JP2016226168A - Stator manufacturing method for rotary electric machine, and stator manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator manufacturing method capable of easily integrating a plurality of coils (winding group) into a stator core regardless of a size of a coil end.SOLUTION: The stator manufacturing method includes: a first winding forming step for forming a first winding assembly 16A in the same shape as a first coil member 14A of a stator core 10; a first winding preparing step for using a stator manufacturing device 30 (first device 30A) including a cylindrical winding support part 42 that can be deformed into a diameter enlarged state and a diameter reduced state to dispose the first winding assembly 16A on an outer peripheral surface of the winding support part 42 in the diameter reduced state while compressing and deforming it in a radial direction along the outer peripheral surface; a first winding inserting step for inserting the first winding assembly 16A into the stator core 10 together with the winding support part 42; and a first winding mounting step for enlarging a diameter of the winding support part 42 inside of the stator core 10 to insert in-slot passage parts 17 of the first winding assembly 16A into slots 12.SELECTED DRAWING: Figure 14

Description

  The present invention relates to a rotating electrical machine (motor, generator, or motor / generator) used in vehicles and the like, and more particularly to a stator manufacturing method and a stator manufacturing apparatus for a radial gap type rotating electrical machine.

  A stator of a radial gap type rotating electrical machine includes an annular stator core in which a plurality of slots are arranged in the circumferential direction, and a winding such as a copper wire (appropriately called a coil) wound around the stator core. The winding structure, that is, how to wind copper wire around the stator core, can be roughly divided into concentrated winding and distributed winding, but the rotating magnetic field produced by the stator is close to a sine wave, and the motor's rotational characteristics and output characteristics are excellent. Therefore, distributed winding is adopted in many rotating electrical machines used for vehicles and the like.

  Patent Document 1 discloses a method (apparatus) for manufacturing a stator of a three-phase motor, which is one of this type of rotating electrical machine. This method forms a coil (winding group) for one phase by wave winding on the outer peripheral surface of a cylindrical member, and slides the coil in the axial direction with respect to the cylindrical member. A stator core is inserted into a desired slot from one axial end side of the stator core, and the coil for three phases is incorporated into the stator core by repeating such coil formation and coil insertion into the slot for each phase. Can do.

JP 2010-166682 A

  However, the method of Patent Document 1 is not necessarily efficient because it is necessary to individually form the coils and insert the coils into the slots for each phase. Therefore, it is conceivable that coils for three phases are formed in advance on the outer peripheral surface of the cylindrical member, and these coils are integrally slid in the axial direction with respect to the cylindrical member and inserted into the slots of the stator core. However, when the winding structure is distributed winding, coils of different phases overlap each other in the radial direction and the axial direction outside the stator core (on the end face in the axial direction). In the method 1, this coil end becomes an obstacle and it becomes difficult to incorporate the coil into the stator core.

  The present invention has been made in view of the above circumstances, and provides a technique capable of easily incorporating a plurality of coils (winding groups) into a stator core regardless of the size of the coil end. Objective.

  In order to solve the above-described problems, the present invention provides a stator core having a plurality of slots arranged in the circumferential direction at regular intervals, each opening inward, and a predetermined number of the stator cores passing through the plurality of specific slots. A stator that is formed in the stator core by winding an element wire, and includes a plurality of winding groups each having an in-slot passage portion that passes through the slot and a crossing portion that passes on an axial end surface of the stator core. A method of manufacturing the stator of a rotating electrical machine provided with a winding forming step of independently forming a winding assembly having the same shape as the plurality of winding groups formed on the stator core, and a cylindrical diameter-enlarged state And a winding support member that can be deformed into a reduced diameter state, and the winding assembly is radially deformed in a state of being compressed and deformed along the outer peripheral surface of the reduced diameter winding support member. surface The winding assembly together with the winding support member from the one end side in the axial direction of the stator core such that the winding preparation step disposed on the winding core is positioned on the outer side in the axial direction of the stator core. A winding insertion step for inserting the passage passing portion in each slot of the winding assembly into the slot by expanding the diameter of the winding support member inside the stator core; Is included.

  According to this method, the winding assembly is inserted into the stator core in a state of being compressed and deformed in the radial direction, and then the winding support portion is expanded in diameter so that each slot passing portion of the winding assembly is passed through. Since each is inserted into the slot, the coil end, that is, the transition portion, does not become an obstacle when the winding assembly is inserted into the stator core. Therefore, regardless of the size of the transition portion (coil end), the winding assembly can be easily inserted into the stator core and incorporated into the stator core.

  In this stator manufacturing method, the winding support member is deformed into a cylindrical diameter-expanded state and a truncated cone-shaped diameter-reduced state, and in the winding preparation step, the winding assembly is transformed into a truncated cone. It is preferably arranged on the outer peripheral surface of the winding support member in a deformed state, and in the winding insertion step, the winding assembly is preferably inserted from the end on the small diameter side into the stator core. is there.

  According to this method, since it is not necessary to deform the one end side in the axial direction of the winding assembly, for example, compared with the case where the entire winding assembly is deformed, the work of the winding preparation process and the winding mounting process is performed. Improves.

  In each of the above stator manufacturing methods, the stator core is such that the gap dimension of each slot in the circumferential direction is larger on the outer peripheral side than the inner peripheral side of the stator core, and the element wire has a bottom side and both sides thereof Is a cross-sectional home base type having a pair of sides extending in parallel with each other and a pair of oblique sides connecting the ends of these sides, and defining the point where the pair of oblique sides are connected as a pointed portion, The in-slot passage portion extends along the radial direction of the stator core such that the pointed portions of adjacent windings face the opposite side of the circumferential direction and the oblique sides of the adjacent windings abut each other. In the winding preparation step, the circumferential thickness of the passage portion in the slot is the gap dimension at the slot inlet. The winding assembly is disposed on the outer peripheral surface of the winding support member in an arrangement state in which the windings constituting the passing portion in the slot are shifted in the radial direction so as to reduce the winding, and the winding mounting In the process, it is preferable that the passing portions in each slot are pressed into the slots by the winding support member to close adjacent windings in the radial direction.

  According to this manufacturing method, the winding group consisting of the cross-sectional home base type strands having a relatively large cross-sectional area can be inserted into the slot having a narrow slot inlet and a wide depth as described above without any gap. Is possible. Therefore, it is advantageous in increasing the linear space factor of the stator.

  On the other hand, a stator manufacturing apparatus of the present invention is a stator manufacturing apparatus that is used in any one of the above-described stator manufacturing methods and supports the winding assembly and is attached to the stator core. A support device that has a winding support portion that can be deformed to a reduced diameter state, and that supports the passing portion in each slot of the winding assembly from the inside; and And a driving device to be deformed.

  According to this manufacturing apparatus, the winding assembly is inserted inside the stator core together with the winding support in a state in which the winding assembly is disposed on the outer peripheral surface of the winding support in the reduced diameter state, By enlarging the diameter of the winding support portion by the driving device, the passing portion in each slot of the winding assembly can be inserted into the slot of the stator core. Therefore, it is possible to satisfactorily implement the stator manufacturing method described above.

  In this stator manufacturing apparatus, it is preferable that the winding support portion be deformed into the diameter-expanded state and the reduced-diameter state having a truncated cone shape.

  According to this manufacturing apparatus, the winding assembly can be inserted inside the stator core in a state of being deformed into a truncated cone shape.

  More specifically, in the above stator manufacturing apparatus, the winding support portions are arranged at regular intervals in the circumferential direction and extend along the center line of the winding support portion, and each slot of the winding assembly is provided. The inner passage portion is formed by a plurality of segments that respectively support the inner passage portion, and the support device further includes a base member that supports the plurality of segments so as to be displaceable in a radial direction of the winding support portion, Each segment is displaced in the radial direction with respect to the base member.

  According to this manufacturing apparatus, in accordance with the deformation of the winding support portion from the reduced diameter state to the expanded diameter state, each segment passes through each slot passing portion of the winding assembly from the inside to enter the stator core slot. Can be inserted. That is, the in-slot passage portion can be individually pushed into the slot by each segment.

  In this case, the plurality of segments are swingably supported by the base member with their lower end portions as fulcrums, and the winding support portion has a cylindrical shape when each segment is in a vertical posture. You may deform | transform into the said diameter-reduced state which makes a truncated cone shape because each segment becomes a tilting attitude | position.

  According to this manufacturing apparatus, the winding assembly is inserted into the inside of the stator core in a state of being deformed into a truncated cone shape, and each slot passing portion of the winding assembly is individually pushed into the slot by each segment. Is possible.

  In this case, the drive device includes an operation member that integrally pushes each segment outward by moving the inside of the winding support portion in a reduced diameter state along the center line. Is preferred.

  According to this manufacturing apparatus, the segments are integrally displaced by a relatively simple mechanism that only moves the operation member along the center line, that is, the winding support portion is reduced from the reduced diameter state to the enlarged diameter state. It is possible to deform it.

  In this case, the operation member has a plurality of contact portions that are arranged in a moving direction of the operation member at a predetermined interval, and contact each segment at a position different from each other in the radial direction of the winding support portion, The plurality of contact portions are preferably formed such that the outer diameter dimension is larger toward the rear side in the moving direction.

  According to this manufacturing apparatus, each segment can be displaced relatively gently as the operation member moves. Therefore, it is possible to smoothly insert the passing portions in the slots of the winding assembly into the corresponding slots while suppressing the segments from moving suddenly.

  In each stator manufacturing apparatus as described above, the winding support part includes a guide wall that is disposed between adjacent segments and regulates displacement in the circumferential direction of each slot passing part of the winding assembly. It may be.

  According to this configuration, it is possible to more smoothly insert the winding assembly into the slot while guiding the passing portion in each slot by the guide wall.

  In this case, when the driving device includes the operation member, it is preferable that the operation member includes a plurality of slits for allowing the guide walls to escape.

  According to this configuration, it is possible to press each slot passing portion of the winding assembly into the slot by the operation member while avoiding interference between the guide walls and the operation member.

  As described above, according to the stator manufacturing method and the stator manufacturing apparatus of the present invention, a plurality of coils (winding groups) can be easily connected to the stator core from the inside of the stator core regardless of the size of the coil end (crossover portion). It becomes possible to incorporate it into.

It is a perspective schematic diagram showing a stator of a rotating electrical machine. It is a longitudinal section schematic diagram showing a stator. It is a plane section schematic diagram showing a stator. (A) is sectional drawing of a coil | winding (elementary wire), (b) is a principal part enlarged view of FIG. FIG. 3 is a developed longitudinal cross-sectional schematic diagram showing a winding path of a winding group, where (a) shows a winding path of a first U-phase winding group, and (b) shows a winding of a second U-phase winding group. Indicates the route. FIG. 2 is a developed plan schematic view (top view) showing a winding path of a first U-phase winding group, (a) showing a winding path of a forward winding group, and (b) showing a reverse winding group. The winding path of is shown. FIG. 3 is a developed plan schematic view (top view) showing a winding path of a second U-phase winding group, (a) showing a winding path of a forward winding group, and (b) showing a reverse winding group. The winding path of is shown. (A) is a perspective schematic diagram explaining the wiring state of the 1st U-phase winding group (positive winding group) derived | led-out from the slot, (b) extracts the coil | winding with a torsion from (a). FIG. FIG. 7 is a schematic cross-sectional view showing a wiring state of a winding group derived from a slot, where (a) is a line IXa-IXa in FIG. 6 (a), and (b) is a line IXb-IXb in FIG. 6 (a). It is a cross-sectional schematic diagram along each line. (A) is a perspective schematic diagram explaining the wiring state of the 1st U-phase winding group (positive winding group) inserted in a slot, (b) is a figure which shows the coil | winding by which twist is returned. It is the isometric view schematic diagram extracted from. It is a cross-sectional schematic diagram which shows the wiring state of the winding group on the axial direction end surface of a stator core, (a) is a XIa-XIa line of Fig.6 (a), (b) is XIb of Fig.6 (a). -XIb line, (c) is a schematic cross-sectional view taken along line XIc-XIc in FIG. 6 (a), and (d) is a cross-sectional schematic view taken along line XId-XId in FIG. 6 (a). FIG. 4 is a schematic cross-sectional view showing a slot portion of a stator, where (a) shows a case where a thick winding with a rectangular cross section (rectangle) is used, (b) shows a case where a thin winding with a circular cross section is used, and (c) shows a cross section. 4 is a schematic cross-sectional view showing a case where a pentagonal home base type winding is used. (A) is sectional drawing of a 1st winding assembly and a stator manufacturing apparatus (1st apparatus), (b) is sectional drawing of the stator manufacturing apparatus and stator core in which the 1st winding assembly was set. is there. (A) is sectional drawing of the stator manufacturing apparatus (1st apparatus) of the state in which the 1st winding assembly was inserted in the stator core with the coil | winding support part, (b) is a 1st winding assembly. FIG. 5 is a cross-sectional view of the stator core and the stator manufacturing apparatus after being mounted. It is sectional drawing of the coil | winding support part (segment) and stator core of a support apparatus. It is sectional drawing of the 2nd operation member of a drive device. (A)-(c) are the stator core and the 1st, 2nd operation which show the state where the passage part in a slot of a winding assembly is pressed by the contact part of the 1st, 2nd operation member, and is inserted in a slot. It is sectional drawing of a member. (A) is sectional drawing of a 2nd winding assembly and a stator manufacturing apparatus (2nd apparatus), (b) is a stator manufacturing apparatus and the 1st winding set in which the 1st winding assembly was set. It is sectional drawing of the stator core with which the solid was mounted | worn. (A) is sectional drawing of the stator manufacturing apparatus (2nd apparatus) of the state in which the 2nd winding assembly was inserted in the stator core with the coil | winding support part, (b) is 1st, 2nd winding It is sectional drawing of the stator core and stator manufacturing apparatus after the wire assembly was mounted | worn. It is sectional drawing of the coil | winding support part (segment) of a support apparatus, a guide wall, and a stator core. (A)-(c) is sectional drawing of the stator core and operation member which show the state by which the passage part in a slot of a coil | winding assembly is pressed by the contact part of an operation member, and is inserted in a slot. (A)-(c) is explanatory drawing explaining the other example of the manufacturing method of a stator.

  Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  Before describing the stator manufacturing method and the stator manufacturing apparatus of the present invention, first, a stator for a rotating electrical machine manufactured using the manufacturing method and the manufacturing apparatus will be described.

  1 to 3 schematically show a stator S of a rotating electrical machine, FIG. 1 is a perspective view, and FIGS. 2 and 3 are sectional views showing the stator S, respectively.

  A stator S shown in the figure is a stator used in a three-phase AC motor (an example of a rotating electric machine) mounted on a hybrid vehicle. Specifically, a three-phase AC motor is constituted by the stator S, a rotor disposed inside the stator S, a casing that accommodates the stator S and the rotor, and the like.

  The stator S includes an annular stator core 10 and a first coil member 14A and a second coil member 14B each including a plurality of winding groups wound around a slot 12 thereof. In the following description, the direction around the central axis of the stator core 10 is referred to as a circumferential direction, and the radial direction of the stator core 10 is simply referred to as a radial direction.

  As shown in FIG. 3, the stator core 10 includes a plurality of slots 12 that open inward and extend radially at a plurality of positions arranged at equal intervals in the circumferential direction. A portion between adjacent slots 12 is a tooth 10 a of the stator core 10. Although not clearly shown in the figure, the cross-sectional shape of each slot 12 is formed so as to expand outward from the inside in the radial direction so that the thickness of the tooth 10a in the circumferential direction is substantially constant over the radial direction. (See FIG. 12C). With this configuration, a more uniform magnetic flux can be formed over the entire radial direction of each tooth 10a.

  The stator core 10 includes 48 slots 12 in this example. As will be described in detail later, each of the U-phase, V-phase, and W-phase winding groups is wound around the stator 10 so as to pass through a specific plurality of slots 12 among the 48 slots 12. . In other words, the stator core 10 includes two adjacent slots 12 into which U-phase winding groups are respectively inserted, two adjacent slots 12 into which V-phase winding groups are respectively inserted, and W Eight sets of slot groups are provided in the circumferential direction of the stator core 10, with two adjacent slots 12 into which phase winding groups are inserted as one set. That is, the rotating electrical machine to which the stator S is applied is an 8-pole rotating electrical machine having 48 slots.

  In FIG. 3, the slots 12 into which the U-phase winding groups are respectively inserted are denoted by reference numerals U1, U2, U3, U4,... U15, U16, and the slots 12 into which the V-phase winding groups are respectively inserted. Are indicated by reference numerals V1, V2, V3, V4,..., V15, V16, and slots 12 into which W-phase winding groups are respectively inserted are indicated by reference signs W1, W2, W3, W4,. In the following description, the symbols U1, U2, U3, U4,... U15, U16 shown in FIG. Similarly, the symbols V1, V2, V3, V4,... V15, V16 in the figure are used as the symbols of the slots into which the V-phase winding groups are respectively inserted, and the slots into which the W-phase winding groups are respectively inserted. W1 · W2, W3 · W4... W15 · W16 are used.

  The stator core 10 is configured by stacking and integrating a plurality of plates made of a magnetic material (steel plate) having a shape as shown in FIG. 3, for example.

  The first coil member 14 </ b> A and the second coil member 14 </ b> B each include a plurality of winding groups wound around the stator core 10. The basic configuration of the first coil member 14A and the second coil member 14B is the same except that the second coil member 14B is provided inside the first coil member 14A. Therefore, in the following description, the first coil member 14A will be described in detail, and the configuration of the second coil member 14B will be referred to as necessary.

  The first coil member 14A includes a pair of U-phase winding groups 20Ua and 20Ub (first U-phase windings) wound around the stator core 10 so as to pass through the slots U1, U2, U3, U4,. Wire group 20Ua and second U-phase winding group 20Ub (see FIG. 4B)) and two wound around stator core 10 so as to pass through slots V1, V2, V3, V4,. Pass through a set of V-phase winding groups 20Va, 20Vb (referred to as first V-phase winding group 20Va and second V-phase winding group 20Vb) and slots W1, W2, W3, W4, ... W15, W16. And a set of two W-phase winding groups 20Wa and 20Wb (referred to as a first W-phase winding group 20Wa and a second W-phase winding group 20Wb) wound around the stator core 10. In FIG. 1, the first coil member 14 </ b> A and the second coil member 14 </ b> B are shown very schematically by collectively grouping the winding groups wound along the same path.

  The U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb have the same basic configuration except that the passing slots 12 are different from each other. Therefore, in the following description, the configuration of the U-phase winding groups 20Ua and 20Ub is described in detail, and the configuration of the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb is referred to as necessary. I will do it. In the following description, upper (upper side) and lower (lower side) refer to the state of the stator S shown in FIG. 1, and inner (inner side) and outer (outer side) refer to the radial direction of the stator core 10. And

  The first U-phase winding group 20Ua is composed of a plurality of windings formed by strands 5 having a pentagonal cross section. Specifically, as shown in FIG. 4A, the strand 1 connects the bottom 2a, a pair of side 2b, 2b extending in parallel from both sides, and the ends of these sides 2b, 2b. A cross-sectional home base type having a pair of oblique sides 2c and 2c. In addition, the part which a pair of hypotenuse 2c connects in the cross section of the strand 1 is called a cusp part. The element wire 1 is provided with an insulating film, and the pointed portion is slightly used to suppress damage to the film due to stress concentration at the time of bending or damage (cracking) of the winding wire (element wire 1). It has a roundness.

  As shown in FIG. 4B, the first U-phase winding group 20Ua is composed of a total of six windings formed by the cross-section home base type strands 1 as described above. Specifically, as shown in the figure, the first U-phase winding group 20Ua includes a positive winding group 22a including three windings r1 to r3 and a reverse winding including three windings r1 ′ to r3 ′. Group 22b. The forward winding group 22a and the reverse winding group 22b are such that the current flowing directions are opposite to each other in the circumferential direction at the coil end portion, and the current flowing directions are the same in the slot 12. As will be described in detail later, the winding insertion direction and the lead-out direction with respect to the slot 12 are opposite to each other.

  Similarly, as shown in FIG. 4B, the second U-phase winding group 20Ub is composed of a total of six windings formed by the home-base type pentagonal wire 1 having a cross section. A forward winding group 24a including three windings r4 to r6 and a reverse winding group 24b including three windings r4 ′ to r6 ′ are included.

  Each of the U-phase winding groups 20Ua and 20Ub is formed by being wound around the stator core 10 by wave winding (a kind of distributed winding) as shown in FIGS. That is, the winding structure of each U-phase winding group 20Ua, 20Ub is a wave winding.

  More specifically, the positions of the slots U1 and U2 will be described as a reference. First, the positive winding group 22a of the first U-phase winding group 20Ua includes the stator core 10 as shown in FIGS. 5 (a) and 6 (a). It is inserted into the slot U1 from the lower side and led out to the upper side, inserted into the slot U4 from the upper side of the stator core 10 and led out to the lower side, and inserted into the slot U5 from the lower side of the stator core 10 and led out to the upper side. Specifically, it is wound around the stator core 10 by wave winding via the slots U1, U4, U5, U8, U9, U12, U13, U16.

  As shown in FIG. 5A and FIG. 6B, the reverse winding group 22b of the first U-phase winding group 20Ua is inserted into the slot U1 from the upper side of the stator core 10 and led out to the lower side. The stator core 10 is wound around the stator core 10 so that it is inserted into the slot U4 from the lower side and led out to the upper side, inserted into the slot U5 from the upper side of the stator core 10 and led out to the lower side. That is, the reverse winding group 22b has the same slots U1, U4, U5, U8, and the same as the positive winding group 22a so that the insertion direction and the leading direction of the winding with respect to the slot 12 are opposite to those of the positive winding group 22a. It is wound around the stator core 10 by wave winding via U9, U12, U13, U16.

  As shown in FIG. 4B, the windings r1 to r3 of the positive winding group 22a and the windings r1 'to r3' of the reverse winding group 22b are arranged in the radial direction of the stator core 10 (in FIG. 4B). In the state of being arranged in a line in the left and right direction, specifically, the windings r1 to r3 of the positive winding group 22a are continuously arranged in a line on one side in the radial direction and adjacent to the positive winding group 22a. Thus, the windings r1 'to r3' of the reverse winding group 22b are inserted into the slots U1 and U4 to U16 in a state where they are continuously arranged in a line. More specifically, the windings in which the pointed portions of the adjacent windings face opposite to each other in the circumferential direction and the hypotenuses 2c of the adjacent windings are in contact with each other and the direction of the pointed portion is common. Of adjacent ones of the windings r1 and r3 of the positive winding group 22a and the windings r2 'of the reverse winding group 22b of the neighboring windings 2b. The windings r1 to r3 are in contact with each other, and the adjacent sides 2b of the winding r2 of the positive winding group 22a and the windings r1 'and r3' of the reverse winding group 22b are in contact with each other. , R1 ′ to r3 ′ are inserted in the slots U1 and U4 to U16.

  As shown in FIGS. 6A and 6B, in the forward winding group 22a and the reverse winding group 22b, the positional relationship between the inside and the outside in the radial direction of the stator core 10 is alternated for each of the slots U1 and U4 to U16. Is wound around the stator core 10 so as to be replaced.

  On the other hand, as shown in FIGS. 5B and 7A, the positive winding group 24a of the second U-phase winding group 20Ub is inserted into the slot U2 from the lower side of the stator core 10 and led out to the upper side. The slots U2, U3, U6, U7, U9 are inserted into the slot U3 from the upper side of the stator core 10 and led out to the lower side, inserted into the slot U6 from the lower side of the stator core 10 and led out to the upper side. It is wound around the stator core 10 by wave winding via U10, U11, U14, U15.

  As shown in FIG. 5B and FIG. 7B, the reverse winding group 24b of the second U-phase winding group 20Ub is inserted into the slot U2 from the upper side of the stator core 10 and led out to the lower side. It is wound around the stator core 10 so that it is inserted into the slot U3 from the lower side and led out to the upper side, inserted into the slot U6 from the upper side of the stator core 10 and led out to the lower side. That is, the reverse winding group 24b has the same slots U2, U3, U6, U7 as the positive winding group 24a so that the insertion direction and the leading direction of the winding with respect to the slot 12 are opposite to those of the positive winding group 24a. It is wound around the stator core 10 by wave winding via U9, U10, U11, U14, U15.

  The windings r4 to r6 of the positive winding group 24a and the windings r4 'to r6' of the reverse winding group 24b are similar to the winding groups 22a and 22b of the first U-phase winding group 20Ua described above, as shown in FIG. As shown in (b), the stator cores 10 are inserted into the slots U2, U3 to U15 in a state of being arranged in a line in the radial direction. As for the second U-phase winding group 20Ub, as shown in FIGS. 7 (a) and 7 (b), the forward winding group 24a and the reverse winding group 24b have the stator core 10 in each of the slots U2, U3 to U15. Is wound around the stator core 10 so that the positional relationship between the inside and the outside in the radial direction is alternately switched.

  Note that the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are formed as pointed windings r1 and r4 positioned on the radially outermost side of the stator core 10, as shown in FIGS. 3 and 4B. In this example, the slots U1, U2,... Are arranged so that the pointed portions of the windings r1, r4 face each other on the same side in the circumferential direction (the lower side in FIG. 4B). ... is inserted into U15 and U16.

  The positive winding group 22a of the first U-phase winding group 20Ua and the positive winding group 24a of the second U-phase winding group 20Ub are axial end faces on the axial end face (upper and lower end faces) of the stator core 10. The windings r1 to r3 and r4 to r6 are arranged along the axial direction of the stator core 10 in a state where the bases 2a are parallel and the oblique sides 2c or the bases 2a are in contact with each other.

  Specifically, as schematically shown in FIG. 8A, the inner two windings r2 of the positive winding group 22a of the first U-phase winding group 20Ua led out from the slot U1 to the upper side of the stator core 10. , R3 are bent at a right angle so as to be substantially horizontal (substantially parallel to the axial end surface of the stator core 10), and the remaining winding r1 is further bent 180 ° inward while being bent at a right angle (FIG. 8). (See (b)), the bottoms 2a of the windings r3 are overlapped with each other so as to contact each other. On the other hand, of the positive winding group 24a of the second U-phase winding group 20Ub led out from the slot U2 to the upper side of the stator core 10, the inner two windings r5 are bent as they are at substantially right angles, and the remaining winding r4. Are overlapped so that the bases 2a of the windings r5 are in contact with each other on the upper side of the winding r5, and the hypotenuses 2c are stacked on the lower side of the winding r1. . As a result, as shown in FIG. 9B, the winding r1 of the positive winding group 22a of the first U-phase winding group 20Ua in a state in which the hypotenuses 2c are in contact with each other or in a state in which the bases 2a are in contact with each other. The windings r4 to r6 of the positive winding group 24a of the second U-phase winding group 20Ub are overlaid on the lower side of .about.r3. 9A is a schematic cross-sectional view of the winding group along the line IXa-IXa in FIG. 6A, and FIG. 9B is the line IXb-IXb in FIG. It is the same cross-sectional schematic diagram along.

  As shown in FIGS. 6 (a) and 7 (a), the positive winding group 22a of the first U-phase winding group 20Ua and the positive winding group 24a of the second U-phase winding group 20Ub are stacked as described above. As it goes to the next slot U3, U4, it is arranged along the upper end surface of the stator core 10 so as to be displaced radially inward of the stator core 10. Then, as schematically shown in FIG. 10A, first, the positive winding group 24a of the second U-phase winding group 20Ub located on the lower side is inserted into the slot U3 from the upper side of the stator core 10. In this case, the lower windings r5 and r6 are bent at a substantially right angle, and the remaining windings r4 are bent at a substantially right angle and arranged outside the other windings r5 and r6. Thus, the positive winding group 24a is inserted into the slot U3 in a state where the windings r4 to r6 are aligned in the radial direction of the stator core 10.

  On the other hand, in the positive winding group 22a of the first U-phase winding group 20Ua, the upper two windings r2 and r3 are bent at a right angle as they are, and the remaining winding r1 is bent at a right angle and 180 ° outward. In a twisted state (see FIG. 10B), they are arranged outside the other windings r2 and r3. Thus, the positive winding group 22a is inserted into the slot U4 in a state where the windings r1 to r3 are arranged in a line in the radial direction of the stator core 10. Note that the winding r1 is twisted 180 ° outward as described above because the winding r1 is led out of the slot U1 and then twisted 180 ° inward to overlap another winding r3. (FIGS. 8A and 8B) to eliminate this twist.

  Here, the arrangement of the positive winding groups 22a and 24a on the upper side of the stator core 10 has been specifically described. However, on the lower side of the stator core 10, the vertical relationship of the positive winding groups 22a and 24a is reversed, that is, FIG. The arrangement is vertically symmetrical with the arrangement of (b). The other arrangements of the positive winding groups 22 a and 24 a are basically common to both the upper and lower sides of the stator core 10.

  Here, although the positive winding groups 22a and 24a have been described, the arrangement of the reverse winding groups 22b and 24b on the upper and lower sides of the stator core 10 is basically the same as that of the positive winding groups 22a and 24a. That is, the arrangement is equivalent to the arrangement in which the windings r1 to r3 and the windings r4 to r6 in FIGS. 9A and 9B are replaced with windings r1 ′ to r3 ′ and windings r4 ′ to r6 ′.

  In this way, the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10. The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are sequentially inserted into a pair of adjacent slots U1, U2, U3, U4,... U15, U16, as described above (FIG. 5). The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are different in the circumferential direction of each pair of slots U1, U2, U3, U4,. Is inserted into the slot 12. That is, the winding group derived from the odd-numbered slot 12 is inserted into the next even-numbered slot 12, while the winding group derived from the even-numbered slot 12 is inserted into the next odd-numbered slot 12. Inserted into. As a result, as described above, the first U-phase winding group 20Ua is inserted into the slots U1, U4, U5, U8, U9, U12, U13, U16, and the second U-phase winding group 20Ub is inserted into the slot slots U2, U3. , U6, U7, U9, U10, U11, U14, U15. In this way, the first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10, so that the positive winding group 22a and the positive winding group 24a do not cross each other, and The first U-phase winding group 20Ua and the second U-phase winding group 20Ub are wound around the stator core 10 by wave winding without the reverse winding group 22b and the reverse winding group 24b intersecting each other.

  The configuration of the U-phase winding groups 20Ua and 20Ub has been described in detail above. However, the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb are basically the same except that the positions of the passing slots 12 are different. Specifically, the configuration is the same as that of the U-phase winding groups 20Ua and 20Ub.

  Note that the U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb are adjacent to each other in the radial direction of the stator core 10 on the upper and lower end surfaces of the stator core 10. They are led out from the slot 12 and displaced from the lead-out position to the next slot 12, respectively, and are displaced inward or outward in the radial direction of the stator core 10 so that the lead-out position differs from the lead-out position in the radial direction. It is inserted into the slot 12.

  This point will be specifically described with reference to FIGS. 9B and 11A to 11D. 9B is a schematic cross-sectional view of the winding group along the line IXb-IXb in FIG. 6A as described above, that is, a schematic cross-sectional view of the winding group at a position between the slot U2 and the slot V1. 11A to 11D are cross-sectional schematic views of winding groups along the XIa-XIa line, the XIb-XIb line, the XIc-XIc line, and the XId-XId line in FIG. 6A, respectively. FIG. 4 is a schematic cross-sectional view of a winding group between slots V1 to U3.

  As shown in these drawings, at the position between the slot U2 and the slot V1, as shown in FIG. 9B, the positive winding group 22a and the second U-phase winding group 20Ub of the first U-phase winding group 20Ua are provided. The positive winding group 24a is vertically stacked. Then, the reverse winding group 22b of the first W-phase winding group 20Wa and the reverse winding group 24b of the second W-phase winding group 20Wb are similarly stacked on the inside of the U-phase winding groups 20Ua and 20Ub. Further, the reverse winding group 22b of the first V-phase winding group 20Va and the reverse winding group 24b of the second U-phase winding group 20Vb are similarly stacked on the inner side.

  The reverse winding group 22b of the second V-phase winding group 20Va located at the innermost position at the position of the slot V1 is inserted into the slot V1, while the positive winding of the second V-phase winding group 20Va from the slot V1. By deriving the group 22a, at the position between the slot V1 and the slot V2, as shown in FIG. 11A, the positive winding group 22a of the first V-phase winding group 20Va becomes the U-phase winding group 20Ua. , 20 Ub.

  Next, the reverse winding group 24b of the second V-phase winding group 20Vb located at the innermost position at the position of the slot V2 is inserted into the slot V2, while the positive winding of the second V-phase winding group 20Vb from the slot V2 is inserted. When the winding group 24a is derived, the positive winding group 24a of the second V-phase winding group 20Vb becomes U-phase winding at the position between the slot V2 and the slot W1 as shown in FIG. 11B. On the outside of the groups 20Ua and 20Ub, the second V-phase winding group 20Va is overlaid on the lower side of the positive winding group 22a.

  Then, the reverse winding group 22b of the innermost second W-phase winding group 20Wa is inserted into the slot W1 at the position of the slot W1, while the positive winding of the second W-phase winding group 20Wa is inserted from the slot W1. When the winding group 22a is derived, at the position between the slot W1 and the slot W2, as shown in FIG. 11C, the positive winding group 22a of the second W-phase winding group 20Wa becomes the V-phase winding. Superposed on the outside of the groups 20Va, 20Vb.

  Then, the reverse winding group 24b of the second W-phase winding group 20Wb located at the innermost position at the position of the slot W2 is inserted into the slot W2, while the positive winding of the second W-phase winding group 20Wb from the slot W2 is inserted. Since the winding group 24a is derived, the positive winding group 24a of the second W-phase winding group 20Wb becomes a V-phase winding at a position between the slot W2 and the slot U3 as shown in FIG. On the outside of the groups 20Va and 20Vb, they are superimposed on the lower side of the positive winding group 22a of the second W-phase winding group 20Wa.

  In this way, the U-phase winding groups 20Ua and 20Ub, the V-phase winding groups 20Va and 20Vb, and the W-phase winding groups 20Wa and 20Wb are arranged adjacent to each other in the radial direction of the stator core 10, and are respectively formed from the slots 12. The winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb are inserted into the slot 12 while being displaced radially inward of the stator core 10 from the lead-out position toward the next slot 12. Are guided in the next slot 12 while maintaining a compact arrangement without crossing each other.

  The configuration of the first coil member 14A has been described above, but the configuration of the second coil member 14B is also equivalent to the first coil member 14A. 3 and 4B, the second U-phase winding group 20Ua of the second coil member 14B has a diameter of the stator core 10 with respect to the first U-phase winding group 20Ua of the first coil member 14A. The second U-phase winding group 20Ub of the second coil member 14B is inserted into the same slot 12 as the first U-phase winding group 20Ua so as to be aligned in a line in the direction, and the second U-phase winding of the first coil member 14A They are arranged in the same slot 12 as the second U-phase winding group 20Ub so as to be aligned in a row in the radial direction with respect to the group 20Ub. The same applies to the V-phase winding groups 20Va and 20Vb and the W-phase winding groups 20Wa and 20Wb of the second coil member 14B.

  According to the stator S as described above, the windings r1 to r3, r1 'to r3'r4 to r6, and r4' to r6 'of the winding groups 20Ua, 20Ub, 20Va, 20Vb, 20Wa, and 20Wb are pentagonal cross sections. Formed by a base type wire 1, windings r1 to r3, r1 'to r3' (windings r4 to r6, r4 'to r6') are inserted into the slot 12 with the hypotenuses 2c in contact with each other Has been. According to such a configuration, since adjacent windings are inserted into the slot 12 in a state where they overlap each other in the radial direction of the stator core 10, windings with a circular or rectangular (rectangular) cross-sectional shape (wires) As compared with the case of using (), windings having a larger cross-sectional area (thick windings) can be closely arranged in the slot 12 in an aligned state. Therefore, it is possible to effectively increase the linear space factor of the stator S (the ratio of the cross-sectional area of the winding to the cross-sectional area of the slot). That is, as described above, the cross-sectional shape of each slot 12 is formed so as to widen from the radially inner side to the outer side of the stator core 10. Therefore, for example, as shown in FIG. 12A, when a thick winding ra having a rectangular cross section is used, the basic structure (even if the length of one side of the cross section is approximately the same as the entrance width of the slot) Compared with the slot in FIG. 12B (the two-dot chain line in FIG. 12A), which is a comparison target, a relatively large gap is formed in the radially outer portion. Further, as shown in FIG. 12B, when a thin winding rb having a circular cross-sectional shape is used, although the slot can be filled with the winding rb in appearance, the windings rb are connected to each other. Since it is impossible to make a close contact without a gap, the total gap area in the slot is considerably large. On the other hand, as shown in FIG. 12C, when the home base type winding rc is used, the length of one side lowered from the pointed portion of the winding rc to the bottom 2a is set to the entrance of the slot 12. If the winding is set to be slightly smaller than the width, a winding having a larger cross-sectional area than the winding ra having a rectangular cross section (rectangular shape) even if the number of windings is the same as the example of FIG. They can be inserted into the slot 12 while being arranged in the radial direction and in close contact with each other. This is because, as described above, adjacent windings rc can be inserted into the slot 12 in a state where they overlap each other in the radial direction. Therefore, compared with the configuration of FIGS. 12A and 12B, the gap area with respect to the slot of FIG. 12B which is a comparison target (the two-dot chain line of FIG. 12C) is effectively reduced. It becomes possible to increase the line space factor.

  The configuration of the stator S has been described above. Next, a method for manufacturing the stator S and an example of a stator manufacturing apparatus used for manufacturing the stator S will be described.

  In the present embodiment, the stator S is generally manufactured by first winding assembly 16A having the same shape as first coil member 14A (a plurality of winding groups) and second coil member 14B (a plurality of windings). Group) and the second winding assembly 16B having the same shape as the stator core 10 are separately formed separately from the stator core 10 (winding forming step), and the winding assemblies 16A and 16B are formed using the stator manufacturing apparatus. This is done by mounting the stator core 10 in order from the one-winding assembly 16A.

  The first winding assembly 16A can be manufactured, for example, as follows. First, one strand 1 is formed into a waveform by forming, and this is further wound three times by forming. Thereby, a winding group corresponding to the positive winding group 22a of the first U-phase winding group 20Ua is formed. Similarly, a total of four winding groups corresponding to the reverse winding group 22b of the first U-phase winding group 20Ua, the positive winding group 22a and the reverse winding group 22b of the second U-phase winding group 20Ub are formed, By combining these, one U-phase winding group including winding groups respectively corresponding to the first U-phase winding group 20Ua and the second U-phase winding group 20Ub is formed.

  Similarly, one V-phase winding group including winding groups respectively corresponding to the first V-phase winding group 20Va and the second V-phase winding group 20Vb, and the first W-phase winding group 20Wa and the second W-phase winding group. One W-phase winding group including winding groups respectively corresponding to the wire group 20Wb is formed, and these U-phase, V-phase and W-phase winding groups are combined. Thereby, the first winding assembly 16A can be formed. The same applies to the second winding assembly 16B.

  FIG. 13A schematically shows the first winding assembly 16A formed in the winding forming step and the stator manufacturing apparatus 30 in a cross-sectional view.

  The stator manufacturing apparatus 30 includes a first device 30A shown in FIG. 13A and a second device 30B shown in FIG. The first device 30A is a device for mounting the first winding assembly 16A to the stator core 10, and the second device 30B is a device for mounting the second winding assembly 16B to the stator core 10.

  The first device 30A includes a support device 32A that supports the first winding assembly 16A and a drive device 34A that drives the support device 32A.

  The support device 32A is inserted into the portion of the first winding assembly 16A that passes through the slot 12 of the stator core 10 (hereinafter referred to as the in-slot passage portion 17 / see FIG. 5A), that is, the slot 12. A winding support portion 42 (corresponding to a winding support member) that supports the portion from the inside, and a portion that passes on the axial end surface of the stator core 10 (hereinafter referred to as the crossover portion 18 / see FIG. 5A). And a base portion 40 that supports the first winding assembly 16A. The winding support portion 42 can be deformed into a diameter-enlarged state having a cylindrical shape and a reduced diameter shape having a truncated cone shape with a constricted upper portion, and the winding support portion 42 has the first winding assembly 16A. Are formed by a plurality of segments 42a that respectively support the in-slot passage portions 17 from the inside, specifically, the same number of segments 42a as the slots 12 of the stator core 10.

  These segments 42a are shaft-like members extending in the vertical direction along the center line C1 of the winding support portion 42, and are arranged at equal intervals on the circumference centered on the center line C1. Each segment 42a has a cross-sectional shape that can be inserted into the slot 12 from the inside of the stator core 10, and has a rectangular cross section in this example (see FIG. 15).

  Each segment 42a is swingably supported on the upper portion of the base portion 40 with the lower end portion as a fulcrum. Specifically, as shown by the alternate long and short dash line in FIG. 13A, the vertical posture is substantially parallel to the center line C1, and the upper end of each segment 42a approaches the center line C1 as shown by the solid line in FIG. It is supported so that it can swing over the inclined posture. With this configuration, the winding support part 42 can be deformed into the diameter-enlarged state in which the whole is cylindrical, and the diameter-reduced state in the truncated cone shape in which the upper part is narrowed.

  The base portion 40 is an annular member having a certain thickness in the vertical direction, and has an opening 41 having a circular cross section penetrating in the vertical direction at the center.

  Of the upper surface portion of the base portion 40, the segment 42a (winding support portion 42) is supported on the peripheral portion of the opening 41, and the outside of the segment 42a is the winding of the first winding assembly 16A. It becomes the mounting part 40a. The diameter of the opening 41 is set to be larger than the inner diameter of the stator core 10, and therefore the diameter of the circle in which the segment 42 a (swinging fulcrum) is arranged is also larger than the inner diameter of the stator core 10.

  The drive unit 34A includes first and second operation members 44 and 45 that push outward the respective segments 42a of the winding support portion 42 in a reduced diameter state, and the operation members 44 and 45 to the center line C1. And an apparatus main body 48 that moves in the vertical direction along the vertical axis.

  The first operation members 44 are arranged in a vertical direction at a predetermined interval, and a plurality of disk-shaped abutments that are in contact with the segments 42 a at different positions in the radial direction of the winding support 42 as the first operation member 44 rises. Abutting portions (first to third abutting portions 46a to 46c) and a shaft portion 47a connecting these abutting portions 46a to 46c.

  The diameter of the abutting portions 46 a to 46 c is set to be larger at the lower side, and the diameter of the lowest third abutting portion 46 c is set to be smaller than the inner diameter of the stator core 10.

  The apparatus main body 48 includes a head (not shown) to which the first and second operation members 44 are detachably mounted, and the actuator 49 that drives the head in the vertical direction. In this example, the actuator 49 is a hydraulic cylinder.

  The second operating member 45 has a configuration similar to the first operating member 44. That is, the second operation member 45 includes a substantially disc-shaped contact portion 46d and a shaft portion 47b. The diameter of the contact portion 46d is set to be larger than the inner diameter of the stator core 10 and slightly smaller than the diameter of the opening 41 of the base portion 40. As shown in FIG. 16, slits 461 are formed at equal intervals in the circumferential direction on the outer peripheral surface of the contact portion 46d. These slits 461 are for releasing the teeth 10 a of the stator core 10. That is, the teeth 10a are interposed in the slit 461 as the second operating member 45 is raised, so that the first winding assembly 16A passes through each slot while avoiding interference between the contact portion 46d and the teeth 10a. The portion 17 can be pushed to a predetermined position in the slot 12 by the contact portion 46d.

  The second operation member 45 is configured to be attachable to the head of the apparatus main body 48 instead of the first operation member 44. As a result, the second operating member 45 is driven in the vertical direction by the apparatus main body 48 in the same manner as the first operating member 44.

  The first device 30A has been described above, but the second device 30B also has the same configuration as the first device 30A except for points described below.

  That is, as shown in FIG. 18A, the second device 30B includes a support device 32B that supports the second winding assembly 16B and a drive device 34B that drives the support device 32B. The support device 32B includes a winding support portion 52 (corresponding to a winding support portion) that supports the in-slot passage portion 17 of the second winding assembly 16B from the inside, and a second winding set via the crossover portion 18. And a base portion 50 that supports the solid 16B. The winding support portion 52 can be deformed into a diameter-enlarged state having a cylindrical shape and a diameter-reduced state having a truncated cone shape whose upper portion is narrowed.

  The winding support part 52 includes a plurality of segments 52a. Each segment 52a is supported by a peripheral edge portion of an opening portion 51 formed in the center of the base portion 50 and penetrating in the vertical direction. Out of the upper surface of the base portion 50, the outside of the segment 42a is the second winding set. It is the winding mounting part 50a of the solid 16B.

  As shown in FIG. 18 (a), the support device 32B of the second device 30B includes guide walls 53 between the adjacent segments 52a. In this respect, the support device 32B of the first device 30A is different from the support device 32A of the first device 30A. The configuration is different. These guide walls 53 restrict the in-slot passage portion 17 of the second winding assembly 16B from shifting in the circumferential direction. Each guide wall 53 is made of a plate-like member extending in the vertical direction, and is provided radially about the center line C <b> 2 of the winding support portion 52. Each guide wall 53 is formed to be continuous with each tooth 10a as shown in FIG. 20 when the winding support 52 is inserted into the stator core 10 together with the second winding assembly 16B. . Therefore, each guide wall 53 is provided so as to protrude to the inside of the opening 51 as shown in FIG.

  The drive device 34B includes one operation member 54 corresponding to the first operation member 44 of the first device 30A, and an apparatus main body 58 having an actuator 59 that moves the operation member 54 in the vertical direction. As the operating member 54 moves up, the first to third contact portions 56a to 56c that contact each segment 54a at different positions in the radial direction of the winding support portion 52, and these contact portions 56a to 56a. And a shaft portion 57 for connecting 56c. Each contact portion 56a to 56c of the operation member 54 has the same configuration as the contact portion 46d of the second operation member 45 of the first device 30A. That is, slits 462 (see FIG. 21) are formed at equal intervals in the circumferential direction on the outer peripheral surfaces of the contact portions 56a to 56c. These slits 462 are for letting the guide wall 53 escape. That is, each guide wall 53 is provided in a state of protruding inside the opening 51 of the base portion 50 as described above, but by interposing the teeth 10a in the slit 462 as the operating member 54 is raised, The in-slot passage portions 17 of the second winding assembly 16B can be pushed into the slots 12 by the contact portions 56a to 56c, while avoiding interference between the contact portions 56a to 56c and the teeth 10a. ing. Note that the second device 30B is not provided with the second operation member 45 unlike the first device 30A.

  The first winding assembly 16A and the second winding assembly 16B formed in the winding forming process are mounted on the stator core 10 based on the following process by using the stator manufacturing apparatus 30 described above. Can do.

(First winding preparation process)
First, as shown to Fig.13 (a), the 1st operation member 44 is mounted | worn with the apparatus main body 48 of 1st apparatus 30A, and the 1st operation member 44 is arrange | positioned at the stroke lower end. Thereby, each segment 42a is inclined, and the winding support part 42 is made into a truncated cone-shaped diameter-reduced state as shown by the solid line in FIG.

  In this state, the first winding assembly 16A is set on the support device 32A of the first device 30A. Specifically, the winding support portion 42 is wound from above the first winding assembly 16A to the winding of the base portion 40 so that the winding support portion 42 is inserted inside the first winding assembly 16A. It mounts on the mounting part 40a. At this time, the first winding assembly 16A is set on the support device 32A so that the in-slot passage portions 17 of the first winding assembly 16A and the segments 42a of the winding support portion 42 correspond to each other.

  Then, as shown in FIG. 13B, the first winding assembly 16 </ b> A is compressed and deformed from the outside in the radial direction along the outer peripheral surface of the winding support portion 42. At this time, the first winding assembly 16A is deformed so that the upper transition portion 18 of the first winding assembly 16A is smaller than the inner diameter of the stator core 10.

(First winding insertion process)
As shown in FIG. 13B, the stator core 10 is prepared, and the first device 30 </ b> A and the stator core 10 are relatively moved in the vertical direction, whereby the first winding assembly 16 </ b> A is combined with the winding support 42. It is inserted inside the stator core 10. In this example, the stator core 10 is fixed to a holder (not shown) so that the position of each slot 12 of the stator core 10 and the position of each segment 42a coincide, that is, each slot 12 and the first winding assembly 16A. After positioning the stator core 10 and the first device 30A in the circumferential direction so that the in-slot passage portions 17 coincide with each other (see FIG. 15), the first device 30A fixed to a lifter (not shown) is attached to the first device 30A. Raised by lifter drive. Accordingly, as shown in FIG. 14B, the first winding assembly 16 </ b> A is inserted into the stator core 10 until the upper transition portion 18 of the first winding assembly 16 </ b> A penetrates the stator core 10. . At this time, in the lower half region of the first winding assembly 16A, the in-slot passage portions 17 are inserted into the slots 12 of the stator core 10 together with the segments 42a.

(First winding mounting process)
14A, the first operation member 44 is inserted into the inside of the winding support portion 42 through the opening 41 of the base portion 40 by driving the actuator 49. As shown in FIG. When the first operating member 44 is lifted in this way, the contact portions 46a to 46c come into contact with the segment 42a in order from the first contact portion 46a, and the segments 42a are pushed outward by this contact. As a result, the winding support 42 is deformed from the reduced diameter state to the expanded diameter state. Then, as the diameter of the winding support portion 42 increases, as shown in FIGS. 17A and 17B, the in-slot passage portions 17 of the first winding assembly 16A are pressed outward through the segments 42a. Are inserted into the slots 12 respectively.

  When the first operating member 44 reaches the upper end of the stroke, specifically, when the third contact portion 46c reaches a position near the upper end of the stator core 10, the first operating member 44 is lowered to the lower end of the stroke. Then, after the first operating member 44 is removed from the apparatus main body 48 and replaced with the second operating member 45, the second operating member 45 is raised. As a result, as shown in FIG. 17C, each in-slot passage portion 17 of the first winding assembly 16 </ b> A is further pressed into the back of the slot 12 by the contact portion 46 d of the second operation member 45. At this time, as shown in the figure, each tooth 10a of the stator core 10 is interposed in a slit 461 formed on the outer peripheral surface of the contact portion 46d, so that it passes through each slot by the outer edge portion of the contact portion 46d. The portion 17 is pressed deeply into the slot 12 together with the segment 42a.

  When the second operating member 45 reaches the upper end of the stroke in this way, specifically, it reaches a position near the upper end of the stator core 10, and when each segment 42a is in an upright posture, the second operating member 45 is lowered to the lower end of the stroke. By lowering the first device 30A by the operation of the outer lifter, the first device 30A is detached from the first winding assembly 16A as shown in FIG. 14B. Thereby, the mounting of the first winding assembly 16A to the stator core 10 is completed.

  When the mounting of the first winding assembly 16A is completed, the second winding assembly 16B is then mounted using the second device 30B. The process and the procedure in this case will be described below. Except where otherwise noted, this is basically the same as when the first winding assembly 16A is mounted.

(Second winding preparation process)
First, as shown in FIG. 18A, the operating member 54 of the second device 30B is arranged at the lower end of the stroke, so that the winding support 52 is reduced in a truncated cone shape. The wire assembly 16B is set on the support device 32B.

  Then, as shown in FIG. 18 (b), the second winding assembly 16 </ b> B is compressed and deformed in the radial direction along the outer peripheral surface of the winding support portion 52. In this case, the second winding assembly 16 </ b> B is deformed so that the in-slot passage portions 17 of the second winding assembly 16 </ b> B are interposed between the adjacent guide walls 53.

(Second winding insertion process)
As shown in FIG. 18 (b), the stator core 10 to which the first winding assembly 16A is mounted is fixed to a holder (not shown), and in this state, the second device 30B is raised by driving a lifter (not shown). Thereby, as shown in FIG. 19A, the second winding assembly 16 </ b> B is inserted into the stator core 10 together with the winding support portion 52. In this case, as shown in FIG. 20, the stator core 10 and the second device 30B are positioned in the circumferential direction so that the teeth 10a of the stator core 10 and the guide walls 53 coincide with each other.

(Second winding mounting process)
As indicated by the white arrow in FIG. 19A, the operation member 54 is inserted into the inside of the winding support portion 52 through the opening 51 of the base portion 50 by driving the actuator 59. When the operating member 54 is lifted in this manner, the contact portions 56a to 56c sequentially contact the segment 52a from the first contact portion 56a as the operation member 54 is lifted, and the segments 52a are pushed outward by this contact. As a result, the winding support 52 is deformed from the reduced diameter state to the expanded diameter state. Then, as the diameter of the winding support portion 52 increases, as shown in FIGS. 20A to 20C, the in-slot passage portions 17 of the second winding assembly 16B are pressed outward through the segments 52a. Each is inserted into the slot 12 while being guided along the guide wall 53.

  At this time, as shown in the figure, the guide walls 53 are interposed in the slits 462 formed on the outer peripheral surfaces of the contact portions 56a to 56c, so that the outer edge portions of the contact portions 56a to 56c allow The passing portion 17 is pressed deeply into the adjacent guide wall 53 together with the segment 52 a and is finally inserted into the slot 12.

  When the operating member 54 reaches the upper end of the stroke in this way, specifically, when the third abutment portion 56c reaches a position near the upper end of the stator core 10 and each segment 52a assumes an upright posture, FIG. As shown, the operating member 54 is lowered to the lower end of the stroke, and the second device 30B is lowered by the operation of a lifter (not shown), thereby detaching the second device 30B from the second winding assembly 16B. Thereby, the mounting of the second winding assembly 16B to the stator core 10 is completed.

  In this way, after the mounting of the second winding assembly 16B is completed, a necessary connection process (such as welding of the windings) is performed, whereby the stator S shown in FIGS. 1 and 2 is completed.

  According to the method for manufacturing the stator S as described above, the first coil member 14A (windings group 20Ua, 20Ub, 20Va, 20Vb, 20Wa, 20Wb) and the first coil assembly having the same shape as the second coil member 14B are used. 16A and the second winding assembly 16B are formed separately, and these winding assemblies 16A and 16B are inserted into the stator core 10 and inserted into the slots 12 from the inside thereof, so that the stator S can be manufactured efficiently. Is possible. In addition, according to the above manufacturing method, the winding assemblies 16A and 1B are compressed and deformed in a truncated cone shape, and the winding assemblies 16A and 16B are inserted into the stator core 10 from the reduced diameter side. That is, the crossover 18 does not get in the way when inserted into the stator core 10. Therefore, there is an advantage that the winding assemblies 16A and 16B can be easily attached to the stator core 10 regardless of the size of the crossover portion 18 (coil end).

  Further, according to the above manufacturing method in which the winding assemblies 16A and 1B are deformed into a truncated cone shape and inserted into the stator core 10, the transition portion 18 on one end side (lower side) of the winding assemblies 16A and 1B is deformed. For example, as will be described later, compared to a method (see FIG. 22) in which the entire winding assemblies 16A and 16B are deformed (reduced diameter, expanded diameter), the work of each winding preparation process and each winding mounting process is performed. There is also an advantage that it is good.

  Although not mentioned in the above description, in the winding preparation step, as shown in FIG. 17A, the circumferential thickness of the in-slot passage portion 17 is made smaller than the gap size at the slot entrance. For example, as shown in the figure, the winding r is described in detail so that the thickness in the circumferential direction of the in-slot passage portion 17 (left and right in FIG. 17A) is equal to the thickness of one winding r. The windings r constituting the in-slot passage portion 17 are shifted from each other in the radial direction (vertical direction in FIG. 17A) so as to be approximately equal to the dimension of the perpendicular drawn from the pointed portion of the cross section to the base 2a. The first winding assembly 16A is arranged on the outer peripheral surface of the winding support portion 42 in the arrangement state, and in the winding mounting step, as shown in FIGS. Adjacent each slot passing portion 17 by pressing it into the slot 12 It is preferred that the winding r together to make packed radially that.

  In this way, it is possible to insert the winding group composed of the cross-sectional home base type strands 1 having a relatively large cross-sectional area into the slot 12 with a narrow inlet and a wide depth without gaps. Therefore, there is an advantage that it is advantageous in increasing the linear space factor of the stator S. This also applies to the case where the second winding assembly 16B is mounted on the stator core 10 as shown in FIGS. 18 (a) to 18 (c). In FIGS. 15, 17, 18, and 20, each slot 12 is illustrated with a constant width for convenience.

  On the other hand, the stator manufacturing apparatus 30 (the first apparatus 30A and the second apparatus 30B) also has the following advantages. That is, according to the stator manufacturing apparatus 30, the winding assembly 16A (16B) is supported from the inside by the winding support portion 42 (52) including a plurality of segments 42a (52a) arranged on the circumference, The operating member 44 (54) provided with the disk-shaped contact portions 46a to 46c (contact portions 56a to 56c) is lifted to push the segments 42a (52a) outward, so that the winding assembly 16A ( 16B), the in-slot passage portions 17 are pushed into the slots 12 by the segments 42a (52a). Therefore, the in-slot passage portions 17 are integrally inserted into the slots 12 by a relatively simple mechanism, that is, the stator core. The winding assembly 16 </ b> A (16 </ b> B) can be mounted from the inside of 10.

  In particular, according to the configuration in which each segment 42a (52a) is swingably supported by the base portion 40 (50) with the lower end portion as a fulcrum as described above, the winding assembly 16A (16B) is connected to the winding support portion. When setting to 42 (52), each segment 42a (52a) and each slot passing portion 17 can be positioned with reference to the lower end of each segment 42a (52a), so that the winding support 42 (52) and There is an advantage that positioning with the winding assembly 16A (16B) can be performed easily and accurately.

  Further, the operation member 44 (54) includes three disk-shaped contact portions 46a to 46c (56a to 56c) having a larger diameter toward the lower side, and the winding support portion 42 (52) is brought into a reduced diameter state. When deforming to the expanded diameter state, as the operating member 44 (45) rises, the contact portions 46a to 46c (56a to 56c) contact the segment 42a (52a) in order of decreasing diameter. Therefore, each segment 42a (52a) can be displaced relatively slowly. Therefore, there is also an advantage that the winding assembly 16A (16B) can be smoothly inserted into the slot 12 while suppressing the segments 42a (52a) from being displaced suddenly.

  Further, the support device 32B of the second device 30B is provided with a guide wall 53, and the guide wall 53 guides the passage portion 17 in each slot of the second winding assembly 16B to the slot 12. It is effectively prevented that the in-slot passage portion 17 is displaced in the circumferential direction. Accordingly, there is an advantage that each in-slot passage portion 17 can be smoothly inserted into the slot 12. In addition, slits 462 are provided on the outer peripheral surfaces of the contact portions 56a to 56c of the operation member 54 so as to allow the guide wall 53 to escape by interposing the guide wall 53. There is also an advantage that each slot passing portion 17 of the second winding assembly 16B can be appropriately pressed and inserted into the slot 12 while avoiding interference with the respective contact portions 56a to 56c of 54. .

  By the way, the stator S manufacturing method and the stator manufacturing apparatus 30 described above are examples of preferred embodiments of the stator manufacturing method and the stator manufacturing apparatus according to the present invention, and the specific method and configuration are the gist of the present invention. As long as it does not deviate from the above, it can be appropriately changed.

  For example, in the above embodiment, the winding assembly 16A (16B) is inserted into the stator core 10 in a state of being deformed into a truncated cone shape whose upper portion is narrowed. ), The entire winding assembly 16A (16B) is reduced in diameter so as to be smaller than the inner diameter of the stator core 10, and the winding assembly 16A (16B) is inserted into the stator core 10 in this state. The diameter may be increased. In the figure, only the first winding assembly 16A is shown, but the same applies to the second winding assembly 16B.

  Further, each of the driving devices 34A and 34B of the stator manufacturing apparatus 30 moves the operation member 44 (54) including the disk-shaped contact portions 46a to 46c (contact portions 56a to 56c), thereby operating the operation. Although each segment 42a (52a) is pushed outward by the member 44 (54), each segment 42a may be driven using a mechanism other than this.

  Further, the stator S of the above embodiment has a wave structure in the winding structure, but the stator manufacturing method and the stator manufacturing apparatus of the present invention are related to a stator having a distributed winding structure or a concentrated winding structure other than the wave winding. Is also applicable.

DESCRIPTION OF SYMBOLS 10 Stator core 12 Slot 14A 1st coil member 14B 2nd coil member 17 Passing part in slot 18 Transition part 20Ua 1st U-phase winding group 20Ub 2nd U-phase winding group 20Va 1st V-phase winding group 20Vb 2nd V-phase winding group 20 Wa First W phase winding group 20 Wb Second W phase winding group 22 a, 24 a Positive winding group 22 b, 24 b Reverse winding group 30 Stator manufacturing device 30 A First device 30 B Second device 32 A, 32 B Support device 34 A, 34 B Driving device 42, 52 Winding support portion 42a, 52a Segment 44 First operating member 45 Second operating member 54 Operating member 48, 58 Main unit S Stator r1-r3, r1'-r3 'Winding r4-r6, r4'-r6 ′ Winding

Claims (11)

A stator core that has a plurality of slots that are arranged at regular intervals in the circumferential direction and each open inward, and a predetermined strand is wound around the stator core so as to pass through a plurality of specific slots. And a stator manufacturing method for a rotating electrical machine comprising a stator including a plurality of winding groups each including an in-slot passage portion passing through the slot and a crossing portion passing over an axial end surface of the stator core. ,
A winding forming step of independently forming a winding assembly having the same shape as the plurality of winding groups formed on the stator core;
Using a winding support member that can be deformed into a cylindrical diameter-expanded state and a reduced-diameter state, the winding assembly is compressed and deformed in the radial direction along the outer peripheral surface of the winding support member in the reduced-diameter state. A winding preparation step to be arranged on the outer peripheral surface in a state of being made,
A winding insertion step of inserting the winding assembly together with the winding support member from the one axial end side of the stator core into the inner side thereof so that the transition portion of the winding assembly is positioned on the outer side in the axial direction of the stator core. When,
A winding mounting step of inserting a passage portion in each slot of the winding assembly into the slot by expanding the diameter of the winding support member inside the stator core. Stator manufacturing method. In the stator manufacturing method of the rotary electric machine according to claim 1,
The winding support member is deformed into a cylindrical diameter-expanded state and a truncated cone-shaped diameter-reduced state,
In the winding preparation step, the winding assembly is disposed on the outer peripheral surface of the winding support member in a state of being deformed into a truncated cone shape,
In the winding insertion step, the winding assembly is inserted into the inside of the stator core from the end portion on the small diameter side thereof. In the stator manufacturing method of the rotary electric machine according to claim 1 or 2,
The stator core is such that the gap dimension of each slot in the circumferential direction is larger on the outer peripheral side than the inner peripheral side of the stator core,
The strand is a cross-sectional home base type having a base and a pair of sides extending parallel to each other from both sides thereof and a pair of oblique sides connecting the ends of the sides.
When the point where the pair of oblique sides are connected to each other is defined as a pointed portion, the in-slot passing portion is configured such that the pointed portions of the windings adjacent to each other face the opposite side of the circumferential direction and the adjacent windings. Inserted into the slot in a state of being arranged along the radial direction of the stator core so that the oblique sides of the line abut each other;
In the winding preparation step, the windings constituting the in-slot passage portion are shifted in the radial direction so that the circumferential thickness of the in-slot passage portion is smaller than the gap size of the slot entrance. Arrange the winding assembly on the outer peripheral surface of the winding support member in an array state,
In the winding mounting step, a stator manufacturing method for a rotating electrical machine is characterized in that adjacent windings are pressed in the radial direction by pressing each slot passing portion into the slot by the winding support member. A stator manufacturing apparatus that is used in the stator manufacturing method for a rotating electrical machine according to any one of claims 1 to 3, and that supports the winding assembly and is attached to the stator core.
A support device that has a winding support portion that can be deformed into a cylindrical diameter-expanded state and a reduced-diameter state, and that supports each through-slot portion of the winding assembly from the inside;
A stator manufacturing apparatus for a rotating electrical machine, comprising: a driving device configured to deform the winding support portion from a reduced diameter state to a larger diameter state. The stator manufacturing apparatus for a rotating electrical machine according to claim 4,
The stator manufacturing apparatus for a rotating electrical machine, wherein the winding support portion is deformed into the expanded diameter state and a reduced diameter state having a truncated cone shape. The stator manufacturing apparatus for a rotating electrical machine according to claim 4 or 5,
The winding support portions are arranged at regular intervals in the circumferential direction and extend along the center line of the winding support portions, and each of the plurality of segments supports the passing portions in the slots of the winding assembly from the inside. Formed by
The support device further includes a base member that supports the plurality of segments so as to be displaceable in a radial direction of the winding support part,
The stator manufacturing apparatus for a rotating electrical machine, wherein the driving device displaces each segment in a radial direction with respect to a base member. The stator manufacturing apparatus for a rotating electrical machine according to claim 6,
The plurality of segments are swingably supported by the base member with their lower ends as fulcrums,
The winding support portion is deformed into the diameter-expanded state in which each segment is in a cylindrical shape when the segments are in a vertical posture and the diameter-reduced state in which the segments are in a truncated cone shape when the segments are in an inclined posture. An apparatus for manufacturing a stator for a rotating electrical machine. The stator manufacturing apparatus for a rotating electrical machine according to claim 7,
The drive device includes an operation member that integrally pushes each segment outward by moving the inside of the winding support portion in a reduced diameter state along the center line. A stator manufacturing apparatus for a rotating electrical machine. The stator manufacturing apparatus for a rotating electrical machine according to claim 8,
The operation member has a plurality of contact portions arranged in a moving direction of the operation member at a predetermined interval, and abutting each segment at different positions in the radial direction of the winding support portion,
The apparatus for manufacturing a stator for a rotating electrical machine, wherein the plurality of abutting portions are formed such that the outer diameter dimension is larger toward the rear side in the moving direction. The stator manufacturing apparatus for a rotating electrical machine according to any one of claims 6 to 9,
The rotating electrical machine characterized in that the winding support part includes a guide wall that is arranged between adjacent segments and regulates displacement in the circumferential direction of each slot passing part of the winding assembly. Stator manufacturing equipment. The stator manufacturing apparatus for a rotating electrical machine according to claim 10,
The drive device includes the operation member,
The stator according to claim 1, wherein the operating member includes a plurality of slits for allowing the guide walls to escape.

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