JP2016092971A - Method of manufacturing stator winding, stator winding, stator, and rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a stator winding that can increase a coil occupation rate, the stator winding, a stator, and a rotary electric machine.SOLUTION: A method of manufacturing a stator winding includes: a winding process (S1) of winding a continuous conductor wire as many times as N rounds; a coil end part molding process (S2) of molding a plurality of coil end parts, projecting from an end face of a stator icon core while not housed in a slot, of the conductor wire of the N rounds wound in the winding process by using a plurality of molding tools arranged on a circumference; and a three-dimensional molding process (S3) of carrying out circular molding for molding the conductor wire circularly by moving all the molding tools radially with the coil end parts retained by the molding tools and slot housing part molding for molding a plurality of slot housing parts to be housed in the slot by moving adjacent molding tools axially in mutually opposite directions simultaneously in parallel wholly or partially. A coil occupation rate can be increased because of the three-dimensional molding.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a stator winding wound around a plurality of slots provided in a stator core, a stator winding, a stator, and a rotating electrical machine.

  Conventionally, an example of a technique related to a manufacturing method of a circumferentially-deployed stator coil in which an insulation covering conductor wire is bent to alternately produce a slot accommodating conductor portion and a coil end conductor portion has been disclosed (see, for example, Patent Document 1). According to this technique, after arranging at least three mold pairs, the mold pairs are moved in a direction approaching each other to form a coil end conductor portion, and the mold pairs are moved in the longitudinal direction of the insulated conductor wire. The operation of moving in the longitudinal direction of the insulation-coated conductor wire while moving in the direction perpendicular to the direction is performed simultaneously with the operation of forming the slot accommodating conductor portion.

JP 2009-194994 A

  However, the technique described in Patent Document 1 is a method of forming a slot accommodating conductor portion by bending an insulation coated conductor wire at a right angle mainly using a mold pair (upper mold and lower mold). Therefore, the coil end conductor portion needs to be formed in a process separate from the formation of the slot accommodating conductor portion. Therefore, there is a problem that man-hours and time are required for forming the stator winding.

  In the technique described in Patent Document 1, the insulation-coated conductor wire is moved in the longitudinal direction and the slot accommodating conductor portion is molded by a mold pair. If the slot accommodating conductor portion is formed so that the insulation-coated conductor wire has a plurality of turns, an error in the coil pitch (interval of the slot accommodating conductor portion) is accumulated even if the manufacturing is performed within the manufacturing tolerance range. . Further, when the insulation-coated conductor wire formed with the slot accommodating conductor portion and the coil end conductor portion is wound so as to be accommodated in the slot, the slot accommodating conductor portion and the coil end conductor portion are already formed. Internal stress is generated in the insulated coated conductor wire. Due to the accumulated error of the coil pitch and the influence of internal stress, the plurality of slot-accommodating conductor portions accommodated in the same slot have a considerable shift in the circumferential direction. Therefore, it is necessary to provide a clearance between the slot accommodating conductor and the slot inner surface in consideration of the circumferential displacement of the slot accommodating conductor. Therefore, there is a problem that the coil space factor occupied by the coil (slot accommodating conductor) in the slot is low.

  The present invention has been made in view of these points, and a first object is to increase the coil space factor. The second purpose is to reduce the man-hours and time required for forming the stator winding.

  A first invention made to solve the above problems is a method of manufacturing a stator winding that is wound around a plurality of slots provided in a stator core. Is an integer greater than or equal to 2) a winding step for winding, and a plurality of coil end portions protruding from the end face of the stator core without being accommodated in the slot, with respect to the conductor wire for N turns wound by the winding step A coil end portion forming step of forming using a plurality of forming dies arranged on the circumference, and all the forming dies in the radial direction (specifically, with the coil end portion held by the forming die) To the slot) by moving the adjacent forming dies in the axial direction (or up and down direction) and in the opposite directions to each other. Contained And having a three-dimensional molding process of performing that a plurality of slot portions all or a slot portion molding for molding a part concurrently.

  According to this configuration, a plurality of coil end portions are formed by the coil end portion forming step, and a plurality of slot accommodating portions are formed by the three-dimensional forming step in the N circumference conductor wires wound by the winding step. The Since the stator winding is manufactured in three steps, the man-hours and time required for forming the stator winding can be reduced. In the three-dimensional forming process, the circular forming and the slot accommodating portion forming are simultaneously performed in a state where the coil end portion is held by the forming die. Therefore, since the circular molding and the slot accommodating portion molding are simultaneously performed, the circumferential displacement of the slot accommodating portion accommodated in the slot can be minimized, the clearance can be reduced, and the coil space factor can be reduced. Can be increased.

  According to a second aspect of the present invention, one or more slot accommodating portions wound around a plurality of slots provided in the stator core and accommodated in the slots, and projecting from the stator core not accommodated in the slots In the stator winding having one or more coil end portions, the coil end portion is bent so that the slot accommodating portion continuous with the end portion of the coil end portion is accommodated in the slot of the same layer. 1st crank part and 2nd crank part, or the 1st crank part and 2nd crank part which are bent so that the slot accommodating part which follows the end of the coil end part may be accommodated in the slot of a different layer. The boundary between the coil end portion and the slot accommodating portion is linearly arranged in the radial direction for N circumferences (N is an integer of 2 or more).

  According to this configuration, in the stator winding for N turns, the boundary between the coil end portion and the slot accommodating portion is arranged linearly in the radial direction. Therefore, the circumferential displacement of the slot accommodating portion accommodated in the slot can be suppressed to a minimum, the clearance can be reduced, and the coil space factor can be increased.

  According to a third aspect of the present invention, in the stator, the stator winding manufactured by the method of manufacturing a stator winding according to any one of claims 1 to 3, or the stator winding according to claim 4 Among these, one or more stator windings are wound around the slot.

  According to this configuration, it is possible to provide a stator that can increase the coil space factor.

  According to a fourth aspect of the present invention, in the rotating electrical machine, the stator according to claim 5 and a rotor are provided.

  According to this configuration, since the stator that increases the coil space factor is provided, it is possible to provide a rotating electrical machine with improved performance if it has the same physique.

  The “stator winding” is also called “stator coil” or “coil”. “Conductor wire” may be of any cross-sectional shape regardless of whether or not the conductive material (wire material) is covered with an insulating film. The “layer” is a layer (circulation) of the stator winding (slot accommodating portion) accommodated in the slot. For example, the number of layers increases from the inner diameter side to the outer diameter side by one layer, two layers, three layers,..., Or increases from the outer diameter side to the inner diameter side by one layer, two layers, three layers,. Although the “number of layers” that is the number of layers depends on the shape (size) of the slot, an arbitrary number may be set. The “simultaneous parallel” between the circular molding and the slot housing portion molding includes not only the entire molding period in the three-dimensional molding process but also a part of the period. “Winding” is also called “winding” or “winding”. The “rotary electric machine” is arbitrary as long as it is a device having a rotating part (for example, a shaft or a shaft). For example, a generator, a motor, a motor generator, and the like are applicable. The “coil space factor” is the ratio of the area occupied by the stator winding (specifically, the slot accommodating portion) in the slot.

It is a flowchart figure which shows an example of the manufacturing process of a stator winding | coil. It is a perspective view which shows an example of a winding process typically. It is a perspective view which shows an example of a wound body typically. FIG. 4 is an enlarged plan view showing an IV part shown in FIG. 3. It is a perspective view which shows typically an example of a coil end part shaping | molding process. It is a top view which shows the example of a relationship between a shaping | molding die and a conductor wire (wound body). It is a perspective view which shows an example of a three-dimensional shaping | molding process typically. It is a graph which shows the example of movement control of a shaping | molding die. It is a perspective view which shows the state at the time of shaping | molding completion. It is a perspective view which shows the boundary of a coil end part and a slot accommodating part. It is a perspective view which shows an example of a molded object. It is a top view which shows an example of a molded object. It is a perspective view which expands and shows the XIII part shown in FIG. It is the side view seen from the XIV direction shown in FIG. It is a top view which shows the example accommodated in the slot of a stator core. It is a perspective view which expands and shows the XVI part shown in FIG. It is the side view seen from the XVII direction shown in FIG. It is a top view which shows the example accommodated in the slot of a stator core. It is a perspective view which shows typically the process in which a molded object is bundled. It is a perspective view which shows typically the process in which a molded object is bundled. It is a perspective view which shows typically the process in which a molded object is bundled. It is a perspective view which shows typically the process in which a molded object is bundled. It is a perspective view which shows typically the state which bundled the some molded object. It is a perspective view which shows typically the structural example of a stator winding | coil. It is a perspective view which shows the structural example of a stator typically. It is a top view which shows typically the structural example of a stator. It is a top view which shows typically the state of the stator winding | winding accommodated in a slot. It is a schematic diagram which shows the structural example of a rotary electric machine.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. Note that unless otherwise specified, “connecting” means electrically connecting. Each figure shows elements necessary for explaining the present invention, and does not necessarily show all actual elements. When referring to directions such as up, down, left and right, the description in the drawings is used as a reference. The alphabetic character of the sign means different elements in upper case and lower case. For example, the molding die 14A and the convex molding member 14a shown in FIG. 5 are separate elements. “Outer diameter side” means the outer side or outer peripheral side in the radial direction, and “inner diameter side” means the inner side or inner peripheral side in the radial direction.

  The stator winding manufacturing process shown in FIG. 1 includes a winding step (S1), a coil end portion forming step (S2), a three-dimensional forming step (S3), and the like. For the sake of clarity, the stator winding is referred to as a conductor wire 12, a wound body 13, a molded body 15, a winding body 17, a stator winding 18 and the like depending on the process. Below, each process is demonstrated easily.

(Wounding step; S1)
In the winding step, the continuous conductor wire 12 is wound in a spiral shape (spiral shape) by N turns along the arrow D1 direction using the winding device 11 shown in FIG. When winding, take into account the amount of springback to return to the original shape. The conductor wire 12 may be cut in advance with a length corresponding to N turns, or may be cut after winding N turns. N as the number of turns may be arbitrarily set as an integer of 2 or more.

  In this embodiment, a flat wire having a rectangular cross section is applied to the conductor wire 12. Three turns (N = 3) are applied as the number of turns. The number of stator windings 18 (conductor wires 12) accommodated in slots 16b shown in FIG. 27A described later, that is, the number of layers M is 6 (M = 6). The number of layers M may be set to an even number. Therefore, the relationship between the number of turns N and the number of layers M satisfies N = M / 2.

  The conductor wire 12 wound around N turns by the winding device 11 is referred to as a “winding body 13”. The wound body 13 has a circular shape with a radius R2 from the center Pc as shown in FIG. 3, and a gap G is provided in the radial direction between the conductor wires 12 as shown in FIG. The radius R2 may be set arbitrarily.

(Coil end part forming step; S2)
In the coil end portion forming step, the coil end portion is formed on the wound body 13 using a plurality of forming dies 14 provided in the forming apparatus. The number of molds 14 may be arbitrarily set according to the number of target coil end portions. In this embodiment, as shown in FIG. 5, 16 sets of molds 14 arranged radially are used. Each set of molding dies 14 is composed of a convex molding member 14a and a concave molding member 14b of a pair of molds, and as shown in FIG. 6, a coil is wound around the wound body 13 (N conductor wires 12). The end part is molded at the same time. The convex molding member 14a has a convex surface for molding. The concave molding member 14b has a concave surface to be molded. The convex shaped member 14a and the concave shaped member 14b are engaged with each other, and a coil end portion 15d (see FIGS. 13 and 16) is formed on the wound body 13.

  The plural sets of molds 14 used in this embodiment include two types of molds 14 having different molding surface shapes. One type is a forming die 14 for forming a shape (see FIG. 13) in which the slot accommodating portions 15a continuous at both ends of the coil end portion 15d are the same layer (L layer). Another type is a forming die 14 for forming a shape (see FIG. 16) in which the slot accommodating portions 15a continuous at both ends of the coil end portion 15d form different layers (L layer and L ± 1 layer). Note that L indicating a layer is a natural number, and when the radix is “1”, L ± 1> 0 is satisfied.

(Three-dimensional molding process; S3)
In the three-dimensional forming process, the circular forming and the slot accommodating portion forming are simultaneously performed in parallel with the coil end portions 15d formed by the plurality of sets of forming dies 14 being held. Simultaneous parallelism may be performed entirely or partially in the three-dimensional forming process. In short, the wound body 13 may be formed into a circular shape by a three-dimensional forming process, and the plurality of slot accommodating portions 15a may be formed.

  Circular molding is molding in which all the molding dies 14 shown in FIG. 5 are moved in the radial direction (moving in the radial direction Dc shown in FIG. 7) to deform the wound body 13 into a circular shape. The radial direction Dc is a direction toward the center Pc shown in FIG. The slot accommodating portion molding is a molding in which a plurality of slot accommodating portions 15a (see FIGS. 13 and 16) accommodated in the slots 16b (see FIGS. 15 and 18) are moved in the axial direction. The axial movement is a movement in which the adjacent molds 14 are in the axial direction and in opposite directions. In the case of molding dies 14A and 14B shown as an example of the molding die 14 in FIG. 7, the molding die 14A is moved in the arrow Du direction, and the molding die 14B is moved in the arrow Dd direction. The arrow Du direction and the arrow Dd direction are opposite to each other in the axial direction.

  In order to execute the three-dimensional molding process, the molding apparatus moves the characteristic line CL shown in FIG. 8 along all the molding dies 14 along the arrow D2. In FIG. 8, the relative movement distance between adjacent molds 14 is taken as the vertical axis, and the distance moved in the radial direction Dc is taken as the horizontal axis. As the vertical axis increases, the slot accommodating portion 15a is formed, and as the horizontal axis decreases, the wound body 13 is formed into a circular shape. When the three-dimensional forming step is executed, the wound body 13 becomes a circular shape having a radius R1, and a relative distance H1 is generated between the adjacent forming dies 14. The radius R1 may be arbitrarily set. For example, the radius R1 may be set according to the thickness (diameter) of the conductor wire 12, the size of the stator core 16, and the like. When the molding is completed, the molded body 15 shown in FIG. 9 is molded.

  Before the three-dimensional forming step, the adjacent forming dies 14 are separated from each other in the circumferential direction as shown in FIG. 5, but are not displaced in the axial direction. On the other hand, after performing the three-dimensional forming process, it becomes as shown in FIG. That is, all the molds 14 are contracted to a distance that sandwiches the molded body 15 and are arranged in a circumferential direction in a cylindrical shape. Adjacent molding dies 14 are alternately shifted in the axial direction by a relative distance H1 that only molds the slot accommodating portion 15a.

  Since the molded body 15 (N conductor wires 12) is molded by moving the molding die 14 as shown in FIGS. 7 and 8, a plurality of functions and effects can be obtained. 1stly, the molded object 15 has the high shape maintenance force which can maintain the shape | molded shape, and can suppress the internal stress which arises at the time of shaping | molding as much as possible. Therefore, after molding, the shape at the time of completion of molding is maintained including the time of conveyance. Secondly, as shown in FIG. 10, the boundary BD between the coil end portion 15d and the slot accommodating portion 15a is linearly arranged in the radial direction (front-rear direction in FIG. 10) with respect to the N conductor wires 12. In other words, the slot accommodating portion 15a is not easily displaced in the circumferential direction (the left-right direction in FIG. 10). Therefore, the slot 16b can be easily accommodated, and the clearance between the teeth 16a can be reduced.

  The molded body 15 manufactured by the above-described stator winding manufacturing process is shown in FIG. 11 in a perspective view and in FIG. 12 in a plan view. The molded body 15 includes a U-shaped molded portion 15A shown in FIGS. 13 to 15 and a U-shaped molded portion 15B shown in FIGS.

  The U-shaped forming portion 15A shown in FIG. 13 is formed such that the slot accommodating portions 15a extending from the coil end portion 15d are the same layer (L layer). That is, as shown in FIG. 14, the first crank part 15b provided at both ends of the coil end portion 15d is molded so that the bending direction (arrow D3 direction) is different from the bending direction of the second crank part 15c (arrow D4 direction). Is done. Therefore, as shown in FIG. 15, the slot accommodating portions 15 a of the U-shaped molded portion 15 </ b> A are accommodated in the same layer (L layer) of the slots 16 b in the stator core 16. The slot 16 b is a space secured between the teeth 16 a of the stator core 16.

  The U-shaped forming portion 15B shown in FIG. 16 is formed such that the slot accommodating portion 15a extending from the coil end portion 15d is a different layer (L layer and L ± 1 layer). That is, as shown in FIG. 17, the bending direction (arrow D5 direction) of the first crank part 15b provided at both ends of the coil end portion 15d is the same as the bending direction (arrow D5 direction) of the second crank part 15c. To be molded. Therefore, as shown in FIG. 18, the slot accommodating portions 15a of the U-shaped molded portion 15B are accommodated in different layers (L layer and L ± 1 layer) of the slots 16b.

(Example of stator winding production)
An example of manufacturing a multi-phase stator winding 18 (see FIG. 24) using a plurality of the molded bodies 15 described above will be described with reference to FIGS. In this embodiment, the plurality of phases are assumed to be three phases (U phase, V phase, W phase). The molded body 15 used as the U phase is referred to as “U phase molded body 15U”, the molded body 15 used as the V phase is referred to as “V phase molded body 15V”, and the molded body 15 used as the W phase is referred to as “W phase molded body 15W”. To do. The pitch P shown in FIGS. 20 and 21 is an interval corresponding to a predetermined number of slots (arbitrarily set to 1 or more). In this embodiment, an example in which the pitch P is “1” will be described.

  When the W-phase molded body 15W is overlapped on the U-phase molded body 15U shown in FIG. 19, the state shown in FIG. 20 is obtained. The U-phase molded body 15U and the V-phase molded body 15V are shifted by the pitch P. When the W-phase molded body 15W is further stacked on the U-phase molded body 15U and the V-phase molded body 15V shown in FIG. 20, the state shown in FIG. 21 is obtained.

  FIG. 22 shows a wound body 17A in which six U-phase molded bodies 15U, two V-phase molded bodies 15V, and two W-phase molded bodies 15W are bundled. FIG. 23 shows a winding body 17B in which 12 pieces are bundled by using four U-phase compacts 15U, four V-phase compacts 15V, and four W-phase compacts 15W. The winding body 17B is in a state in which the two sets of winding bodies 17A are displaced in the upper and lower two stages of FIG. That is, each set of winding bodies 17A has a gap G shown in FIG. When the two sets of winding bodies 17A are shifted so that the slot accommodating portion 15a, the coil end portion 15d, and the like are at the same position, the stator winding 18 shown in FIG. 24 is manufactured.

(Example of stator production)
When the multi-phase stator winding 18 described above is wound so as to be accommodated in the slot 16b of the stator core 16, the stator 19 (stator) shown in FIGS. 25 and 26 is manufactured. The stator core 16 is formed into a donut shape. There is no limitation on the method of accommodating the stator winding 18 in the slot 16b.

  A connection terminal 18t (terminal group) shown in FIG. 25 is an end of the stator winding 18 used for connection with an external device (for example, the control device 105 shown in FIG. 28). As shown in the figure, by concentrating the connection terminals 18t, connection to an external device can be easily performed.

  FIG. 27 shows the slot 16b of the stator 19 in which the stator winding 18 is accommodated. The number (number of layers M) of the stator windings 18 (conductor wires 12) accommodated in the slots 16b shown in FIG. 27 is 6 (M = 6). The stator winding 18 bundles a plurality of molded bodies 15 (see FIGS. 23 and 24), and each molded body 15 has a boundary BD between the coil end portion 15d and the slot accommodating portion 15a in the radial direction. It is difficult to shift in the circumferential direction along the straight line (see FIG. 10). Therefore, the clearance between the stator winding 18 and the teeth 16a can be reduced. As shown in FIG. 27A, since the slot width W1, which is the distance between the teeth 16a, can be reduced, the coil space factor can be increased.

  For comparison, an example in the case of applying the technique described in Patent Document 1 is shown in FIG. In the technique described in Patent Document 1, since the stator winding 18 is displaced in the circumferential direction, it is necessary to ensure a large clearance so as to avoid interference when accommodated in the slot 16b. Therefore, the slot width W2 must be larger than the slot width W1 (W2> W1), and the coil space factor is lower than that in the case of FIG.

(Manufacturing example of rotating electrical machine)
The rotating electrical machine 100 shown in FIG. 28 can be manufactured by assembling the stator 19 and the rotor 102 (rotor) described above into the housing 101. The rotating electrical machine 100 is an example of an inner rotor type motor generator.

  A rotating electrical machine 100 illustrated in FIG. 28 includes a housing 101, a bearing 103 (bearing), a rotating shaft 106, and the like in addition to the stator 19 and the rotor 102.

  The stator 19 includes the stator winding 18 manufactured as described above, the stator core 16, and the like. The rotor 102 is disposed on the inner diameter side of the stator 19 via a gap. The rotor 102 may be configured in any way as long as magnetic flux flows between the rotor 19 and the stator 19. The rotating shaft 106 is rotatably supported by the housing 101 via a bearing 103. The rotating shaft 106 is fixed to the rotor 102 or integrally formed with the rotor 102. In any case, the rotating shaft 106 and the rotor 102 rotate in cooperation. The housing 101 includes a frame, a housing, and the like, and may be formed with an arbitrary shape and material as long as it can accommodate the stator 19, the rotor 102, the rotating shaft 106, and the like.

  The control device 105 is a device that controls the rotation of the rotating electrical machine 100 (specifically, the rotating shaft 106), and corresponds to, for example, an ECU (Electronic Control Unit) or a computer. This control device 105 includes at least an inverter that converts electric power, and may further include a converter that converts voltage. The rotating electrical machine 100 (specifically, the connection terminal 18t shown in FIG. 25) and the control device 105 are connected by a connection line 104.

  Since the stator 19 included in the rotating electrical machine 100 has a high coil space factor, if the physique is the same, a large amount of magnetic flux flows, so that the performance can be improved.

[Other Embodiments]
Although the form for implementing this invention was demonstrated above, this invention is not limited to the said form at all. In other words, various forms can be implemented without departing from the scope of the present invention. For example, the following forms may be realized.

  In the embodiment described above, a rectangular wire is applied as the conductor wire 12 (see FIG. 2). Instead of this form, a conductor wire other than a rectangular wire may be applied. The other conductor wire corresponds to, for example, a round wire having a circular cross section (including an elliptical shape) or a litz wire formed by rolling a plurality of thin wires. Only the form of the conductor wire 12 is different, and the stator winding 18, the stator 19, and the rotating electrical machine 100 can be manufactured by the same process as that of the above-described embodiment. Therefore, the same effect as that of the above-described embodiment. Can be obtained.

  In the above-described embodiment, three windings (N = 3) are applied as the number of windings (N windings) around which the conductor wire 12 is wound in the winding process (see FIGS. 4 and 6). Instead of this form, an integer other than 3 and 2 or more may be applied. Since the number of turns is merely different and the stator winding 18, the stator 19, and the rotating electrical machine 100 can be manufactured by the same process as that of the above-described embodiment, the same effect as that of the above-described embodiment can be obtained. Can do.

  In the above-described embodiment, the wound body 13 is formed so as to form a circumferential shape having a radius R2 from the center Pc (see FIG. 3). Instead of this form, the wound body 13 may be formed in a shape other than the circumferential shape. Other shapes are, for example, elliptical or polygonal. Only the shape of the wound body 13 to be molded is different, and the stator winding 18, the stator 19, and the rotating electrical machine 100 can be manufactured by the same process as the above-described embodiment. Similar effects can be obtained.

  In the above-described embodiment, the stator core 16 is formed in a donut shape (cylindrical shape) (see FIGS. 25 and 26). Instead of this form, a plurality of divided core parts may be fixed. The divided iron core portion may be formed into a fan shape and fixed to form a donut shape (cylindrical shape) as a whole. There is no limitation on the method of fixing the divided core portion, and the presence or absence of a frame (fixed frame) is not limited. Since only the form of the stator core 16 is different, it is possible to obtain the same effects as the above-described embodiment.

  In the above-described embodiment, the rotary electric machine 100 is constituted by an inner rotor type motor generator (see FIG. 28). Instead of this form, the rotor 102 may be constituted by an outer rotor type motor generator disposed on the outer diameter side of the stator 19 via a gap. Not only the inner rotor type and the outer rotor type, but also a generator or an electric motor may be used. Since only the form of the rotating electrical machine 100 is different, it is possible to obtain the same function and effect as the above-described embodiment.

[Function and effect]
According to the embodiments described above and other embodiments, the following effects can be obtained.

  (1) In the method of manufacturing the stator winding 18, the winding step (S1) for winding the continuous conductor wire 12 for N turns, and the conductor wire 12 for N turns wound by the winding step are accommodated in the slot 16b. A coil end portion forming step (S2) for forming a plurality of coil end portions 15d protruding from the end face of the stator core 16 using a plurality of forming dies 14 arranged on the circumference, and a forming die 14. While the coil end portion 15d is held, all the forming dies 14 are moved in the radial direction to form the conductor wire 12 in a circular shape, and the adjacent forming dies 14 are axially connected to each other. A three-dimensional forming step (S3) in which a plurality of slot accommodating portions 15a accommodated in the slots 16b are moved in the opposite direction to form the slot accommodating portions 15a in parallel in whole or in part. And configured to include (FIGS. 1 to 3, 5, 7, 8, 9).

  According to the configuration of (1) above, a plurality of coil end portions 15d are formed by the coil end portion forming step, and a plurality of coil end portions 15d are formed by the three-dimensional forming step. A slot accommodating portion 15a is formed. Since the stator winding 18 is manufactured in three steps, the man-hours and time required for forming the stator winding 18 can be reduced. In the three-dimensional molding process, the circular molding and the slot housing part molding are performed in parallel while the coil end portion 15d is held by the molding die 14. Therefore, since the circular molding and the slot accommodating portion molding are simultaneously performed, the circumferential displacement of the slot accommodating portion 15a accommodated in the slot 16b can be minimized, and the clearance can be suppressed to be small and the coil space can be reduced. The rate can be increased.

  (2) The winding process is configured such that the conductor wire 12 is wound so that N = M / 2, where M is the number of stator windings 18 (conductor wire 12) accommodated in one slot 16b ( (Refer FIG. 4, FIG. 27 (A)). According to this structure, the accommodation in the slot 16b can be performed easily.

  (3) The three-dimensional molding process is configured to perform radial movement for performing circular molding and radial movement for performing slot housing portion molding along the characteristic line L1 (predetermined characteristic line) (FIG. 7). , See FIG. According to this structure, since it shape | molds in three dimensions, the shape maintenance force which can maintain the shape | molded shape is high, and the internal stress produced at the time of shaping | molding can be suppressed as much as possible. Therefore, after molding, the shape at the time of completion of molding is maintained including the time of conveyance. Further, the boundary BD between the coil end portion 15d and the slot accommodating portion 15a is not easily shifted in the circumferential direction along the radial direction of the N conductor wires 12 (see FIG. 10). Therefore, the slot 16b can be easily accommodated, and the clearance between the teeth 16a can be reduced.

  (4) In the stator winding 18, the coil end portion 15d includes a first crank portion 15b and a first crank portion 15b that are bent so that the slot accommodating portion 15a extending from the coil end portion 15d is accommodated in the slot 16b of the same layer (L). 2 crank part 15c (see FIGS. 13 to 15), or first crank part 15b bent so that slot accommodating part 15a extending from coil end part 15d is accommodated in slot 16b of a different layer (L ± 1) And the second crank portion 15c (see FIGS. 16 to 18), and the boundary BD between the coil end portion 15d and the slot accommodating portion 15a is arranged linearly in the radial direction for N circumferences (see FIG. 10, see FIGS. 25 and 26). According to this configuration, in the stator winding 18 for N circumferences, the boundary between the coil end portion 15d and the slot accommodating portion 15a is linearly aligned in the radial direction. Therefore, the circumferential displacement of the slot accommodating portion 15a accommodated in the slot 16b can be suppressed to a minimum, and the clearance can be reduced to increase the coil space factor.

  (5) In the stator 19, the stator winding 18 manufactured by the manufacturing method (S1 to S3) of the stator winding 18 or the stator winding 18 having the feature (4) above, The above stator winding 18 is configured to be wound around the slot 16b (see FIG. 18). According to this configuration, it is possible to provide the stator 19 that can increase the coil space factor.

  (6) The rotating electrical machine 100 is configured to include the stator 19 and the rotor 102 (see FIG. 27). According to this configuration, since the stator 19 that increases the coil space factor is provided, the rotating electrical machine 100 with improved performance can be provided with the same physique.

DESCRIPTION OF SYMBOLS 12 Conductor wire 14 Mold 15 Molded body 15a Slot accommodating part 15d Coil end part 16 Stator core 16b Slot 18 Stator winding 19 Stator 100 Rotating electrical machine S1 Winding process S2 Coil end part molding process S3 Three-dimensional molding process

Claims (6)

In the method of manufacturing the stator winding (18) wound around the plurality of slots (16b) provided in the stator core (16),
A winding step (S1) of winding a continuous conductor wire for N turns (N is an integer of 2 or more);
A plurality of coil end portions (15d) that are not accommodated in the slots and project from the end face of the stator core are arranged on the circumference of the N conductor wires wound by the winding step. A coil end portion forming step (S2) for forming using a forming die (14, 14A, 14B),
While the coil end portion is held in the mold, all the molds are moved in the radial direction to form the conductor wires into a circular shape, and the adjacent molds are axially arranged. A three-dimensional forming step (S3) in which all or a part of the slot accommodating portions forming the plurality of slot accommodating portions (15a) accommodated in the slots by being moved in opposite directions to each other is performed in parallel. When,
A method of manufacturing a stator winding, comprising:   2. The winding step includes winding the conductor wires so that N = M / 2, where M (M is an even number) is the number of the conductor wires accommodated in one slot. The manufacturing method of the stator winding | winding of description.   The said three-dimensional shaping | molding process performs the radial direction movement which performs the said circular shape, and the axial direction movement which performs the said slot accommodating part shaping | molding along a predetermined characteristic line (L1). Or the manufacturing method of the stator coil | winding of 2. One or more slot accommodating portions wound around a plurality of slots provided in the stator core and accommodated in the slots, and one or more coil end portions protruding from the stator core without being accommodated in the slots In a stator winding having
The coil end portion includes a first crank portion (15b) and a second crank portion (15c) which are bent so that the slot accommodating portion extending from an end portion of the coil end portion is accommodated in the slot of the same layer, or The slot accommodating portion extending from the coil end portion has the first crank portion and the second crank portion bent so as to be accommodated in the slots of different layers,
The stator winding, wherein a boundary between the coil end portion and the slot accommodating portion is linearly arranged in a radial direction for N circumferences (N is an integer of 2 or more).   A stator winding manufactured by the method for manufacturing a stator winding according to any one of claims 1 to 3, or one or more stator windings of the stator winding according to claim 4. Stator (19), characterized in that a wire is wound around said slot.   A rotating electrical machine (100) comprising the stator according to claim 5 and a rotor (102).

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