JP2016187245A - Manufacturing method of stator and stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a stator capable of fixing the electric conductors while bonding reliably in the slots of the stator core, while reducing the contact resistance during electrification, and to provide a stator.SOLUTION: A manufacturing method of a stator 3 has a preparation step for preparing a plurality of electric conductors 11, 12, where recesses 11a, 12a are formed in one end face in the center axis direction, and salients 11b, 12b that can be fitted in the recesses 11a, 12a are formed in the other end face, and a bonding step for inserting respective electric conductors 11, 12 from both open ends of a slot 21 and by widening a junction 10, formed by fitting the recesses 11a, 12a and salients 11b, 12b of the inserted electric conductors 11, 12 in the slot 21, in the width direction of the slot 21, sandwiching the junction 10 by the inner wall of the slot 21, thereby bonding the electric conductors 11, 12 and fixing the same in the slot 21.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a stator manufacturing method and a stator.

  Conventionally, a technique for manufacturing a stator by inserting electric conductors from both open ends of a plurality of slots formed in the stator core and joining the inserted electric conductors in the slot is known. In this technique, the leading ends of the electrical conductors are butted and joined in the slot (see, for example, Patent Document 1). For example, a concave portion or a convex portion is formed on the leading end surface of the electrical conductor, and these are fitted to make electrical The conductors are joined together (see, for example, Patent Document 2).

JP 2009-194999 A JP 2006-158044 A

  However, as in the prior art, sufficient bonding strength cannot be obtained only by fitting the concave and convex portions, and there is a possibility that the bonding between the electrical conductors may be released by a force generated by vibration or cooling. Further, in the conventional structure, since the concave portion and the convex portion are simply fitted, the contact area between the electric conductors cannot be sufficiently secured, and there is a possibility that the energization resistance is increased and the performance as the stator is lowered.

  The present invention has been made in view of the above, and an object of the present invention is to provide a stator manufacturing method and a stator that can reduce electrical resistance while being able to reliably join and fix electrical conductors in a slot of a stator core. It is in.

  (1) In the present invention, electrical conductors (for example, electrical conductors 11 and 12 described later) are respectively provided from both open ends of a plurality of slots (for example, slot 21 described later) formed in a stator core (for example, stator core 2 described later). A method of manufacturing a stator (for example, a stator 3 described later) that inserts and joins the inserted electrical conductors in the slot, and a recess (for example, a recess 11a, 12a described later) is provided on one end surface in the axial direction. A preparatory step (for example, a preparatory step described later) for preparing a plurality of electric conductors formed with convex portions (for example, convex portions 11b, 12b described later) formed on the other end face and formed on the other end surface; A joint portion (for example, a joint portion 10 described later) formed by inserting electric conductors from both open ends of the slot and fitting the concave portions and the convex portions of the inserted electric conductors in the slot. A joining step (for example, a joining step described later) in which the joining portion is sandwiched between the inner walls of the slot and thereby the electrical conductors are joined to each other and fixed in the slot. , A stator manufacturing method (for example, a stator 3 manufacturing method described later) is provided.

In the manufacturing method according to the invention of (1), first, a preparatory step of preparing a plurality of electric conductors in which a concave portion is formed on one end surface in the axial direction and a convex portion that can be fitted to the concave portion is formed on the other end surface. Provide. Next, a joining step is provided, in which electrical conductors are inserted from both open ends of the slot, and the joints formed by fitting the recessed portions and the projecting portions of the inserted electrical conductors in the slot are formed in the width direction of the slot. Widen. As a result, the joint is sandwiched between the inner walls of the slot, so that the electrical conductors are joined and fixed in the slot.
Thereby, according to the invention of (1), in addition to the joint by fitting the concave portion and the convex portion of the electric conductor, it is possible to sandwich and fix the widened joint portion between the electric conductors on the inner wall of the slot. Bonding strength between electrical conductors can be increased. Moreover, since the joint part of a recessed part and a convex part is clamped by the inner wall of a slot, sufficient contact area of a recessed part and a convex part can be ensured, and an energization resistance can be reduced. Therefore, according to the invention of (1), the electrical conductors can be reliably joined and fixed in the slot of the stator core, and the energization resistance can be reduced.

  (2) In the invention of (1), before the joining step, an insulating step in which an insulating member (for example, an insulating member 4 described later) having a surface formed of a thermosetting resin is disposed on the inner wall surface of the slot. It is preferable to further include (for example, an insulating step described later).

  In the invention of (2), the insulating member whose surface is formed of a thermosetting resin is disposed on the inner wall surface of the slot before the joining step. As a result, the joint between the concave portion and the convex portion is more firmly joined by the adhesive action of the thermosetting resin of the insulating member and is more firmly fixed in the slot.

  (3) In the invention of (1) or (2), in the joining step, the joint portions of the adjacent electrical conductors in the slot are formed at positions shifted alternately in the depth direction of the slot. Is preferred.

  In the invention of (3), each joint portion between the adjacent electrical conductors in the slot is formed at a position shifted alternately in the depth direction of the slot. Thereby, since each junction part of the electrical conductors which adjoin in a slot does not adjoin, the effect of the above-mentioned invention of (1) and (2) is acquired, ensuring insulation.

  (4) In the invention according to any one of (1) to (3), the preparation step cuts one electric conductor (for example, one electric conductor 100 described later) to cut the concave portion and the convex portion. A cutting step (for example, a cutting step to be described later) for obtaining an electric conductor having the concave portion and an electric conductor having the convex portion, and pressing the concave portion from the width direction of the electric conductor to reduce the width of the concave portion. It is preferable to have a width correction step (for example, a width correction step described later) that is smaller than the width of the convex portion.

In the invention of (4), as a preparatory step, a cutting step is first provided in which a single electric conductor is cut to form a concave portion and a convex portion, and an electric conductor having a concave portion and an electric conductor having a convex portion are obtained. Next, a width correcting step is provided in which the concave portion is pressed from the width direction of the electric conductor to make the width of the concave portion smaller than the width of the convex portion.
Thereby, the convex part which has a width | variety larger than the width | variety of this recessed part will be fitted by the recessed part, and the width | variety of a junction part can be reliably expanded in the width direction of a slot by fitting. Moreover, when fitting a convex part to a recessed part, an oxide film which exists in both surfaces can be removed because a convex part slides the inside of a recessed part and the surfaces mutually rub against each other. Therefore, the bonding strength can be further increased, and the energization resistance can be further reduced.

  (5) In the invention of (4), the preparation step is performed by crushing a cut portion (for example, a cut portion 110 described later) of the electric conductor in the thickness direction immediately before, during or immediately after the cutting step. It is preferable to further include a crushing step (for example, a crushing step described later) for expanding the width.

  In the invention of (5), a crushing step for expanding the width by crushing the cut portion of the electric conductor in the thickness direction is provided immediately before, during or immediately after the cutting step. Thereby, since the width of the cut portion of the electric conductor crushed in the crushing step becomes the width of the concave portion and the convex portion of the electric conductor, the width of the joint portion where the concave portion and the convex portion are fitted can be surely widened. The width can be adjusted easily.

  (6) A stator in which electrical conductors are joined in a plurality of slots formed in the stator core, and a width of a joined portion where the electrical conductors are joined is larger than a width of a portion excluding the joined portion. The width of the joined portion where the electrical conductors are joined is larger than the width of the portion excluding the joined portion, so that the joined portion is sandwiched between the inner walls of the slots, thereby joining the electrical conductors together. A stator fixed in the slot.

  According to the stator of the invention of (6), the same effect as that of the invention of (1) can be obtained.

  (7) It is preferable that the joints between the electrical conductors adjacent in the slot are alternately shifted in the depth direction of the slot.

  According to the stator of the invention of (7), the same effect as that of the invention of (3) can be obtained.

  According to the present invention, it is possible to provide a stator manufacturing method and a stator capable of reliably joining and fixing electrical conductors in a slot of a stator core and reducing energization resistance.

It is a cross-sectional schematic diagram which shows the structure of the stator which concerns on one Embodiment of this invention. It is a perspective view which shows the stator core which concerns on this embodiment. It is a figure for demonstrating a cutting process. It is a figure which shows the electrical conductor formed by cutting and separating. It is a figure for demonstrating the width correction process. It is a figure which shows a cutting process. It is a figure which shows a cutting process. It is a figure which shows the width correction process. It is a figure which shows the lamination process in shaping | molding of an insulating member. It is a figure which shows the edge part bending process in shaping | molding of an insulating member. It is a figure which shows the bending process in shaping | molding of an insulating member. It is a figure which shows the shape adjustment process in shaping | molding of an insulating member. FIG. 4 is a plan view showing a state before the insulating member 4 is arranged in the slot 21. FIG. 4 is a plan view showing a state in which an insulating member 4 is disposed in a slot 21. 4 is a plan view showing a state in which an insulating member 4 and a plurality of electric conductors 11 and 12 are arranged in a slot 21. FIG. It is sectional drawing which shows the state which inserted the electrical conductor in the slot from the open end below the slot. It is sectional drawing which shows the state which inserted the electrical conductor in the slot from the open end above a slot. It is sectional drawing which shows the position of each junction part of the electrical conductors adjacent within a slot. It is a schematic diagram of the joining apparatus which fits and joins electrical conductors. It is a schematic diagram of the joining apparatus which fits and joins electrical conductors. It is a figure which shows a state when electrical conductors are joined in the slot of a stator core which has a fastening core part. It is a figure which shows a state when electrical conductors are joined in the slot of the stator core which has a fastening core part. It is sectional drawing of the lamination direction in the upper layer part of the stator core which has a fastening core part. It is sectional drawing of the lamination direction in the middle layer part of the stator core which has a fastening core part. It is sectional drawing of the lamination direction in the lower layer part of the stator core which has a fastening core part. It is the sectional view on the AA line of FIG. 16A. It is the BB sectional view taken on the line of FIG. 16A. It is a figure which shows the state before fitting the recessed part and convex part of a conventional general electrical conductor. It is a figure which shows the state which made the convex part fit in the recessed part of a conventional general electrical conductor. It is a figure which shows a state when using the recessed part and convex part of a conventional general electric conductor by fitting.

  Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings. Note that, in the description of the second embodiment, the same reference numerals are given to configurations common to the first embodiment, and description thereof is omitted as appropriate.

  In the manufacturing method of the stator 3 according to the first embodiment of the present invention, the electric conductors 11 and 12 are inserted from both open ends of the plurality of slots 21 formed in the stator core 2, respectively. Are joined in the slot 21 to manufacture the stator 3. Hereinafter, after describing the configuration of the stator 3 manufactured by the method of manufacturing the stator 3 according to the present embodiment, the method of manufacturing the stator 3 according to the present embodiment will be described in detail.

FIG. 1 is a schematic cross-sectional view showing the configuration of the stator 3 according to the present embodiment. Specifically, FIG. 1 is a schematic cross-sectional view when the stator 3 is cut in the thickness direction. FIG. 2 is a perspective view showing the stator core 2 according to this embodiment.
As shown in FIGS. 1 and 2, the stator 3 has a substantially annular shape and includes a coil 1 and a stator core 2. A rotating electrical machine is configured by disposing a rotor (not shown) rotatably inside the stator 3.

  The stator core 2 is formed by laminating a plurality of substantially annular steel plates. As shown in FIG. 2, the stator core 2 is provided with a plurality of annular slots 21 penetrating in the direction of the rotation axis (the central axis of the stator core 2). That is, a plurality of slots 21 are provided at equal intervals in the circumferential direction of the stator core 2.

  Each slot 21 is formed to extend radially from the inner peripheral edge of the stator core 2 toward the radially outer side. Each slot 21 communicates with a slit 22 extending in the rotation axis direction formed at equal intervals in the circumferential direction on the inner peripheral surface of the stator core 2.

  As shown in FIG. 1, the coil 1 is formed by inserting electrical conductors 11 and 12 from both open ends of the slot 21 and joining the inserted electrical conductors 11 and 12 in the slot 21. Here, although the electric conductors 11 and 12 are attached with different symbols for the sake of convenience, they are constituted by the same electric conductor. For convenience, the electrical conductor 11 is disposed above the stator core 2 (upper in FIG. 1), and the electrical conductor 12 is disposed below the stator core 2 (lower in FIG. 1).

  The coil 1 is formed by alternately arranging and joining electric conductors 11 and 12 in the circumferential direction. Further, eight electric conductors 11 and 12 are alternately arranged adjacent to each other in the radial direction of the stator core 2 (the direction perpendicular to the paper surface of FIG. 1).

  The electrical conductors 11 and 12 are configured to include first housing portions 111 and 121 and second housing portions 112 and 122 that are housed in the slot 21, and connection portions 113 and 123 that connect the housing portions. . The electric conductors 11 and 12 are formed by a wire made of a long rectangular wire, and are obtained by bending both ends in the central axis direction at a substantially right angle to form both accommodating portions.

  The first accommodating portions 111 and 121 are accommodated and arranged in the slot 21. The lengths of the first conductors 111 and 121 in the central axis direction of the electric conductors 11 and 12 are longer than those of the second receivers 112 and 122 described later. In other words, the first accommodating portions 111 and 121 have a longer insertion length into the slot 21 than the second accommodating portions 112 and 122. Specifically, the first accommodating portions 111 and 121 are inserted from one end side of the slot 21 and inserted to the vicinity of the other end side.

  The second accommodating portions 112 and 122 are accommodated and arranged in the slot 21. The second housing portions 112 and 122 are formed such that the lengths of the electric conductors 11 and 12 in the central axis direction are shorter than those of the first housing portions 111 and 121 described above. In other words, the second housing portions 112 and 122 have a shorter insertion length into the slot 21 than the first housing portions 111 and 121. Specifically, the second accommodating portions 112 and 122 are inserted from one end side of the slot 21, but are inserted only up to the vicinity of the one end side.

  As shown in FIG. 1, the first housing portion 111 and the second housing portion 112 of the electric conductor 11 are inserted into the slot 21 from the upper end of the slot 21. On the other hand, the first housing part 121 and the second housing part 122 of the electric conductor 12 are inserted into the slot 21 from the lower end of the slot 21. And the 1st accommodating part 111 of the electric conductor 11 and the 2nd accommodating part 122 of the electric conductor 12 are faced | matched and joined. Further, the second housing portion 112 of the electrical conductor 11 and the first housing portion 121 of the electrical conductor 12 are abutted and joined.

  The connecting part 113 connects the first housing part 111 and the second housing part 112. The connecting part 123 connects the first housing part 121 and the second housing part 122. The connecting portion 113 is disposed above the stator core 2, and the connecting portion 123 is disposed below the stator core 2.

A concave portion 11a is formed on one end surface of the electric conductor 11 in the central axis direction, and a convex portion 11b is formed on the other end surface. More specifically, the concave portion 11 a is formed on the distal end surface of the first accommodating portion 111, and the convex portion 11 b is formed on the distal end surface of the second accommodating portion 112.
Further, a concave portion 12a is formed on one end surface in the central axis direction of the electric conductor 12, and a convex portion 12b is formed on the other end surface. More specifically, the concave portion 12 a is formed on the distal end surface of the first accommodating portion 121, and the convex portion 12 b is formed on the distal end surface of the second accommodating portion 122.

  As shown in FIG. 1, a plurality of joint portions 10 are formed by fitting the convex portions 11b and 12b to the concave portions 11a and 12a. The plurality of joints 10 connect the plurality of electrical conductors 11 and 12 adjacent in the circumferential direction to form the coil 1. As shown in FIG. 1, the joints 10 are alternately arranged up and down in the circumferential direction. In addition, the joint portions 10 of the electrical conductors 11 and 12 that are adjacent in the radial direction in the same slot 21 are alternately shifted in the depth direction of the slot 21 (see FIG. 8 described later).

  The width of the joint portion 10 is larger than the width of the portion excluding the joint portion 10. That is, the joint portion 10 protrudes in the width direction of the slot 21 and is widened. As a result, the joint 10 is sandwiched between the inner walls of the slot 21, whereby the recesses 11 a and 12 a and the protrusions 11 b and 12 b are firmly joined and the electrical conductors 11 and 12 are fixed in the slot 21. Has been.

Next, a method for manufacturing the stator 3 according to this embodiment will be described.
The manufacturing method of the stator 3 according to the present embodiment includes a preparation process, an insulation process, and a joining process.
First, the preparation process will be described. In the preparation step, the above-described electric conductors 11 and 12 are prepared. That is, a plurality of electrical conductors 11 and 12 are prepared in which concave portions 11a and 12a are formed on one end surface in the central axis direction, and convex portions 11b and 12b that can be fitted to the concave portions 11a and 12a are formed on the other end surface.

Specifically, the preparation process includes a cutting process and a width correction process. In addition, a crushing process is provided immediately before, during or immediately after the cutting process.
Here, FIG. 3 is a figure for demonstrating a cutting process. FIG. 4 is a diagram showing the electrical conductors 11 and 12 formed by being cut and separated. FIG. 5 is a diagram for explaining the width correction process.

  FIG. 3 shows a state where one electrical conductor 100 is cut. As shown in FIG. 3, in the cutting step, one electrical conductor 100 is cut to form the recess 12 a and the projection 11 b, and the electrical conductor 12 having the recess 12 a and the electrical conductor 11 having the projection 11 b are obtained. . The concave portion 11a of the electric conductor 11 and the convex portion 12b of the electric conductor 12 are obtained in the same manner. In the present embodiment, the bottoms of the recesses 11a and 12a and the tips of the projections 11b and 12b are formed in a tapered shape.

  Further, in the crushing process immediately before, during or immediately after the cutting process, the cutting portion 110 of the electric conductor 100 is crushed in the thickness direction by using a cutting force as shown in FIG. At this time, side clamps 81, 81 are arranged on both outer sides of the cutting part 110 of the electric conductor 100. As a result, the width of the cut portions 110, that is, the concave portions 11a and 12a of the electric conductors 11 and 12, and the convex portions 11b and 12b are restricted by the side clamp pressure. As a result, the width of the concave portions 11a and 12a and the convex portions 11b and 12b is reduced. Adjusted.

  As shown in FIG. 4, the width of the convex portion 11b of the electric conductor 11 formed by cutting and separating is set to L1, and the width of both side portions 12c and 12c of the concave portion 12a of the electric conductor 12 formed by cutting and separating similarly. Is L2, and the width of the slot 21 is L4 (see FIG. 9 described later). At this time, a relationship of L1 + 2L2> L4 is established between these widths and lengths. That is, in this state, the width of the portion of the electrical conductor 12 where the recess 12 a is formed is larger than the width of the slot 21. The tightening allowance ΔL at this time is represented by ΔL = (L1 + 2L2−L4) / 2.

  FIG. 5 shows a state in which the recess 12 a is pressed from the width direction of the electric conductor 12. In the width correction step shown in FIG. 5, the concave portion 12a is pressed from the width direction of the electric conductor 12, so that the width of the concave portion 12a is corrected to be smaller than the width of the convex portion 11b. Specifically, pressing devices 82 and 82 are arranged on both outer sides of the portion of the electric conductor 12 where the recess 12a is formed, and the width of the portion is corrected by the pressing pressure until the width becomes L3. At this time, a relationship of L3 <L4 is established between the width L3 of the portion and the width L4 of the slot 21. That is, the width L3 of the portion of the electric conductor 12 where the recess 12a is formed is corrected to be smaller than the width of the slot 21 so that the electric conductor 12 can be inserted into the slot 21.

  In addition, with reference to FIGS. 6A to 6C, the preparation process will be described in more detail while showing an apparatus that performs the preparation process of the present embodiment. 6A and 6B are diagrams showing a cutting process. FIG. 6C is a diagram illustrating a width correction process. In these FIG. 6A-FIG. 6C, the top view and side view of each process are shown collectively.

As shown in FIG. 6A, in the cutting process, first, the shape of the electric conductors 11 and 12 is half-cut from one electric conductor 100 by the press die device 83. At the time of half punching, the cutting portion 110 of the electric conductor 100 is crushed in the thickness direction by the cutting force of the press die device 83, so that the width is widened (crushing step). At this time, as described above, the side clamps 81 and 81 are arranged on both outer sides of the cut portion 110 of the electric conductor 100 (not shown in FIG. 6A), and thereby, the cut portion 110, that is, the concave portion 11a of the electric conductors 11 and 12 is arranged. , 12a and the widths of the convex portions 11b, 12b are regulated by the side clamp pressure, so that the widths of the concave portions 11a, 12a and the convex portions 11b, 12b are adjusted.
At this time, the half-extracted electrical conductors 11 and 12 are pushed back upward by the restoring force of the spring members 83a and 83a provided below the mold of the press mold apparatus 83 to return to the original positions. .

  Next, as shown in FIG. 6B, the half-cut electrical conductors 11 and 12 are pressed by a pressing device (not shown). Thereby, the electric conductors 11 and 12 are separated from the single electric conductor 100.

Next, as shown in FIG. 6C, in the width correction step, the portions are pressed from the outside by pressing devices 82 and 82 arranged on both outer sides of the portions where the recesses 11a and 12a of the electric conductors 11 and 12 are formed. Thereby, the width of the said part is narrowed and the width | variety of recessed part 11a, 12a is corrected small.
Thus, the preparation process is completed.

Next, the insulating process will be described.
In the insulating step, the insulating member 4 whose surface is formed of a thermosetting resin is disposed on the inner wall surface of the slot 21 before the joining step described later. In describing this insulating step, first, the forming of the insulating member will be described.
7A to 7D are diagrams illustrating a molding process of the insulating member 4. Specifically, FIG. 7A shows a lamination process, FIG. 7B shows an end bending process, FIG. 7C shows a bending process, and FIG. 7D shows a correction process.

In the laminating process shown in FIG. 7A, the thermosetting resin sheet 41, the insulating sheet 40, and the thermosetting resin sheet 41 are laminated in this order. Thereby, the insulating member 4 having a surface formed of a thermosetting resin is obtained.
As the thermosetting resin, for example, a resin having a thermosetting temperature of 150 ° C. is used. In the molding process of the insulating member 4 according to the present embodiment, by performing molding while heating at a low temperature of about 100 ° C. so that the thermosetting resin is not completely cured, it breaks at the time of bending molding described later. Is avoided. Moreover, what has pressure resistance is used as a thermosetting resin.

  In the end bending process shown in FIG. 7B, both end portions in the longitudinal direction of the insulating member 4 are bent at substantially right angles in the same direction. Specifically, for example, the bent pieces 4a and 4a are formed by press molding using a mold whose temperature is set to 100 ° C.

  In the bending step shown in FIG. 7C, the insulating member 4 on which the bent pieces 4a, 4a are formed is bent so as to have a substantially rectangular shape in side view. Specifically, for example, the insulating member 4 having a substantially rectangular shape in side view is obtained by bending using a mold whose temperature is set to 100 ° C.

  In the correction process shown in FIG. 7D, the shape of the insulating member 4 having a substantially rectangular shape in side view is further corrected. Specifically, the shape is corrected by pressing with a sizing material from the outside of the insulating member 4. Thus, the insulating member 4 having a shape that can be inserted into the slot 21 is obtained.

  Next, in this insulating process, the insulating member 4 obtained as described above is disposed on the inner wall surface of the slot 21. 8A is a plan view showing a state before the insulating member 4 is arranged in the slot 21, FIG. 8B is a plan view showing a state in which the insulating member 4 is arranged in the slot 21, and FIG. 4 is a plan view showing a state in which an insulating member 4 and a plurality of electric conductors 11 and 12 are arranged in a slot 21. FIG.

  As shown in FIG. 8A, the slot 21 penetrates vertically and has a substantially rectangular shape in plan view. The above-described insulating member 4 is inserted into the slot 21 as shown in FIG. 8B. At this time, since the outer shape of the insulating member 4 is a shape along the inner wall surface of the slot 21, the outer surface of the insulating member 4 contacts the inner wall surface of the slot 21. And as shown to FIG. 8C, the several electric conductors 11 and 12 are inserted inside the insulating member 4 by the joining process mentioned later.

Next, the joining process will be described.
FIG. 9 is a cross-sectional view showing a state in which the electric conductor 12 is inserted into the slot 21 from the open end below the slot 21. As shown in FIG. 9, first, in the main joining step, one of the electric conductors 11 and 12 is inserted from one open end of the slot 21. At this time, the width dimension L4 of the slot 21 in which the insulating member 4 is arranged on the inner wall surface is set larger than the width dimension of the inserted electric conductors 11 and 12, and the electric conductor 12 is easily inserted. .

  Next, FIG. 10 is a cross-sectional view showing a state where the electric conductor 11 is inserted into the slot 21 from the open end above the slot 21. As shown in FIG. 10, the other one of the electric conductors 11 and 12 is inserted from the other open end of the slot 21. At this time, both electrical conductors are abutted so that the recess 12a and the protrusion 11b fit in the slot 21. Then, as shown in FIG. 10, the concave portion 12 a and the convex portion 11 b are fitted, whereby the width of the concave portion 12 a is widened, and the joint portion 10 widened in the width direction of the slot 21 is formed. Thereby, the pressure P from the inner wall of the slot 21 acts on the joint portion 10 and is sandwiched between the inner walls, whereby the electric conductors 11 and 12 are joined and fixed in the slot 21. At this time, since the insulating member 4 disposed on the inner wall surface of the slot 21 has pressure resistance, a dimensional change due to the pressure P is suppressed.

  In addition, when fitting the recessed part 12a and the convex part 11b, the convex part 11b slides in the recessed part 12a, and the surfaces mutually rub, and the oxide film which exists in both surfaces is removed. Moreover, after fitting the recessed part 12a and the convex part 11b, the thermosetting resin which comprises the surface of the insulating member 4 acts as an adhesive agent by heating to 150 degreeC, and it hardens | cures completely. Thereby, the joint portion 10 is joined more firmly and is more firmly fixed in the slot 21.

  FIG. 11 is a cross-sectional view showing the position of each joint 10 between the electrical conductors 11 and 12 adjacent in the slot 21. As shown in FIG. 11, in this joining process, the joint portions 10 of the electrical conductors 11, 12 adjacent in the radial direction in the slot 21 are formed at positions shifted alternately in the depth direction of the slot 21. The The distance L5 in the depth direction of the slot 21 between these joints 10 is set to a distance that ensures sufficient insulation.

Next, a modification of this embodiment will be described.
FIG.12 and FIG.13 is a schematic diagram of the joining apparatus which fits and joins the electrical conductors 11 and 12. FIG. In FIG. 12 and FIG. 13, the illustration of the slot 21 is omitted for the sake of convenience, but in actuality, bonding is performed in the slot 21. Using these joining devices, the electrical conductors 11 and 12 may be fitted and joined together.

  In the joining apparatus shown in FIG. 12, the support base 85 that supports the electric conductor 12 is configured to be able to vibrate up and down. A press slide 84 that supports the electric conductor 11 is configured to be movable up and down. In this joining apparatus, the press slide 84 is lowered at a low speed while vibrating the support base 85 up and down. Then, when the concave portion 12a and the convex portion 11b are fitted, the convex portion 11b slides while vibrating in the concave portion 12a, and the surfaces rub against each other, so that the oxide film present on both surfaces is more reliably obtained. It is supposed to be removed.

  On the other hand, in the joining apparatus shown in FIG. 13, the support base 87 that supports the electric conductor 12 is fixed. A press slide 86 that supports the electric conductor 11 is configured to be movable up and down. In this joining apparatus, the press slide 86 is moved up and down at high speed while the electric conductor 12 is fixed by the support base 87. Then, when the concave portion 12a and the convex portion 11b are fitted, the convex portion 11b slides while moving up and down in the concave portion 12a at a high speed, and the surfaces rub against each other. It is more reliably removed.

  Next, FIG. 14 is a diagram showing a state when the electrical conductors 11 and 12 are joined in the slot 21A of the stator core 2A having the fastening core portion 2a. FIG. 15 is a diagram showing a state when the electrical conductors 11 and 12 are joined in the slot 21A of the stator core 2A having the fastening core portion 2a.

  As shown in FIG. 14, a fastening core portion 2a protruding into the slot 21A may be provided in a part of the stacking direction of the stator core 2A formed by stacking a plurality of steel plates. At this time, the width L20 of the slot 21A in the fastening core portion 2a is set to be larger than the width L10 of the portion of the electric conductor 12 where the recess 12a is formed. The fastening allowance ΔL at this time is represented by ΔL = (L10−L20) / 2.

  As shown in FIG. 15, when the electric conductors 11 and 12 are joined in the slot 21A of the stator core 2A having the fastening core portion 2a, the concave portion 12a and the convex portion 11b are fitted to expand the width of the concave portion 12a. The formed joining portion 10 is sandwiched between the inner walls of the fastening core portion 2 a having a small width of the slot 21 </ b> A, so that the electrical conductors 11 and 12 are more firmly joined and fixed more firmly in the slot 21. It has become.

In the stator core 2A having the above-described tightening core portion 2a, the position where the tightening core portion 2a is provided will be described with reference to FIGS. 16A to 18.
Here, FIG. 16A is a cross-sectional view in the stacking direction in the upper layer portion of the stator core 2A having the fastening core portion 2a. FIG. 16B is a cross-sectional view in the stacking direction of the middle layer portion of the stator core 2A having the tightening core portion 2a. FIG. 16C is a cross-sectional view in the stacking direction of the lower layer portion of the stator core 2A having the fastening core portion 2a. 17 is a cross-sectional view taken along line AA in FIG. 16A, and FIG. 18 is a cross-sectional view taken along line BB in FIG. 16A.

  As shown in FIGS. 16A to 18, the fastening core portion 2 a is provided in the upper layer portion and the lower layer portion, but is not provided in the middle layer portion. This is because the tightening core portion 2a sandwiching the joint portion 10 is arranged separately from the upper layer and the lower layer in order to avoid the inability to ensure insulation due to the proximity of the joint portions 10 to each other. . Further, as is clear from a comparison between FIG. 16A and FIG. 16C, the fastening core portions 2a are alternately provided in the radial direction of the stator core 2A.

The effect of this embodiment having the above configuration will be described in comparison with the conventional case.
First, FIG. 19 is a diagram for explaining a joint portion 90 of conventional general electric conductors 91 and 92. Specifically, FIG. 19A is a diagram showing a state before fitting the concave portion and the convex portion, FIG. 19B is a diagram showing a state where the convex portion is fitted in the concave portion, and FIG. It is a figure which shows a state when fitting and using a convex part.
As shown in FIG. 19A, a concave portion 91a formed on one end surface in the central axis direction of a conventional electric conductor 91 and a convex portion 92b formed on one end surface in the central axis direction of the electric conductor 92 are fitted to each other. Has a shape. More specifically, the width 91W of the concave portion 91a is usually formed slightly smaller than the width 92W of the convex portion 92b. Further, the depth 91D of the concave portion 91a is formed substantially the same as the depth 92D of the convex portion 92b.

  Next, as shown in FIG. 19B, when the convex portion 92b is fitted into the concave portion 91a, the concave portion 91a is deformed to the outside and its width is slightly widened. As a result, the restoring forces 9P and 9P of the concave portion 91a act on the convex portion 92b. As a result, the convex portion 92b is sandwiched by the concave portion 91a and the electric conductors 91 and 92 are joined to each other.

Next, as shown in FIG. 19C, forces 9F and 9F generated by vibration and cold heat act on the electrical conductors 91 and 92 in use in a direction to release the fitting (joining) between the concave portions 91a and the convex portions 92b. . At this time, in the conventional electric conductors 91 and 92, there is only a joining force (static frictional force) 2 μP generated by the restoring forces 9P and 9P by only fitting the concave portions 91a and the convex portions 92b. As a result of exceeding (static friction force) 2 μP, the bonding is released.
Further, as shown in FIG. 19C, in the conventional electric conductors 91 and 92, the contact between the concave portion 91a and the convex portion 92b is weak, and a sufficient contact area is not obtained. For this reason, the energization resistance is increased and the performance as a stator is lowered.

On the other hand, in the manufacturing method according to the present embodiment, first, concave portions 11a and 12a are formed on one end surface in the central axis direction, and convex portions 11b and 12b that can be fitted to the concave portions 11a and 12a are formed on the other end surface. A preparation step for preparing the plurality of electric conductors 11 and 12 was provided. Next, a joining step is provided, and the electric conductors 11 and 12 are inserted from both open ends of the slot 21, and the concave portions 11 a and 12 a and the convex portions 11 b and 12 b between the inserted electric conductors 11 and 12 are inserted in the slot 21. The joint 10 formed by fitting was widened in the width direction of the slot 21. Thus, the electrical conductors 11 and 12 are joined and fixed in the slot 21 by the joint 10 being sandwiched between the inner walls of the slot 21.
Thereby, according to this embodiment, in addition to the joint by fitting of the concave portions 11a and 12a of the electric conductors 11 and 12 and the convex portions 11b and 12b, the electric conductors 11 and 12 are widened on the inner wall of the slot 21. Since the joining portion 10 can be sandwiched and fixed, the joining strength between the electric conductors 11 and 12 can be increased. Further, since the joint portion 10 between the concave portions 11a and 12a and the convex portions 11b and 12b is sandwiched between the inner walls of the slot 21, a sufficient contact area between the concave portions 11a and 12a and the convex portions 11b and 12b can be secured, and the energization resistance can be reduced. . Therefore, according to the present embodiment, the electrical conductors 11 and 12 can be reliably joined and fixed in the slot 21 of the stator core 2 and the energization resistance can be reduced.

  In the present embodiment, the insulating member 4 whose surface is formed of a thermosetting resin is disposed on the inner wall surface of the slot 21 before the joining step. As a result, the joint portion 10 between the concave portions 11 a and 12 a and the convex portions 11 b and 12 b is more firmly joined by the adhesive action of the thermosetting resin of the insulating member 4 and is more firmly fixed in the slot 21.

  In the present embodiment, the joint portions 10 between the electrical conductors 11 and 12 adjacent in the slot 21 are formed at positions shifted alternately in the depth direction of the slot 21. Thereby, since each junction part 10 of the electrical conductors 11 and 12 adjacent in the slot 21 does not adjoin, the above-mentioned effect is acquired, ensuring insulation.

In the present embodiment, as a preparatory step, first, one electrical conductor 100 is cut to form the recesses 11a and 12a and the projections 11b and 12b, and the electrical conductors 11 and 12 having the recesses 11a and 12a and the projections. A cutting step for obtaining the electric conductors 11 and 12 having 11b and 12b is provided. Next, a width correcting step was performed in which the recesses 11a and 12a were pressed from the width direction of the electrical conductors 11 and 12 so that the widths of the recesses 11a and 12a were smaller than the widths of the projections 11b and 12b.
Thereby, the convex portions 11b and 12b having a width larger than the width of the concave portions 11a and 12a are fitted into the concave portions 11a and 12a, and the width of the joint portion 10 is reduced by the fitting in the width direction of the slot 21. Can be reliably widened. Further, when the convex portions 11b and 12b are fitted into the concave portions 11a and 12a, the convex portions 11b and 12b slide in the concave portions 11a and 12a and the surfaces are rubbed with each other, so that the oxide films existing on both surfaces Can be removed. Therefore, the bonding strength can be further increased, and the energization resistance can be further reduced.

  In the present embodiment, a crushing step for expanding the width by crushing the cut portion 110 of the electric conductor 100 in the thickness direction is provided immediately before, during or immediately after the cutting step. Thereby, since the width of the cut portion 110 of the electric conductor 100 crushed in the crushing step becomes the width of the concave portions 11a, 12a and the convex portions 11b, 12b of the electric conductors 11, 12, the concave portions 11a, 12a and the convex portions 11b, While the width | variety of the junction part 10 which 12b fits can be expanded reliably, the width | variety can be adjusted easily.

  Moreover, according to the stator 3 which concerns on this embodiment, there exists an effect similar to the above-mentioned effect.

  It should be noted that the present invention is not limited to the above-described embodiment, and modifications and improvements within the scope that can achieve the object of the present invention are included in the present invention.

DESCRIPTION OF SYMBOLS 1 ... Coil 2 ... Stator core 3 ... Stator 4 ... Insulating member 10 ... Joining part 11, 12 ... Electric conductor 11a, 12a ... Concave part 11b, 12b ... Convex part 100 ... One electric conductor 110 ... Cutting part

Claims (7)

A stator manufacturing method in which electric conductors are inserted from both open ends of a plurality of slots formed in the stator core, and the inserted electric conductors are joined in the slot,
A preparation step of preparing a plurality of electrical conductors in which a concave portion is formed on one end surface in the axial direction and a convex portion that can be fitted to the concave portion is formed on the other end surface;
An electric conductor is inserted from both open ends of the slot, and a joint formed by fitting a concave portion and a convex portion of the inserted electric conductors in the slot is widened in the width direction of the slot. And a joining step of sandwiching the joint portion between the inner walls of the slot, thereby joining the electrical conductors and fixing the electrical conductor in the slot.   The method of manufacturing a stator according to claim 1, further comprising an insulating step of disposing an insulating member having a surface formed of a thermosetting resin on an inner wall surface of the slot before the joining step.   3. The stator manufacturing method according to claim 1, wherein in the joining step, the joining portions of the adjacent electrical conductors in the slot are formed at positions alternately shifted in the depth direction of the slot. The preparation step includes
A step of cutting the one electric conductor to form the concave portion and the convex portion, and obtaining the electric conductor having the concave portion and the electric conductor having the convex portion,
4. The stator manufacturing method according to claim 1, further comprising: a width correcting step of pressing the concave portion from the width direction of the electric conductor to make the width of the concave portion smaller than the width of the convex portion. 5. The preparation step includes
The stator manufacturing method according to claim 4, further comprising a crushing step of expanding a width by crushing a cut portion of the electric conductor in a thickness direction immediately before, during or immediately after the cutting step. A stator in which electrical conductors are joined together in a plurality of slots formed in the stator core,
The width of the joined portion where the electrical conductors are joined is larger than the width of the portion excluding the joined portion, so that the joined portion is sandwiched by the inner wall of the slot, thereby joining the electrical conductors. A stator fixed in the slot.   The stator according to claim 6, wherein each joint portion between the electrical conductors adjacent to each other in the slot is alternately displaced in the depth direction of the slot.

Images