the 1st reference slot space | interval D1 opposes the 1st coil side part 31 arrange | positioned in the setting position in the 1st side part 51 of the slot 40 where the 1st coil side part 31 is arrange | positioned in the circumferential direction C. The second coil side portion 32 disposed at the set position and the circumferential direction C in the portion (hereinafter referred to as “first portion”) and the second side surface portion 52 of the slot 40 in which the second coil side portion 32 is disposed. It is a space | interval with the part (henceforth "2nd part") which opposes. The first reference slot interval D1 is individually defined for all combinations of the pair of coil side portions 30 connected by the crossover portion 38. As described above, the setting position is a layer position in the present embodiment. In FIG. 6, in order to facilitate understanding of the invention, the target interval A is the reference interval so as to overlap the coil unit 10 (broken line) and the stator core 2 (two-dot chain line) in a state of being arranged at the set position in the slot 40. The coil unit 10 (solid line) formed to be larger than B is shown. At this time, the coil sides 30 corresponding to each other are overlapped so as to be arranged at the same position in the radial direction R.

  In the present embodiment, the distance between the first side surface portion 61 of the first coil side portion 31 and the second side surface portion 62 of the second coil side portion 32 is the same as the first side surface portion 61 of the first coil side portion 31 and the second side portion 62. The distance between the coil side portion 32 and the second side surface portion 62, specifically, the imaginary line connecting the central portion of the first side surface portion 61 in the radial direction R and the radial direction R of the second side surface portion 62. The distance between the imaginary line connecting the center of In addition, this distance is the distance (for example, radial direction R) between the 1st side surface part 61 of the 1st coil side part 31 and the 2nd side surface part 62 of the 2nd coil side part 32 in the cross section orthogonal to the axial direction L. It is also possible to set it as the distance between the center parts. In the present embodiment, the first reference slot interval D1 is set to a distance between the first portion and the second portion, specifically, an imaginary line connecting a central portion of the first portion in the radial direction R, The distance between the two portions and the virtual line connecting the central portion in the radial direction R is used. Note that the first reference slot interval D1 may be a distance between the first portion and the second portion in the cross section orthogonal to the axial direction L (for example, the distance between the central portions in the radial direction R).

  As described above, in the present embodiment, the portion of the transition portion 38 excluding the offset portion 37 is formed in an arc shape that extends along the circumferential direction C when viewed in the axial direction L. In the present embodiment, the coil unit 10 is formed such that the diameter of the arc is larger than the diameter of the coil 3 wound around the stator core 2, as shown in FIG. The distance between the first side face 61 of the one coil side 31 and the second side face 62 of the second coil side 32 is made larger than the first reference slot distance D1.

  The placement process P2 is a process of placing the plurality of coil units 10 in a ring shape along the circumferential direction C as shown in FIG. In the present embodiment, as described above, the coil unit is configured such that the diameter of the arc-shaped portion in the crossover portion 38 in the axial direction L is larger than the diameter when the coil 3 is wound around the stator core 2. 10 is formed, and in the placement step P2, a cylindrical region having a larger diameter than the cylindrical region (see FIG. 9) in which the plurality of coil units 10 are disposed in a state of being wound around the stator core 2, A plurality of coil units 10 are arranged. At this time, the plurality of coil units 10 are arranged so that the plurality of coil units 10 are arranged in the same mutual positional relationship as the state in which the plurality of coil units 10 are wound around the stator core 2 after the pressurization step P3.

  The pressurizing step P3 uses the coil 3 (here, the coil unit 10 shown in FIG. 6) formed so that the target interval A is different from the reference interval B, and extends so that the target interval A matches the reference interval B. This is a step of deforming the portion 38 by an external force. Here, that the target interval A matches the reference interval B means that the interval between the pair of coil sides 30 is an interval at which each of the pair of coil sides 30 can be inserted into the slot 40. This is a concept including the case where the target interval A and the reference interval B are deviated in addition to the case where the interval A and the reference interval B coincide. In the present embodiment, as described above, the coil unit 10 formed so that the target interval A is larger than the reference interval B is used. Therefore, in the pressurization step P3, the target interval A is specifically reduced. In this case, the crossover portion 38 is deformed so that the distance between the first coil side portion 31 and the second coil side portion 32 connected by the crossover portion 38 is reduced as indicated by an arrow in FIG. In the present embodiment, the first connecting portion 38 is connected by the connecting portion 38 until the target interval A matches the reference interval B by deforming the connecting portion 38 so that the diameter of the arc-shaped portion in the connecting portion 38 is reduced. The interval between the coil side portion 31 and the second coil side portion 32 is reduced.

  In the present embodiment, in the pressurizing step P3, the coil 3 (in this example, a plurality of coil units 10) arranged in a cylindrical shape having the axial direction L as an axis in the arranging step P2 is arranged in the radial direction R over the entire circumference. The plurality of transition portions 38 distributed in the circumferential direction C are deformed. In the present embodiment, as shown in FIG. 7, the pressurizing direction in the pressurizing step P3 is a direction toward the inside of the radial direction R, and the pressurizing portion in the pressurizing step P3 is the crossing portions 38 on both sides in the axial direction L. It is. In the pressurizing step P3, the cylindrical region in which the plurality of coil units 10 are arranged is reduced in diameter to a region similar to the state wound around the stator core 2. In this state, each of the plurality of coil units 10 is arranged in the same mutual positional relationship as the state wound around the stator core 2. In FIG. 7, the case where the pressurization process P3 is performed using the pressurization jig | tool 90 which has an arc-shaped inner peripheral surface is illustrated. That is, in this example, the external force for deforming the crossover portion 38 is a pressing force applied to the crossover portion 38 by the pressing jig 90. The pressure jig 90 is arranged separately on both sides in the axial direction L, and a space in which the core piece 20 can be moved in the radial direction R is formed between the pressure jigs 90 on both sides in the axial direction L. .

  In the winding step P4, the pair of coil side portions 30 connected by the crossover portion 38 are predetermined in different slots 40 while maintaining the state where the crossover portion 38 is deformed by the pressurization step P3. This is a step of winding the coil 3 around the stator core 2 so as to be arranged at a set position (a predetermined layer in this example). That is, at the time of execution of the winding process P4, a state in which an external force for deforming the transition part 38 is applied to the transition part 38 is maintained. In the present embodiment, as shown in FIG. 8, in the winding step P <b> 4, a plurality of core pieces 20 are used, and the coil 3 is outside in the radial direction R and at the same position in the coil side 30 and the axial direction L. The plurality of disposed core pieces 20 are moved inward in the radial direction R, and each of the coil side portions 30 is disposed at a set position in the slot 40. In this embodiment, after arrange | positioning the several core piece 20 along the outer periphery of the cylindrical arrangement | positioning area | region where the several coil unit 10 is arrange | positioned, the position of each radial direction R of the said several core piece 20 is aligned. However, all of the plurality of core pieces 20 are moved inward in the radial direction R, and each of the coil side portions 30 is disposed in the slot 40. At this time, since the state where the crossing portion 38 is deformed by the pressurizing step P3 is held, that is, the state where the target interval A matches the reference interval B, the core piece 20 is moved in the radial direction R. By moving inward, the coil side 30 can be easily inserted into the slot 40.

  As shown in FIG. 9, the pressure release process P <b> 5 is a process executed after the execution of the winding process P <b> 4, and removes an external force for deforming the crossover part 38 and connects the pair of crossover parts 38. This is a step of bringing each of the coil side portions 30 into contact with the side surface portions 50 of the slots 40 facing the opposite sides in the circumferential direction C. In the present embodiment, the external force for deforming the crossing portion 38 is removed by releasing the pressurization in the radial direction R on the coil 3 (in this example, the pressurization in the direction toward the inside of the radial direction R). In the example shown in FIG. 9, the case where the pressurization with respect to the coil 3 is cancelled | released by moving the pressurization jig | tool 90 to the outer side of radial direction R is illustrated. When the pressure release process P5 is executed, the plurality of core pieces 20 are fixed to each other, for example, by holding the outer peripheral surface. Although details are omitted, the stator 1 (the rotating electrical machine 100) is manufactured by performing, for example, a mounting process, a joining process, a coil fixing process, and the like after the pressure release process P5. Here, the mounting step is a step of mounting a cylindrical fixing member on the outer peripheral surface of the plurality of core pieces 20 arranged in an annular shape (for example, fitting by shrink fitting). The joining step is a step of joining the connection portions 39 of different coil units 10 together. The coil fixing step is a step of fixing the coil 3 to the stator core 2 and is, for example, a varnish impregnation step for impregnating a varnish, a mold filling step for filling a mold, or the like.

  As described above, in the pressurizing step P3, the crossing portion 38 is deformed by the external force so that the target interval A matches the reference interval B. Under the present circumstances, the linear conductor 34 which comprises the coil unit 10 including the transition part 38 is formed using the material which can be plastically deformed in addition to elastic deformation. That is, when the load for deforming the transition portion 38 is smaller than the elastic limit, the transition portion 38 is elastically deformed. When the load is larger than the elastic limit, the transition portion 38 is plastically deformed in addition to the elastic deformation. . In the present embodiment, as the coil unit 10, a coil unit 10 is used which is formed into a shape capable of matching the target interval A with the reference interval B by elastically deforming the crossing portion 38. That is, in the present embodiment, the pressurizing step P3 is a step of elastically deforming the crossover portion 38 so that the target interval A matches the reference interval B. In the present embodiment, as described above, the interval between the first side surface portion 61 of the first coil side portion 31 and the second side surface portion 62 of the second coil side portion 32 is larger than the first reference slot interval D1. The coil unit 10 formed to be large is used (see FIG. 6). Therefore, when the pressure applied to the coil 3 is released in the pressure release process P5, the first coil side portion 31 is brought into contact with the first side surface portion 51 of the slot 40 by the restoring force generated in the transition portion 38. The second coil side portion 32 can be brought into contact with the second side surface portion 52 of the slot 40. At this time, each of the first coil side portion 31 and the second coil side portion 32 is pressed against the side surface portion 50 by a force corresponding to the restoring force generated in the crossover portion 38, so The position of the coil unit 10 with respect to the stator core 2 is maintained by using the frictional force generated between the side part 51 and the frictional force generated between the second coil side part 32 and the second side part 52. Is possible.

  Thus, in this embodiment, after removing the external force (load) for deforming the transition portion 38 so that the target interval A matches the reference interval B as the coil unit 10, the restoration that occurs in the transition portion 38 is performed. A coil unit is used in which each of the first coil side portion 31 and the second coil side portion 32 can be brought into contact with the side surface portion 50 facing the opposite sides in the circumferential direction C by force. Further, in the present embodiment, the first coil side portion 31 is disposed so as to contact the first side surface portion 51 of the slot 40 and the second coil side portion 32 is the slot after the pressure release step P5 is executed. It arrange | positions so that the 2nd side part 52 of 40 may contact | abut. Therefore, in one slot 40, the coil side portions 30 that contact the first side surface portion 51 and the coil side portions 30 that contact the second side surface portion 52 are alternately arranged along the radial direction R one by one. Is done.

  In addition, as the coil unit 10, it is also possible to use what was formed in the shape which can match the object space | interval A with the reference | standard space | interval B by plastically deforming the crossover part 38. FIG. In this case, the pressurizing step P3 is a step of plastically deforming the transition portion 38 in addition to elastic deformation so that the target interval A matches the reference interval B. Even in this case, when the pressurization to the coil 3 is released by the pressurization release process P5, a restoring force (restoring force by springback) corresponding to the elastic deformation is generated in the crossing portion 38. Therefore, also in this case, the first coil side 31 is brought into contact with the first side surface 51 of the slot 40 and the second coil side 32 is set to the second side of the slot 40 by the restoring force generated in the crossing portion 38. It can be brought into contact with the side surface portion 52. However, in this case, the difference between the distance between the first side surface portion 61 of the first coil side portion 31 and the second side surface portion 62 of the second coil side portion 32 and the first reference slot interval D1 is elastically deformed. It is necessary to set the size so that each of the first coil side 31 and the second coil side 32 can be brought into contact with the side surface 50 by a restoring force corresponding to the minute.

3. Other Embodiments Finally, other embodiments according to the present invention will be described. Note that the configurations disclosed in the following embodiments can be applied in combination with the configurations disclosed in other embodiments as long as no contradiction arises.

(1) In the above embodiment, the configuration using the coil unit 10 formed so that the target interval A is larger than the reference interval B has been described as an example in the pressurizing step P3. However, the embodiment of the present invention is not limited to this. That is, in the pressurization process P3, it is also possible to employ a configuration using the coil unit 10 formed so that the target interval A is smaller than the reference interval B. That is, it is possible to prepare the coil unit 10 that is molded so that the target interval A is smaller than the reference interval B in the preparation step P1. In this case, for example, a coil unit 10 as shown in FIG. 11 can be used. The coil unit 10 shown in FIG. 11 includes the second coil side part 62 and the second coil side part of the first coil side part 31 with respect to the first coil side part 31 and the second coil side part 32 connected by the crossing part 38. The coil unit is formed such that the distance between the first side surface portion 61 and the first side surface portion 32 is smaller than the second reference slot distance D2. Here, the 2nd reference slot space | interval D2 opposes the 1st coil side part 31 arrange | positioned in the setting position in the 2nd side part 52 of the slot 40 where the 1st coil side part 31 is arrange | positioned in the circumferential direction C. This is the distance between the portion and the portion facing the second coil side portion 32 arranged at the set position and the circumferential direction C in the first side surface portion 51 of the slot 40 where the second coil side portion 32 is arranged.

  As described above, when the coil unit 10 formed so that the target interval A is smaller than the reference interval B is used, when the pressurization to the coil 3 is released by the pressurization release process P5, The first coil side portion 31 abuts on the second side surface portion 52 of the slot 40 and the second coil side portion 32 abuts on the first side surface portion 51 of the slot 40 by the restoring force generated. . Further, in this case, the pressurizing direction in the pressurizing step P3 is different from the above-described embodiment, and is a direction toward the outside of the radial direction R. In the pressurizing step P3, a cylindrical shape in which a plurality of coil units 10 are arranged The region may be configured to have a diameter expanded to the same region as that wound around the stator core 2.

(2) In the above embodiment, a configuration in which the target interval A is the distance (straight line distance) between the first coil side part 31 and the second coil side part 32 connected by the crossing part 38 will be described as an example. did. However, the embodiment of the present invention is not limited to this. For example, when the first coil side part 31 and the second coil side part 32 connected by the crossing part 38 are arranged at the same position in the radial direction R as in the state wound around the stator core 2 (see FIG. 6). The difference (angle difference) in the circumferential direction C between the first coil side 31 and the second coil side 32 in FIG. The distance between the first side surface 61 of the first coil side 31 and the second side surface 62 of the second coil side 32 described above, the second side 62 and the second coil side of the first coil side 31. Similarly, each of the distance between the first side surface portion 61, the first reference slot distance D1, and the second reference slot distance D2 can be set to a difference in position (angular difference) in the circumferential direction C. .

(3) In the above embodiment, in the winding step P4, a plurality of core pieces 20 are used, and the plurality of core pieces 20 arranged on the outer side in the radial direction R with respect to the coil 3 are directed toward the inner side in the radial direction R. The configuration in which each of the coil side portions 30 is moved and arranged at the set position in the slot 40 has been described as an example. However, the embodiment of the present invention is not limited to this. For example, by inserting the coil 3 formed in the same cylindrical shape as the state wound around the stator core 2 in the axial direction L with respect to the stator core 2, each of the coil side portions 30 is set to a set position in the slot 40. It is also possible to adopt a configuration in which they are arranged. In this case, unlike the above embodiment, the stator core 2 may be formed integrally in the circumferential direction C.

(4) In the above embodiment, in the pressurizing step P3, the crossing portion 38 is deformed so that the diameter of the arc-shaped portion changes when viewed in the axial direction L of the crossing portion 38. The configuration that matches the interval B has been described as an example. However, the embodiment of the present invention is not limited to this. For example, it is possible to adopt a configuration in which the target interval A is matched with the reference interval B by deforming the transition portion 38 so that the bending angle of the top portion of the transition portion 38 in the radial direction R changes.

(5) In the above embodiment, the configuration in which the coil 3 is wound around the stator core 2 by lap winding has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the coil 3 may be wound around the stator core 2 by wave winding. In this case, the pair of coil side portions 30 connected by the crossing portion 38 on one side in the axial direction L is formed such that the target interval A is larger than the reference interval B, and the crossing on the other side in the axial direction L is performed. About a pair of coil side part 30 connected by the part 38, it is set as the structure which uses the coiled coil 3 shape | molded so that the object space | interval A may become smaller than the reference | standard space | interval B by the pressurization process P3. it can.

(6) In the above embodiment, the configuration in which the slot 40 is a parallel slot has been described as an example. However, the embodiment of the present invention is not limited to this. For example, a part or all of the slots 40 may be formed so that the width in the circumferential direction C becomes smaller toward the inner side in the radial direction R. In this case, the side surfaces of the teeth 23 on both sides in the circumferential direction C (two side surfaces facing opposite to each other in the circumferential direction C) are formed in parallel to each other, that is, the teeth 23 are parallel teeth. You can also. In this way, when the width in the circumferential direction C of the slot 40 varies depending on the position in the radial direction R, for example, the shape of each of the plurality of coil side portions 30 arranged in the slot 40 is the coil side. It is preferable that the portions 30 are different from each other depending on the position in the radial direction R where the portions 30 are arranged.

(7) In the above-described embodiment, the configuration in which the shape of the orthogonal cross section of the linear conductor 34 configuring the coil 3 is rectangular has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the coil 3 may be configured using a linear conductor 34 having a square or circular cross-sectional shape.

(8) Regarding other configurations as well, the embodiments disclosed herein are illustrative in all respects, and the embodiments of the present invention are not limited thereto. In other words, configurations that are not described in the claims of the present application can be modified as appropriate without departing from the object of the present invention.

  The present invention provides a core in which a plurality of slots extending in the axial direction and the radial direction of a cylindrical core reference surface are arranged in a distributed manner in the circumferential direction of the core reference surface, and arranged in the slot while being wound around the core. And a coil having a transition part that connects the coil side part and the pair of coil side parts on the outer side in the axial direction of the core.

2: Stator core (core)
3: Coil 20: Core piece 23: Teeth 30: Coil side part 31: First coil side part 32: Second coil side part 38: Crossing part 40: Slot 50: Side face part 100: Rotating electrical machine A: Target interval B: Reference interval C: circumferential direction C1: circumferential first direction C2: circumferential second direction D1: first reference slot interval D2: second reference slot interval L: axial direction P3: pressurization process (deformation process)
P4: Winding step P5: Pressure release step (deformation release step)
R: radial direction S: core reference plane

Claims (5)

A plurality of slots extending in the axial direction and the radial direction of the cylindrical core reference surface are arranged in the slot in a state of being wound around the core and a plurality of cores distributed in the circumferential direction of the core reference surface. A coil having a bridge portion that connects a coil side portion and a pair of the coil side portions on the outer side in the axial direction of the core, and a method of manufacturing a rotating electrical machine,
The interval between the pair of coil sides connected by the crossing portion is set as the target interval, and the target interval in the state where the coil is wound around the core in the pair of coil sides is set as a reference interval.
Using the coil shaped so that the target interval is different from the reference interval, and deforming the transition portion with an external force so that the target interval matches the reference interval;
Each of the pair of coil side portions connected by the crossover portion is arranged at a predetermined set position in the slot different from each other while maintaining the state where the crossover portion is deformed by the deformation step. And a winding step of winding the coil around the core;
After execution of the winding process, the external force is removed, and the pair of coil sides connected by the crossing part are brought into contact with the side parts of the slots facing the opposite sides of the circumferential direction. A method of manufacturing a rotating electrical machine comprising: a releasing step.   In the deforming step, the coils arranged in a cylindrical shape having the axial direction as an axis as a center are pressurized in the radial direction over the entire circumference, and a plurality of the transition portions distributed in the circumferential direction are deformed. The manufacturing method of the rotary electric machine of Claim 1.   In the winding step, a plurality of core pieces having teeth formed between adjacent slots are used, and the plurality of core pieces arranged on the outer side in the radial direction with respect to the coil are moved inward in the radial direction. The method of manufacturing a rotating electrical machine according to claim 2, wherein each of the coil side portions is arranged at the set position by moving the coil side portions toward each other. Of the pair of coil sides connected by the crossing part, the coil side on the circumferential first direction side, which is one side of the circumferential direction, is the first coil side, and the circumferential first direction is The coil side on the circumferential second direction side that is the opposite side is the second coil side,
A portion of the side surface facing the circumferential second direction side of the slot in which the first coil side portion is disposed, a portion facing the first coil side portion disposed at the set position in the circumferential direction; The distance between the second coil side portion disposed at the set position and the portion facing the circumferential direction in the side surface portion facing the first circumferential direction side of the slot where the two coil side portions are disposed is first. As a reference slot interval,
In the deformation step, an interval between a side surface portion of the first coil side portion facing the circumferential first direction side and a side surface portion of the second coil side portion facing the circumferential second direction side is defined as the first reference. The manufacturing method of the rotary electric machine as described in any one of Claim 1 to 3 using the said coil shape | molded so that it might become larger than a slot space | interval. Of the pair of coil sides connected by the crossing part, the coil side on the circumferential first direction side, which is one side of the circumferential direction, is the first coil side, and the circumferential first direction is The coil side on the circumferential second direction side that is the opposite side is the second coil side,
A portion of the side surface facing the circumferential first direction side of the slot in which the first coil side portion is disposed, a portion facing the first coil side portion disposed at the set position in the circumferential direction; The distance between the second coil side portion disposed at the set position and the portion facing the circumferential direction in the side surface portion facing the second direction in the circumferential direction of the slot where the two coil side portions are disposed is a second interval. As a reference slot interval,
In the deformation step, a distance between a side surface portion facing the second circumferential direction side of the first coil side portion and a side surface portion facing the first circumferential direction side of the second coil side portion is determined by the second reference. The manufacturing method of the rotary electric machine as described in any one of Claim 1 to 3 using the said coil shape | molded so that it might become smaller than a slot space | interval.

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