JP2017093172A - Stator and method of manufacturing stator - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator in which infiltration degree of adhesive is uniform between respective segment conductors constituting a segment coil.SOLUTION: A method of manufacturing a stator 10 includes a step of forming a segment coil 15 by inserting a plurality of segment conductors 16 into a slot 14, and winding around teeth 13, a step of arranging a press member 20 for pressing each segment conductor 16 of the segment coil 15 against the yoke 12 side, radially inside of the stator than the segment coil 15, a step of pouring an insulating adhesive 17 into the slot 14, while pressing each segment conductor 16 from the radially inside of the stator to the yoke 12 side by means of the press member 20, and a step of hardening the adhesive 17.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a stator and a method for manufacturing the stator, and more particularly to a stator for a rotating electrical machine including a segment coil and a method for manufacturing the same.

  Conventionally, a stator for a rotating electrical machine including a segment coil is known. A segment coil is a coil in which a segment conductor, which is generally a flat wire, is wound around a tooth of a stator core, and is fixed to the stator core using an adhesive called varnish, for example. Patent Document 1 discloses a stator in which varnish is infiltrated into a slot of a stator core into which a plurality of segment conductors are inserted, thereby fixing the segment conductors and fixing a segment coil to the stator core.

  FIG. 4 is a view showing a conventional stator 50. 4A is a plan view showing a part of the stator 50, and FIG. 4B is a cross-sectional view taken along the line BB in FIG. In FIG. 4A, the segment conductor 16 is cut at a position corresponding to the axial end surface 11 a of the stator core 11. As shown in FIG. 4, the segment coil 51 is fixed to the stator core 11 using an adhesive 17. The adhesive 17 that has penetrated into the slots 14 is filled between the teeth 13 and the segment conductors 16 and between the segment conductors 16. The adhesive 17 is poured into the slot 14 from the axial end surface 11a side of the stator core 11, for example. An insulating sheet 18 (see FIG. 4B) is disposed between the segment conductor 16 and the teeth 13.

JP2013-121296A

  By the way, although the segment conductor 16 which comprises the segment coil 51 is inserted in the slot 14 and wound by the teeth 13, it is not easy to arrange the space | interval of the segment conductors 16 located in the slot 14 mutually. If the interval between the segment conductors 16 is non-uniform, the adhesive 17 penetrates a lot in a portion where the interval is wide, while the adhesive 17 hardly penetrates a portion where the interval is narrow. Variation). And when the dispersion | variation in the penetration state of this adhesive agent 17 generate | occur | produces, the eigenvalue of the stator 50 will remove | deviate from the target range, for example, the electromagnetic vibration radiation sound of the rotary electric machine using the stator 50 will increase, and the dispersion | variation in a vibration peak will be carried out. May cause problems such as an increase in size.

  An object of the present invention is to provide a stator in which the penetration of adhesive is uniform between the segment conductors constituting the segment coil.

  A stator manufacturing method according to the present invention includes an annular yoke, and a plurality of teeth protruding inward in the stator radial direction from the inner peripheral surface of the yoke, and a stator core having slots formed between the teeth, A method of manufacturing a stator including a segment coil wound around a tooth, the step of inserting a plurality of segment conductors into the slot and winding the tooth around the tooth to form the segment coil, and the segment A step of disposing a pressing member that presses the segment conductors of the segment coil toward the yoke side on the inner side in the stator radial direction than the coil; and the pressing members move the segment conductors from the stator radial inner side to the yoke side. In the pressed state, a process of pouring an insulating adhesive into the slot, and curing the adhesive Characterized in that it comprises a that step.

  A stator according to the present invention includes an annular yoke, and a plurality of teeth protruding inward in the stator radial direction from the inner peripheral surface of the yoke, and a stator core having slots formed between the teeth, and inserted into the slots A segment coil including a plurality of segment conductors, each segment conductor having a structure wound around the teeth, the stator being provided radially inward of the segment coil, and the segment A pressing member that presses each segment conductor of the coil toward the yoke; and an insulating adhesive that penetrates into the slot and fixes the segment conductor to the teeth together with the pressing member. To do.

  According to the present invention, by using the pressing member that presses each segment conductor of the segment coil to the yoke side, the interval between the segment conductors in the slot becomes substantially constant, and the penetration of the adhesive between the segment conductors is uniform. A simple stator can be provided. That is, in the stator obtained by the manufacturing method of the present invention, the adhesive is uniformly filled between the segment conductors. Therefore, the vibration of the stator is suppressed, and the eigenvalue is stably maintained within the target design range. When the eigenvalue of the stator is stabilized, for example, electromagnetic vibration radiation sound of a rotating electrical machine can be suppressed, and design for preventing resonance with peripheral devices becomes easy.

It is a perspective view which shows the stator which is an example of embodiment. It is a perspective view which expands and shows a part of stator core. (A) is a top view which shows a part of stator, (b) is AA sectional drawing in (a). (A) is a top view which shows a part of conventional stator, (b) is BB sectional drawing in (a).

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
The drawings are all schematically described, and the dimensional ratios of the components drawn in the drawings should be determined in consideration of the following description. Further, it is assumed from the beginning that a plurality of embodiments and modifications are used in appropriate combination.

  Hereinafter, the stator 10 in which the pressing member 20 is incorporated is illustrated as a stator that is an example of the embodiment, but the stator may have a configuration that does not include the pressing member. In this case, however, a pressing member is used to press each segment conductor of the segment coil outward in the radial direction of the stator in the stator manufacturing process.

  FIG. 1 is a perspective view showing the stator 10, and FIG. 2 is an enlarged perspective view showing a part of the stator core 11. 1 and 2 and FIG. 3 described later, the stator radial direction is indicated by an arrow X, the stator axial direction orthogonal to the stator radial direction is indicated by an arrow Y, and the stator circumferential direction is indicated by an arrow Z. Hereinafter, these directions may be referred to as a radial direction X, an axial direction Y, a circumferential direction Z, or simply a radial direction, an axial direction, and a circumferential direction, and are also used to describe each component of the stator 10.

  As shown in FIG. 1, the stator 10 includes a stator core 11 and a plurality of segment coils 15 fixed to the stator core 11. The stator core 11 includes an annular yoke 12 and a plurality of teeth 13 protruding radially inward from the inner peripheral surface of the yoke 12. Slots 14 are formed between the teeth 13. The stator core 11 is configured by, for example, laminating a plurality of electromagnetic steel plates punched in an annular shape in the axial direction Y. However, the structure of the stator core 11 is not particularly limited, and may be a structure in which a plurality of divided cores made of a steel plate laminate or a dust core are arranged in an annular shape.

  The segment coil 15 includes a plurality of segment conductors 16 (see FIG. 3 described later) inserted into the slots 14, and the segment conductors 16 are wound around the teeth 13. The segment coil 15 includes, for example, U-phase, V-phase, and W-phase coils, and the respective phase coils are sequentially arranged in the circumferential direction Z of the stator core 11. As will be described in detail later, the stator 10 includes a pressing member 20 that is provided on the radially inner side of the segment coil 15 and presses each segment conductor 16 of the segment coil 15 toward the yoke 12 side. The pressing member 20 is preferably an annular member.

  As shown in FIG. 2, a plurality of teeth 13 are provided at intervals in the circumferential direction Z. It is preferable that the shapes and dimensions of the teeth 13 are substantially the same, and the intervals between the teeth 13 adjacent in the circumferential direction Z are substantially equal. Between adjacent teeth 13, slots 14 that are grooves extending in the radial direction X are formed. As with the teeth 13, the slots 14 are preferably formed at substantially equal intervals in the circumferential direction Z. The teeth 13 and the slots 14 are alternately arranged in the circumferential direction Z, and are generally formed over the entire length of the stator core 11 in the axial direction Y.

  The teeth 13 preferably have an overhanging portion 13a formed at the inner end portion in the radial direction X, which is the tip portion thereof. In the present embodiment, the radially inner end portion of the tooth 13 projects to both sides in the circumferential direction Z to form a projecting portion 13a. The overhanging portion 13 a narrows the width of the slot 14 along the circumferential direction Z at the radially inner end of the slot 14 and prevents the segment conductor 16 from coming out of the slot 14. The slot 14 is preferably formed with a substantially constant width except for the radially inner end.

  Hereinafter, with reference to FIG. 3 in particular, the segment coil 15 and the pressing member 20 will be described in detail. FIG. 3A is a plan view showing a part of the stator 10, and FIG. 3B is a cross-sectional view taken along line AA in FIG. In FIG. 3A, the segment conductor 16 is cut at a position corresponding to the axial end surface 11 a of the stator core 11. Moreover, illustration of the insulating sheet 18 is omitted.

  As shown in FIG. 3, the segment coil 15 is composed of a plurality of segment conductors 16 inserted into the slot 14. In the slot 14, an insulating sheet 18 (see FIG. 3B) interposed between the tooth 13 and the segment conductor 16 is provided. The insulating sheet 18 is made of, for example, a single resin sheet, is bent into a substantially U shape, and is inserted into the slot 14. In the example shown in FIG. 3B, the axial length of the insulating sheet 18 is longer than that of the stator core 11, both axial end portions of the sheet are folded outside the slot 14, and the both end portions are axial end portions of the stator core 11. Engage with the surface.

  The segment coil 15 is fixed to the stator core 11 while being insulated from the stator core 11 by the insulating sheet 18. The plurality of segment conductors 16 constituting the segment coil 15 are, for example, rectangular wires having a substantially rectangular cross section, and are arranged in a line in the slot 14. The width of the slot 14 (the length in the circumferential direction Z) is set slightly wider than the length of the segment conductor 16 in the circumferential direction Z. In addition, the space | interval of the overhang | projection parts 13a of the adjacent teeth 13 is narrower than the length of the circumferential direction Z of the segment conductor 16. FIG. The segment coil 15 generally has a high space factor, which is a volume ratio of the segment conductors 16 occupying in the slots 14, and the rotating electrical machine using the stator 10 is excellent in output efficiency.

  For the segment conductor 16, for example, a rectangular wire formed in a substantially U shape is used. The segment conductor 16 includes two leg portions extending in parallel to each other and a connecting portion connecting the leg portions. In the present embodiment, the two leg portions of the segment conductor 16 are inserted into the two slots 14 spaced apart in the circumferential direction Z from the other axial end surface 11b side of the stator core 11 (FIG. 3A shows the segment). The legs of the conductor 16 are shown). By sequentially inserting the plurality of segment conductors 16 into the two slots 14 in the same manner, the leg portions of the segment conductors 16 are aligned in the slots 14. The length of each leg is longer than the length of the slot 14 in the axial direction, and the tip portion of each leg projects from the axial end surface 11 a of the stator core 11.

  Each segment conductor 16 generally has an insulating coating, but a metal core is exposed at the tip of each leg protruding from the axial end surface 11a of the stator core 11. For example, the distal end portion of each leg is bent in the circumferential direction Z so that the segment conductor 16 surrounds the teeth 13 and is welded to the leg of another segment conductor 16 of the in-phase coil. A plurality of segment conductors 16 are bent and welded in the same manner, so that a segment coil 15 wound around the teeth 13 is formed.

  Each segment conductor 16 is fixed to the teeth 13 with an insulating adhesive 17. The segment conductors 16 are fixed to each other by an adhesive 17. The adhesive 17 penetrates into the slot 14 and is filled between the teeth 13 and the segment conductors 16 and between the segment conductors 16 to fix the segment conductors 16 to the teeth 13, and between the adjacent segment conductors 16. To fix.

  For the adhesive 17, for example, a curable resin adhesive called varnish is used. The adhesive 17 is preferably a thermosetting type mainly composed of a thermosetting resin, but may contain a solvent or the like, and is a dry curable type that is cured by removing the solvent by volatilization. Also good. The adhesive 17 may be a two-component curable type. As will be described in detail later, the adhesive 17 is poured into the slot 14 from the axial one end face 11a side of the stator core 11.

  The pressing member 20 is provided on the radially inner side of the stator core 11 with respect to the segment coil 15 as described above. The pressing member 20 is a member that presses each segment conductor 16 of the segment coil 15 from the yoke 12 side, that is, from the radially inner side to the radially outer side. By providing the pressing member 20, the interval between the segment conductors 16 arranged in the slot 14 becomes substantially constant, and the penetration degree (penetration depth) of the adhesive 17 between the segment conductors 16 is made uniform. It can be said that the pressing member 20 is a correction tool that aligns the intervals between the segment conductors 16 arranged in the slot 14. In the present embodiment, the pressing member 20 is fixed to the tooth 13 by the adhesive 17.

  Even when the pressing member 20 is provided, there is a gap between the segment conductors 16 so that the adhesive 17 penetrates. However, the gap is smaller than when the pressing member 20 is not used (see FIG. 4), and the size of the gap is made uniform. That is, the interval between the segment conductors 16 is substantially constant. Each segment conductor 16 is pressed against the segment conductor 16 adjacent to the radially outer side in the slot 14 by the pressing member 20, for example, and the segment conductor 16 positioned on the outermost radial direction is pressed against the inner peripheral surface 12 a of the yoke 12. ing.

  The pressing member 20 presses at least one axial end portion of the segment coil 15 protruding from the axial end surface 11a of the stator core 11, that is, the distal end portion of the leg portion of the segment conductor 16 constituting the axial end portion. It is preferable to do. In the present embodiment, the pressing member 20 is disposed on the axial end surface 11 a of the stator core 11. Since the variation in the spacing between the segment conductors 16 in the slot 14 tends to be larger on the distal end side of the leg portion than on the connecting portion side of the segment conductor 16, the distal end portion of the leg portion is pressed by the pressing member 20. The spacing between the segment conductors 16 can be made uniform easily.

  The pressing member 20 is preferably formed in an annular shape as described above. In the present embodiment, one annular pressing member 20 having a substantially square cross section is provided on one axial end surface 11 a of the stator core 11. For example, a plurality of bar-shaped members can be provided as the pressing member 20, but in this case, a jig, an apparatus, or the like that presses each bar-shaped member from the radially inner side to the outer side in the manufacturing process is required. When the annular pressing member 20 is used, such a pressing jig or the like becomes unnecessary by setting the outer diameter to an appropriate length, for example. In addition, the cross-sectional shape of the annular pressing member 20 is not limited to a rectangular shape, and may be a circular shape.

  The outer diameter of the pressing member 20 is a length in which a pressing force to the outer side in the radial direction is applied to all the segment conductors 16 in the slot 14 in a state where the pressing member 20 is disposed on the axial end surface 11a of the stator core 11. It is preferable to set to. That is, it is preferable that the segment conductors 16 are brought into contact with each other, and the segment conductors 16 positioned on the outermost radial direction have an outer diameter that can be pressed against the inner peripheral surface 12 a of the yoke 12.

  The inner diameter of the pressing member 20 is such that, for example, the pressing member 20 is disposed on the one end surface 11 a in the axial direction of the stator core 11 so as to avoid interference with the rotor disposed in the stator 10. The length is set so as not to protrude inward in the radial direction. The width of the pressing member 20 in the radial direction X is not particularly limited as long as the width satisfies the outer diameter and the inner diameter, for example. The width in the axial direction Y of the pressing member 20 is set to a length that prevents the pressing member 20 from projecting from one axial end of the segment coil 15 in a state where the pressing member 20 is disposed on the axial one end surface 11a. Is preferred. However, since the reaction force from each segment conductor 16 acts on the pressing member 20, it is necessary to have a width that does not cause plastic deformation at least by the reaction force.

  It is preferable to use an insulating resin member for the pressing member 20 so as not to affect the magnetic characteristics of the rotating electrical machine. Although it does not specifically limit as resin which comprises the press member 20, For example, resin excellent in oil resistance and heat resistance is used.

  The manufacturing process of the stator 10 includes a step (1) of forming the segment coil 15, a step (2) of disposing the pressing member 20 on the radially inner side of the segment coil 15, and a step of pouring the adhesive 17 into the slot 14. (3) and the process (4) of hardening the adhesive agent 17 are included. Although the pressing member 20 is used only in the manufacturing process and may be removed after the adhesive 17 is cured, the pressing member 20 is preferably incorporated in the stator 10 from the viewpoint of improving productivity. That is, the adhesive 17 preferably fixes the segment conductors 16 together with the pressing members 20 to the teeth 13.

  In step (1), a plurality of segment conductors 16 are inserted into the slots 14 and wound around the teeth 13 to form the segment coils 15. The formation method of the segment coil 15 is not specifically limited, A conventionally well-known method is applicable. In the present embodiment, the two leg portions of each segment conductor 16 are sequentially inserted into the two slots 14 spaced apart in the circumferential direction Z from the other axial end surface 11 b side of the stator core 11. And the front end part of each leg part which protruded from the axial direction one end surface 11a of the stator core 11 is bend | folded in the circumferential direction Z so that the segment conductor 16 may surround the teeth 13 and may be wound by the teeth 13, and the same phase Weld with the leg of another segment conductor 16 of the coil. Thus, the segment coil 15 wound around the teeth 13 is formed.

  In the step (2), the pressing member 20 is disposed radially inward of the segment coil 15. The pressing members 20 may be disposed on both sides of the stator core 11 in the axial direction, for example, but in this embodiment, the annular pressing members 20 are disposed only on the one axial end surface 11a. Specifically, of the plurality of segment conductors 16 inserted into each slot 14, the pressing member 20 is pressed against the segment conductor 16 located on the innermost radial direction, and is pressed from the segment coil 15 while pressing the pressing member 20 outward in the radial direction. Also, the pressing member 20 is fitted inside in the radial direction. By disposing the pressing member 20 in this way, the segment conductors 16 come into contact with each other, and the segment conductor 16 positioned on the outermost radial direction is pressed against the inner peripheral surface 12 a of the yoke 12. The interval between the segment conductors 16 arranged in the slot 14 is substantially constant.

  In the step (3), an insulating adhesive 17 is poured into the slot 14 in a state where the segment conductors 16 are pressed from the radially inner side to the radially outer side by the pressing member 20. The adhesive 17 is dropped from, for example, the axial end surface 11a side of the stator core 11 onto the tooth 13 around which the segment coil 15 is wound. At this time, a part of the adhesive 17 flows into the slot 14 and penetrates into the slot 14. In this embodiment, since the pressing member 20 is incorporated in the stator 10, it is preferable that the adhesive 17 is dropped so as to adhere to the pressing member 20.

  The adhesive 17 having fluidity in an uncured state penetrates into the slots 14 and is filled between the teeth 13 and the segment conductors 16 and between the segment conductors 16. In the state where each segment conductor 16 is pressed by the pressing member 20, the interval between the segment conductors 16 is substantially constant by the pressing force as described above. In this state, the adhesive 17 is dropped and penetrated into the slot 14, whereby the penetration depth of the adhesive 17 between the segment conductors 16 can be made uniform. That is, the filling amount of the adhesive 17 between the segment conductors 16 can be made substantially the same.

  In step (4), the adhesive 17 that has penetrated into the slot 14 is cured. Generally, since a thermosetting adhesive is used as the adhesive 17, at least a portion to which the uncured adhesive 17 is attached is heated at a predetermined temperature necessary for curing. When the adhesive 17 contains a solvent, the solvent is volatilized and removed in the heating step. When the adhesive 17 is cured, the segment conductors 16 are fixed to the teeth 13 together with the pressing member 20, and the segment conductors 16 are fixed to each other.

  As described above, by using the pressing member 20, the interval between the segment conductors 16 becomes substantially constant in the slot 14, and the stator 10 having a uniform penetration depth of the adhesive 17 between the segment conductors 16 can be obtained. If the penetration depth of the adhesive 17 between the segment conductors 16 is made uniform, for example, the eigenvalue of the stator 10 is stabilized, the electromagnetic vibration radiation sound of the rotating electrical machine is reduced, and a design for preventing resonance with peripheral devices. Becomes easier. Moreover, since the space | interval of each segment conductor 16 becomes small by using the press member 20, it is also possible to raise the space factor of the segment conductor 16 and to increase the output of a rotary electric machine.

  10, 50 Stator, 11 Stator core, 11a One axial end surface, 11b Other axial end surface, 12 Yoke, 12a Inner peripheral surface, 13 teeth, 13a Overhang, 14 slots, 15, 51 Segment coil, 16 Segment conductor, 17 Adhesive, 18 Insulating sheet, 20 Press member

Claims (2)

A stator core including an annular yoke, and a plurality of teeth protruding inward in the stator radial direction from the inner peripheral surface of the yoke, and a segment coil wound around the teeth, and a stator coil wound around the teeth; A stator manufacturing method comprising:
Inserting a plurality of segment conductors into the slot and winding them around the teeth to form the segment coil;
Disposing a pressing member that presses each segment conductor of the segment coil to the yoke side on the inner side in the stator radial direction than the segment coil; and
A step of pouring an insulating adhesive into the slot in a state in which each of the segment conductors is pressed from the radially inner side of the stator to the yoke side by the pressing member;
Curing the adhesive;
A method for manufacturing a stator. A stator core including an annular yoke, and a plurality of teeth protruding inward in the stator radial direction from an inner peripheral surface of the yoke, and a stator core having slots formed between the teeth;
A segment coil including a plurality of segment conductors inserted into the slot, each segment conductor being wound around the teeth;
A stator with
A pressing member that is provided on the inner side in the stator radial direction than the segment coil and presses the segment conductors of the segment coil toward the yoke;
An insulating adhesive that penetrates into the slot and fixes the segment conductors together with the pressing member to the teeth;
Having a stator.

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