JP2016052234A - Manufacturing method of rotary electric machine stator with lead wire - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent vibrations of a lead wire without generating an additional component for fixing the lead wire in a stator including a segment coil, in accordance with a manufacturing method of a rotary electric stator with a lead wire.SOLUTION: The manufacturing method includes a conductor segment insertion step (S10), a lead wire arrangement step (S12) and a curve formation step (S15). The conductor segment insertion step includes inserting legs in a plurality of conductor segments forming the segment coil into a slot from one end side of a stator core in an axial direction and projecting the legs from another end face of the stator core in the axial direction. The lead wire arrangement step includes arranging partial legs among a plurality of legs which are projected from the other end face of the stator core in the axial direction, over an U-shaped part of the lead wire and arranging both side portions of the U-shaped part on the stator core. The curve formation step includes curving and forming portions of the legs projected from the other end face of the stator core, in a circumferential direction.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method of manufacturing a rotating electrical machine stator with a lead wire including a stator coil including a plurality of segment coils and a lead wire disposed between the stator coil and the stator core.

  Conventionally, a stator coil of a rotating electrical machine may use a segment coil formed by connecting a plurality of conductor segments. On the other hand, it is not preferable that the temperature of the stator rises above a predetermined level. For this reason, the stator temperature may be measured by a temperature sensor. Patent Document 1 describes that a temperature sensor is attached to a neutral wire for neutral point connection of a distributed winding stator coil of a rotating electrical machine.

  Patent Document 2 describes that a temperature sensor is fixed to an insulator attached to a tooth of a stator core.

  Patent Document 3 describes that a heat shrink tube is used for the wiring of the temperature sensor, the wire is positioned, and the heat shrink tube is thermally contracted in this state to fix the wiring path.

JP 2013-219961 A JP 2013-158078 A JP 2010-81742 A

  When a temperature sensor is attached to the stator as in the configuration described in Patent Document 1, a lead wire for signal transmission is connected to the temperature sensor, and this lead wire is usually arranged along the outer periphery of the stator. The lead wire may vibrate and collide with the stator during use. For this reason, it is necessary to fix the lead wire and suppress its vibration. However, when the lead wire is fixed to the outer peripheral portion of the stator in order to suppress the vibration of the lead wire, additional parts for fixing the lead wire are generated, which increases the manufacturing cost and weight.

  An object of the present invention is to provide a method of manufacturing a rotating electrical machine stator with lead wire that can suppress vibration of the lead wire without generating additional parts for fixing the lead wire in the rotating electrical machine stator with lead wire having a segment coil. It is.

  A manufacturing method of a rotating electrical machine stator with lead wire according to the present invention includes a plurality of teeth protruding in a radial direction from an inner peripheral surface of an annular yoke, and a plurality of slots formed between the adjacent teeth. A stator coil including a stator core and a plurality of segment coils wound around the plurality of teeth, the segment coil being formed by connecting a plurality of conductor segments, the stator coil, and the stator core And a lead wire-equipped rotating electrical machine stator including a lead wire having a U-shaped portion disposed between the two. In the method for manufacturing a rotating electrical machine stator with lead wires according to the present invention, linear leg portions of the plurality of conductor segments are inserted into the slot from one end side in the axial direction of the stator core, and the axial direction of the stator core, etc. An insertion step for projecting from the end surface, and among the plurality of leg portions projecting from the other axial end surface of the stator core, a part of the leg portion is straddled by the U-shaped portion, and the U-shaped portion is disposed on the stator core. A lead wire arranging step for arranging both side portions, and in a state where both side portions of the U-shaped portion are arranged on the stator core, a portion protruding from the other axial end surface of the stator core in each leg portion is bent in the circumferential direction. By forming, a bending in which a part of the bent portion of each leg portion is opposed to the both sides of the U-shaped portion on the outer side in the axial direction of the stator. And a forming step.

  According to the method for manufacturing a rotating electrical machine stator with lead wire according to the present invention, in the rotating electrical machine stator with lead wire having a segment coil, the structure for suppressing the vibration of the lead wire without generating an additional part for fixing the lead wire is provided. realizable.

It is a flowchart which shows each step in the manufacturing method of the rotary electric machine stator with a lead wire of embodiment which concerns on this invention. It is a schematic perspective view which shows the rotary electric machine stator with a lead wire manufactured by embodiment which concerns on this invention. FIG. 3 is a perspective view showing a state in which a one-phase segment coil is mounted on a stator core in the rotating electrical machine stator of FIG. 2. FIG. 3 is a schematic perspective view showing a first coil element formed by a segment coil for one phase in the rotating electric machine stator of FIG. 2. It is a figure which shows the state before mounting | wearing with a stator core in the conductor segment which comprises the segment coil contained in the rotary electric machine stator of FIG. In embodiment which concerns on this invention, it is a figure which sees the circumferential direction part of the stator in a conductor segment insertion step seeing from an outer diameter side to an inner diameter side. It is the figure seen from the upper part of FIG. In embodiment which concerns on this invention, in the lead wire arrangement | positioning step, it is the figure which looked at the circumferential direction part of the stator to the axial direction. In embodiment which concerns on this invention, it is a schematic diagram of the partial segment coil of the circumferential direction which shows that the circumferential direction length of the leg part which forms a crossover becomes smaller than the circumferential direction length of another leg part. In embodiment which concerns on this invention, it is a figure corresponding to the A section of FIG. 6 in a crossover preforming step. In embodiment which concerns on this invention, it is a figure corresponding to the A section of FIG. 6 in a bending formation step. It is the figure seen from the upper part of FIG. FIG. 10 is a diagram corresponding to FIG. 8 in the lead wire placement step in another example of the embodiment according to the present invention. FIG. 13 is a view corresponding to FIG. 12 after the bending step in another example of the embodiment according to the present invention.

  Embodiments according to the present invention will be described below in detail with reference to the drawings. The shapes, quantities, and the like described below are illustrative examples and can be changed depending on the specifications of the rotating electrical machine stator. Below, the same code | symbol is attached | subjected and demonstrated to the same structure. The rotating electrical machine stator constitutes the rotating electrical machine in combination with a rotor fixed to the rotating shaft. The rotating electrical machine is used as a motor or a generator, or a motor generator having both functions of a motor and a generator. Below, when attaching a temperature sensor to a rotary electric machine stator, the case where the lead wire connected to a temperature sensor is fixed to a stator is demonstrated. The lead wire may be connected to an electrical component other than the temperature sensor.

  FIG. 1 is a flowchart showing each step in the method of manufacturing a rotating electrical machine stator 10 with lead wires (FIG. 2) of the present embodiment. The present embodiment is characterized by a method of arranging the lead wires 71 (FIG. 2). In particular, the manufacturing method of this embodiment includes a conductor segment insertion step (S10), a lead wire placement step (S12), and a bending step (S15) of the conductor segment 31 (FIG. 5). Then, as shown in FIGS. 6 and 8 to be described later, a part of the plurality of leg portions 32 protruding from the side opposite to the insertion direction by inserting the straight leg portions 32 of the conductor segments 31 into the slots 15 of the stator core 12. The lead wire 71 is disposed on the stator core 12 so as to straddle the wire. Thereafter, the plurality of leg portions 32 are bent in the circumferential direction. Therefore, the lead wire 71 can be fixed on the end face of the stator 10 by the leg portion 32 of the conductor segment 31.

  First, the configuration of the rotating electrical machine stator 10 with lead wire will be described, and then the manufacturing method of the rotating electrical machine stator 10 with lead wire will be described. Hereinafter, the rotating electrical machine stator 10 with lead wires is simply referred to as the stator 10. FIG. 2 is a schematic perspective view showing the stator 10. FIG. 3 is a perspective view showing the stator 10 with the U-phase segment coil 30 attached to the stator core 12. FIG. 4 is a schematic perspective view showing the first U-phase coil element 21 u formed by the U-phase segment coil 30 in the stator 10.

  The stator 10 includes a stator core 12, two stator cuffs 40, a U-phase coupling coil body 20u, a V-phase coupling coil body 20v, a W-phase coupling coil body 20w, which are three-phase coupling coil bodies, and a lead wire 71. Prepare. The three-phase coupling coil bodies 20u, 20v, and 20w constitute the stator coil 20 as a three-phase coil assembly as a whole.

  The stator core 12 is made of a magnetic material. The stator core 12 includes an annular yoke 13 and a plurality of stator teeth 14 projecting radially from the inner peripheral surface of the yoke 13. Stator core 12 has a plurality of slots 15 formed between adjacent stator teeth 14. Here, the “circumferential direction” refers to a circumferential direction around the central axis O of the stator 10. The “radial direction” refers to the radial direction orthogonal to the central axis O, and the “axial direction” refers to the axial direction of the stator 10.

  The two stator cuffs 40 are disposed on both axial end surfaces of the stator core 12 as shown in FIG. As shown in FIGS. 6 and 7 described later, the stator cuff 40 is formed by integrally connecting an outer annular portion 41, an inner annular portion 42, and a plurality of cuff teeth 43. The inner annular portion 42 is disposed inside the outer annular portion 41. The plurality of cuff sates 43 connect the circumferential positions of the outer annular portion 41 and the inner annular portion 42 radially. The stator cuff 40 has a plurality of cuff slots 44 which are holes formed by being surrounded by a cuff teeth 43 adjacent in the circumferential direction, an outer annular portion 41 and an inner annular portion 42. The stator cuff 40 is used for assisting bending work of a conductor segment 31 (FIG. 5) constituting a segment coil 30 (FIG. 4) described later. FIG. 7 shows only one of the two stator cuffs 40, but the two stator cuffs 40 have the same shape.

  Of the three-phase coupling coil bodies 20u, 20v, and 20w, the U-phase coupling coil body 20u will be described first. As shown in FIGS. 3 and 4, the U-phase coupling coil body 20u is formed of a first U-phase coil element 21u on the power line side and a second U-phase coil element 22u on the neutral point side. As will be described later, the U-phase coil elements 21u and 22u are formed in substantially the same shape by connecting a plurality of segment coils 30 (FIG. 4) in an annular shape. A U-phase lead wire 23u provided at one end of the first U-phase coil element 21u is connected to a U-phase power line (not shown) on the power supply side. The other end of the first U-phase coil element 21u is connected to one end of the second U-phase coil element 22u via a connecting wire 38 (FIG. 11) described later. The connecting wire 38 is formed by a part of a conductor segment 31 (FIG. 5) described later. The other end of second U-phase coil element 22u is connected to a neutral point bus bar (not shown) as a neutral point of stator coil 20. One element coil constituting each U-phase coil element 21u, 22u corresponds to one segment coil 30. Each segment coil 30 is formed by connecting a plurality of conductor segments 31 (FIG. 5), which will be described later, in the radial direction.

  As shown in FIGS. 3 and 4, the first U-phase coil element 21 u has a plurality of segment coils 30 denoted by reference numerals C <b> 1, C <b> 2. The second U-phase coil element 22u has a plurality of segment coils 30 labeled C9, C10... C16. In the plurality of segment coils 30, C1, C2,... C16 are sequentially arranged from the power line connection side toward the neutral point connection side. In each U-phase coil element 21u, 22u, the plurality of segment coils 30 are arranged at a plurality of positions in the circumferential direction of the stator core 12.

  Each segment coil 30 is bent at one end or the other end of a plurality of U-shaped conductor segments 31 (FIG. 5) so as to protrude outward from the other axial end of the stator core 12 (upper end in FIG. 3). Then, the end portions of the bent portions are joined together by welding. Each segment coil 30 is wound around the plurality of stator teeth 14 in a state in which a part of the segment coils 30 is inserted into the two slots 15 that are separated in the circumferential direction across the plurality of slots 15 in the stator core 12.

  In the operation of forming each segment coil 30, first, a plurality of U-shaped conductor segments 31 shown in FIG. 5 are prepared. Each conductor segment 31 has two leg portions 32 that are parallel to each other, and a connecting portion 33 that connects one end of each leg portion 32 and is formed in a mountain shape. Each conductor segment 31 is formed by covering an intermediate portion in the length direction of a conductor wire 34 having a rectangular shape with a rectangular cross section with an insulating film 35 and exposing both ends of the conductor wire 34 from the insulating film 35. .

  The conductor segments 31 are inserted into the two slots 15 in a state where a plurality of conductor segments 31 are arranged in the radial direction from one axial end side (lower end side in FIG. 3) of the stator core 12. In addition, the leg portions 32 of the conductor segments 31 forming the segment coils 30 are inclined with respect to the axial direction so that the portions protruding outward from the other axial end surface (upper end surface in FIG. 3) of the stator core 12 approach each other. It is bent and formed.

  The tip of the bent portion of the conductor segment 31 is further bent so as to extend outward in the axial direction. And in the some conductor segment 31, the front-end | tip part extended in the axial direction of the conductor segment 31 of the same phase adjacent to radial direction is joined and connected by welding, such as TIG welding. As a result, the plurality of conductor segments 31 are connected to each other by bending portions protruding outward from the other axial end of the stator core 12. The stator cuff 40 is used when the leg portion 32 of the conductor segment 31 is bent as will be described later.

  As shown in FIG. 4, the first U-phase coil element 21 u is formed in an annular shape by connecting the ends of the plurality of segment coils 30. In FIG. 4, the segment coils 30 adjacent in the circumferential direction have their winding directions opposite to each other in the current direction. Similarly to the first U-phase coil element 21u, the second U-phase coil element 22u (FIG. 3) is also formed in an annular shape by connecting the end portions of the plurality of segment coils 30. In each of the U-phase coil elements 21u and 22u, the leg portions 32 of the respective segment coils 30 are inserted into the plurality of slots 15 while being shifted to one side in the circumferential direction by one slot 15.

  3 and 4, a segment coil 30 indicated by C8 and disposed at the other circumferential end of the first U-phase coil element 21u, and indicated by C9 and disposed at one circumferential end of the second U-phase coil element 22u. The segment coil 30 is connected via a crossover wire 38 by welding. Thereby, the U-phase coupling coil body 20u is formed. A U-phase lead wire 23u is formed by a radially outer leg 32 of the segment coil 30 that is indicated by C1 and is arranged at one circumferential end of the first U-phase coil element 21u.

  The V-phase coupling coil body 20v and the W-phase coupling coil body 20w (FIG. 2) are also configured similarly to the U-phase coupling coil body 20u. Similarly to the U-phase coupling coil body 20u, the segment coil 30 arranged at one end in the circumferential direction of the V-phase coupling coil body 20v and the W-phase coupling coil body 20w also has a V-phase lead wire 23v and a W-phase lead wire 23w. Are formed respectively. V-phase lead wire 23v and W-phase lead wire 23w are connected to a V-phase power line and a W-phase power line (not shown), respectively.

  Such a V-phase coupling coil body 20v is arranged so as to be wound around the plurality of stator teeth 14 while being shifted to one side in the circumferential direction by two slots 15 with respect to the U-phase coupling coil body 20u. The W-phase coupling coil body 20w is further shifted from the V-phase coupling coil body 20v by one of the two slots 15 toward one side in the circumferential direction, and is arranged to be wound around the plurality of stator teeth 14.

  Such multiple-phase connecting coil bodies 20u, 20v, 20w are connected by a neutral bus bar (not shown) to form the stator coil 20. The stator coil 20 includes two coil ends 36 and 37 that protrude outward from both axial ends of the stator core 12.

  A lead wire 71 is disposed and fixed between a part of the stator coil 20 in the circumferential direction and the stator core 12. The lead wire 71 has a U-shaped portion 72 bent into a U-shape, and is connected to the temperature sensor 70 (FIG. 2). The temperature sensor 70 is composed of, for example, a thermistor. The lead wire 71 is formed by integrating two electric wires connected to the temperature sensor 70 into one. Furthermore, the temperature sensor 70 is fixed by being sandwiched between neutral point bus bars (not shown). The detection unit of the temperature sensor 70 detects the temperature of the stator coil 20 in contact with the neutral point bus bar. The detection signal of the temperature sensor 70 is transmitted to a control device (not shown) via the lead wire 71. The stator coil 20 and the lead wire 71 are fixed to the stator core 12 together with the stator cuff 40 by a varnish.

  Next, a method for manufacturing the stator 10 will be described with reference to FIGS. 1 and 6 to 12. First, a plurality of U-shaped conductor segments 31 are prepared in a state where two stator cuffs 40 are disposed on both axial end surfaces of the stator core 12. Then, as the conductor segment insertion step of S10 in FIG. 1, the straight leg portions 32 of the plurality of conductor segments 31 are moved from the one axial end side (lower end side in FIG. 6) of the stator core 12 to the slot 15 as shown in FIG. It is inserted and protruded from the other axial end surface (upper end surface in FIG. 6) of the stator core 12. At the time of insertion, the plurality of leg portions 32 are arranged in the radial direction (front and back direction in FIG. 6) in each slot 15. A portion closer to the distal end of each leg 32 is projected from the outer opening end of the cuffer slot 44 in the stator cuff 40 on the other axial end side (upper end side in FIG. 6) of the stator core 12 as a distal projecting portion 32a.

  The stator cuff 40 on the other axial end side of the stator core 12 may be disposed on the other axial end surface of the stator core 12 after the conductor segment insertion step. Moreover, the leg part 32 shown with a diagonal lattice in FIG.6, FIG.10, FIG.11 is a leg part for the crossover 38 (FIG. 9) formation. The crossover-forming leg portion 32 has a distal end side protruding portion 32 a that is shorter than the standard leg portion 32 for forming the segment coil 30. This is because, as will be described later, in order to form the segment coil 30, the standard leg portion 32 needs to be bent in the frequency dividing direction of three slots as shown in FIG. This is because the leg portion 32 may be bent in the frequency dividing direction of two slots. In the state after the conductor segment insertion step, as shown in FIG. 7, the tip side protruding portions 32 a of the leg portions 32 protrude in the axial direction of the stator core 12 from the outer opening end of the cuffer slot 44.

  As shown in FIG. 7, in the slot 15 in the circumferential portion of the stator core 12, in the slot 15 in which the connecting wire forming leg 32 is disposed, the sandy ground B is formed on the outer diameter side of the connecting wire forming leg 32. As shown in FIG.

  Next, the leg radial expansion step of S11 in FIG. 1 is performed. In the leg radial expansion step, each pair adjacent in the radial direction is considered in consideration of the tip-side protruding portions 32a of a plurality of pairs of legs 32 that are adjacent to each other in each slot 15 from the inner diameter side toward the outer diameter side. A part of the tip side protruding portion 32a is bent to the outer diameter side so that a gap is formed between them. As a result, the full width in the radial direction of the plurality of tip side protrusions 32a is expanded. For this reason, as shown in FIG. 8, a gap in the radial direction indicated by a diagonal lattice is formed between each set. By forming the gap as described above, when the segment coil 30 is formed as shown in FIG. 11 to be described later, one turn of the segment coil 30 is used as a turn portion, and an insulation distance is provided between the turn portions in the radial direction. Can be easily secured.

  Next, as a lead wire arranging step of S12 in FIG. 1, as shown in FIG. 8, a lead wire 71 is formed in the vicinity of the stator cuff 40 with the tip side protruding portions 32a in the circumferential direction of the plurality of tip side protruding portions 32a. The U-shaped part 72 is straddled. Then, linear portions 72 b on both sides of the U-shaped portion 72 are arranged on the stator core 12. The folded portion 72a of the U-shaped portion 72 is disposed near the inner periphery of the stator core 12 in the arrangement state of the straight portion 72b. The U-shaped portion 72 may be hooked while being in contact with the leg portion 32, but the U-shaped portion 72 may be disposed on the stator core 12 with a gap between the U-shaped portion 72 and the leg portion 32.

  Then, as shown in FIGS. 2 to 4, as the lead wire bending step of S <b> 13 in FIG. 1, the outer opening end of the cuff slot 44 of the stator cuff 40 is formed by the leg portions 32 for forming the lead wires 23 u, 23 v, 23 w of each phase. The part protruding from the outer diameter side is bent at a substantially right angle. Then, the end portion of the leg portion 32 is bent at a substantially right angle so as to extend outward in the axial direction of the stator 10 (S13).

  Next, the crossover preforming step of S14 in FIG. 1 is performed. First, the crossover line 38 (FIG. 9) will be described. FIG. 9 is a partial circumferential view showing that the circumferential length d2 of the crossover-forming leg 32 is smaller than the circumferential length d3 of another standard leg 32 in the present embodiment. It is a schematic diagram of the segment coil 30.

  Referring to FIGS. 3, 4, and 9, the U-phase coupling coil body 20 u will be described by using two coil elements 21 u and 22 u formed in an annular shape via a crossover line 38. It is formed by connecting. Specifically, the C8 segment coil 30 located at the other circumferential end of the first U-phase coil element 21u is connected to the C9 segment coil 30 located at one circumferential end of the second U-phase coil element 22u via the jumper wire 38. Connected to. The leg portions 32 on both sides of the segment coils 30 of C1 and C8 are respectively inserted into two slots 15 (FIG. 6) separated by 6 slots.

  The plurality of leg portions 32 on the opposite sides of the C1, C8 segment coils 30 located at both ends in the circumferential direction of the first U-phase coil element 21u are alternately inserted into the common slot 15 in the radial direction. In the leg portion 32 of the conductor segment 31 forming the C1 and C8 segment coils 30, the joining end portion 32b, which is the distal end portion of the distal end side protruding portion 32a, is separated by 3 slots from both ends at the respective circumferential center positions. Arranged. At the joining end portion 32b, the conductor wire 34 is exposed from the insulating film 35 as shown in FIG.

  On the other hand, the C9 segment coil 30 is arranged so as to be shifted in one slot 15 frequency division direction (to the right in FIG. 9) with respect to the C1 segment coil 30. The connecting wire 38 is formed by bending the tip side protruding portion 32a toward the C8 segment coil 30 side at the leg 32 at one end in the circumferential direction (the right end in FIG. 9) of the conductor segment 31 forming the C9 segment coil 30. Is done. The crossover wire 38 is joined by welding to the joining end portion 32b of the distal end side protruding portion 32a of the C9 segment coil 30 to connect the C8 and C9 segment coils 30 together. Thus, the circumferential length of the crossover line 38 is two slots. For this reason, the circumferential direction length d2 of the crossover wire 38 is shorter than the circumferential direction length d3 of the front end side protruding portion 32a of the standard leg portion 32. Therefore, as shown in FIG. 11, even if the intermediate portion of the tip-side protruding portion 32a is bent at a substantially right angle with respect to the axial direction in the leg portion 32 for forming the crossover line indicated by the diagonal lattice, Does not interfere with the legs 32 of the

  In the crossover preforming step of S14, in a state where the joining end portion 32b of the leg portion 32 for forming the crossover wire 38 is inserted into the hole of the crossover wire rotating jig (not shown) arranged on the upper side of FIG. The connecting wire rotating jig is rotated in one direction (in the direction of arrow P in FIG. 10) for one slot 15 minutes. As a result, the tip side protruding portion 32a of the leg portion 32 for forming the crossover 38 is twisted in the circumferential direction to be bent. In FIG. 10, among the leg portions 32, the leg portion 32 at the outermost radial end is indicated by a solid line, and the leg portion 32 that is shifted to the inner diameter side from the leg portion 32 at the outermost radial direction is indicated by a two-dot chain line. ing.

  Next, the bend forming step of S15 in FIG. 1 is performed. In the bend forming step, with the both side portions of the U-shaped portion 72 of the lead wire 71 disposed on the stator core 12, the distal end side protruding portions 32a of the leg portions 32 including the connecting wire forming leg portions 32 are surrounded. Bend in the direction. Accordingly, as shown in FIGS. 11 and 12, a part of the bent portion of each leg portion 32 faces the both sides of the U-shaped portion 72 outward in the axial direction of the stator 10. As a result, the lead wire 71 can be sandwiched and fixed between the leg portion 32 and the stator core 12. In addition, it is good also as a structure which the lead wire 71 is separated without contacting the leg part 32.

  Further, in the bending formation step, the tip side protruding portion 32a of the leg portion 32 of the conductor segment 31 is bent and formed on the upper surface of the cuff satice 43 on the curved surface portion having a circular arc shape at both ends in the circumferential direction. In the bending formation step, each tip-side protruding portion 32a is twisted and bent by three slots in one circumferential direction or the other circumferential direction by a rotating jig (not shown) arranged on the upper side of FIGS. . The rotating jig includes a first rotating element that twists each tip side protruding portion 32a to one side in the circumferential direction and a second rotating element that twists each tip side protruding portion 32a to the other side in the circumferential direction. Are rotatably arranged to have the same central axis. In a state where the joining end portion 32b of each distal end side protruding portion 32a is inserted into the hole of each rotating element, each rotating element rotates to twist each distal end side protruding portion 32a.

  Thus, in a state where the joining end portion 32b extends in the axial direction, the stator core 12 side portion is bent in the circumferential direction so as to be inclined with respect to the axial direction with respect to the joining end portion 32b of each distal end side protruding portion 32a. The In the bending formation step, among the plurality of tip side protrusions 32a, the tip end side protrusion 32a at the radially outermost end is bent by three slots in the other direction (the direction of arrow Q1 in FIG. 11). Further, since the connecting wire forming leg 32 is bent in advance in one direction (in the direction of arrow P in FIG. 10) by the connecting wire pre-forming step shown in FIG. 10, the arrow in FIG. As shown by Q2, it is bent by two slots in the other direction. For example, regarding the angle around the central axis of the stator, when 6 slots are 45 °, 3 slots are 22.5 ° and 2 slots are 15 °. Then, as shown in FIG. 11, in the leading end side protruding portion 32a of the crossover-forming leg portion 32, the gap between the joining end portion 32b and the vicinity of the stator cuff 40 is abruptly made substantially perpendicular to the axial direction. To be bent. For this reason, relatively large spaces T1 and T2 are formed on both ends in the circumferential direction in the vicinity of the stator cuffer 40 at the distal end side protruding portion 32a of the leg portion 32 for forming the crossover wire 38.

  And as a welding step, the stator coil 20 including the plurality of segment coils 30 is formed by joining two joining ends 32b in the radial direction as a set by welding such as TIG welding (S16). .

  Finally, as a varnish fixing step, the stator coil 20 is impregnated with the varnish to fix the stator coil 20, the stator cuff 40 and the U-shaped portion 72 of the lead wire 71 to the stator core 12 with the varnish (S17). In the varnish fixing step, the axial direction of the stator core 12 is aligned with the vertical direction, and one of the two coil ends 36 and 37 is disposed on the upper side. In this state, varnish is dropped from above. The varnish is impregnated on one side in the axial direction of the stator coil 20 by dropping the varnish. Thereafter, the stator core 12 is turned upside down, and the varnish is similarly dropped from above with the other coil end 37 disposed on the upper side. Thus, the varnish is impregnated on the other axial side of the stator coil 20.

  Then, the varnish is cured by keeping the stator coil 20 warm with a heat retaining device (not shown). Accordingly, the stator coil 20, the stator cuff 40, and the U-shaped portion 72 of the lead wire 71 are fixed to the stator core 12 by the varnish, whereby the stator 10 is formed.

  According to the method for manufacturing the stator 10, the U-shaped portion 72 of the lead wire 71 is disposed between the stator core 12 and the stator coil 20. For this reason, in the stator 10 having the segment coil 30, it is possible to realize a structure that suppresses the vibration of the lead wire 71 without generating an additional part for fixing the lead wire 71. Moreover, since the U-shaped portion 72 is fixed to the stator core 12 by the varnish, the vibration of the lead wire 71 can be further suppressed. Therefore, since there are no additional parts, the weight and manufacturing cost can be reduced. Moreover, the cost required for development of additional parts can be omitted. The varnish fixing step may be omitted. Even when the lead wire is not fixed by the varnish, the movement of the U-shaped portion 72 is restricted by the stator core 12 and the stator coil 20, so that the vibration of the lead wire 71 can be suppressed. Further, the stator cuff 40 may be omitted, and a cuff may be used as a bending jig when the leg 32 is bent.

  In addition, when the U-shaped portion 72 is disposed so as to be hooked on the leg portion 32 of the conductor segment 31, the vibration of the lead wire 71 can be further suppressed. The lead wire placement step (S12) shown in FIG. 1 is performed after the radial extension step (S11) of the legs 32. In the radial expansion step, the leg portion 32 is not bent in the circumferential direction, so that no inconvenience occurs even if the lead wire placement step is performed after the radial expansion step. Of course, the lead wire placement step may be performed before the radial expansion step.

  On the other hand, a comparative example is also conceivable in which the step of placing the lead wire 71 between the stator core 12 and the stator coil 20 is performed after the bending forming step of S15 shown in FIG. However, in this comparative example, when the lead wire 71 is arranged on the stator core 12, it is necessary to push the lead wire 71 while spreading the leg portion 32 of the conductor segment 31 constituting the stator coil 20. Large stresses can occur. In this embodiment, generation of such an unnecessary large stress can be prevented.

  FIG. 13 is a diagram corresponding to FIG. 8 in the lead wire placement step in another example of the present embodiment. FIG. 14 is a diagram corresponding to FIG. 12 after the bending step in this example.

  In the manufacturing method of this example, in the lead wire arranging step (S12) shown in FIG. 1, the tip side protrusion 32a in the circumferential direction is second and third from the radially outermost end as shown in FIG. The folded portion 72a of the lead wire 71 is inserted into the gap between the leading end side protruding portion 32a. Then, both side portions of the U-shaped portion 72 are disposed on the stator cuffs 40.

  Thus, in the state after the bending step (S15) shown in FIG. 1, the U-shaped portion 72 is disposed between the stator coil 20 and the stator core 12, as shown in FIG.

  According to the configuration of this example, the lead wire 71 can be shortened as compared with the configuration of FIGS. Further, the folded portion 72 a of the U-shaped portion 72 is not disposed near the inner periphery of the stator core 12. For this reason, it is possible to more easily realize a configuration in which interference between a rotor (not shown) disposed on the inner diameter side of the stator 10 and the lead wire 71 is prevented. Other configurations and operations are the same as those in FIGS. 1 to 12.

  As a second example of another manufacturing method, the lead wire placement step shown in S12 in FIG. 1 is replaced with the crossover preforming step in S14 and the bending step in S15 as shown by (α) in FIG. You may go between. In the lead wire arranging step, as shown by a broken line β in FIG. 10, the folded portion of the lead wire 71 is formed in the gap between the leg portion 32 for forming the crossover wire 38 (FIG. 11) and the leg portion 32 adjacent to the inner diameter side. The U-shaped part 72 is disposed on the stator cuff 40 while inserting the 72a. The gap for inserting the folded portion 72a corresponds to the oblique lattice portion indicated by C in FIG. After the jumper wire pre-forming, even if the tip side protruding portion 32a of the leg 32 for forming the jumper wire 38 is bent in the direction of arrow P in FIG. 10, relatively large spaces are formed on both sides in the circumferential direction. The For this reason, the U-shaped part 72 can be easily arranged around the tip side protruding part 32a.

  1 is performed, a part of the stator coil 20 is arranged on the outer side in the axial direction of both side portions in the U-shaped portion 72 at the position indicated by the broken line β in FIG. As described in the configuration of FIGS. 1 to 12, relatively large spaces T <b> 1 and T <b> 2 (FIG. 1) are formed on both sides in the circumferential direction near the stator cuff 40 in the leading end side protruding portion 32 a for forming the connecting wire 38. . For this reason, the U-shaped portion 72 can be easily disposed between the stator core 12 and the stator coil 20. Other configurations and operations are the same as those in FIGS. 1 to 12.

  In the configuration of this example, the lead wire placement step may be performed before the crossover wire preforming step indicated by S14 in FIG. Thereby, the U-shaped portion 72 can be arranged at the position indicated by the broken line γ in FIG.

  DESCRIPTION OF SYMBOLS 10 Rotating electrical machine stator with stator (stator), 12 stator core, 13 yoke, 14 stator teeth, 15 slots, 20 stator coil, 20u U-phase coupling coil body, 20v V-phase coupling coil body, 20w W-phase coupling coil body, 21u First U-phase coil element, 22u Second U-phase coil element, 23u U-phase lead wire, 23v V-phase lead wire, 23w W-phase lead wire, 24 radial direction portion, 25 axial direction portion, 30 segment coil, 31 conductor segment, 32 Leg part, 32a Tip side protruding part, 32b Joining end part, 33 Connecting part, 34 Conductor wire, 35 Insulating film, 36, 37 Coil end, 38 Crossover, 40 Stator cuff, 41 Outer annular part, 42 Inner annular part , 43 cuff satis, 44 cuffs slot, 70 temperature sensor, 7 1 Lead wire, 72 U-shaped part, 72a Folded part, 72b Straight part.

Claims (1)

A plurality of teeth projecting radially from the inner peripheral surface of the annular yoke, a stator core having a plurality of slots formed between the adjacent teeth, and a plurality of segments wound around the plurality of teeth. A stator coil including a coil, wherein the segment coil is formed by connecting a plurality of conductor segments;
A method of manufacturing a rotating electrical machine stator with a lead wire comprising a lead wire having a U-shaped portion disposed between the stator coil and the stator core,
An insertion step of inserting straight leg portions in the plurality of conductor segments into the slot from one axial end side of the stator core and projecting from the other axial end surface of the stator core;
A lead wire arrangement in which a part of the leg portions of the plurality of leg portions protruding from the other axial end surface of the stator core is straddled by the U-shaped portion, and both side portions of the U-shaped portion are arranged on the stator core. Steps,
In a state where both side portions of the U-shaped portion are disposed on the stator core, each leg portion is formed by bending a portion protruding from the other axial end surface of the stator core in the circumferential direction. And a bending step of making a part of the bent portion of each leg portion face the outside of the stator in the axial direction of the stator.

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