JP2018117477A - Stator manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a stator manufacturing method capable of improving a space factor of coils by accommodating the coils in a high density in slots while avoiding interference between adjacent coils.SOLUTION: A stator manufacturing method that manufactures a stator of rotary electric machine including a stator core 3 in which split cores 6 are annularly arranged and that includes a back yoke 11 having a predetermined radial width and extending in a circular arc shape and teeth 12 projecting radially inward from a circumferential intermediate part of the back yoke 11, and coils 2 wound around the teeth 12 of the split cores 6 includes a coil winding step S1 of winding the coils 2 around the teeth 12 beyond a virtual line L1 drawn along a peripheral end face 11ac of the back yoke 11, a heating step S2 of heating the split cores 6 around which the coils 2 are wound, and a compression step S3 of pressing the heated coils 2 in a circumferential direction.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a stator manufacturing method, and more particularly to a stator manufacturing method for manufacturing a stator of a rotating electrical machine composed of a plurality of divided cores arranged in an annular shape.

  In a rotating electrical machine used for driving a vehicle such as a hybrid vehicle, a rotor is rotatably supported inside a case. As a stator, there is known a stator in which a plurality of divided cores around which a coil is wound are arranged in an annular shape (for example, Patent Document 1).

  As shown in FIG. 9, in the stator core 60 constituted by such a plurality of divided cores 50, the core body 51 of the divided core 50 includes a back yoke 52 extending in an arc shape and a circumferential intermediate portion of the back yoke 52. Teeth 53 projecting radially inward, and coils 54 are concentratedly wound around the teeth 53 of each divided core 50.

Japanese Patent Laid-Open No. 2006-116419

  In the stator of a rotating electrical machine, it is required to improve the space factor of the coil in the slot in order to increase the magnetomotive force.

  However, in a stator of a rotating electrical machine constituted by a plurality of divided cores 50 arranged in an annular shape, a coil 54 is wound around a tooth 53 beyond an imaginary line L1 drawn along the circumferential end surface of the back yoke 52. When it is turned, it interferes with the coil 54 of the adjacent split core 50 in the slot SLT during assembly. Therefore, a gap K is inevitably generated between the coils 54 and 54 of the adjacent split cores 50, and it is difficult to increase the space factor.

  The present invention has been made in view of the above-mentioned problems, and its purpose is to improve the space factor of the coil by accommodating the coils in the slot at a high density while avoiding interference between adjacent coils. Is to provide a simple stator manufacturing method.

In order to achieve the above object, the invention according to claim 1
A back yoke (for example, a back yoke 11 in an embodiment described later) having a predetermined radial width and a tooth (for example, described later) that protrudes radially inward from a circumferential intermediate portion of the back yoke. A stator core (e.g., a stator core 3 in an embodiment described later) configured by annularly arranging divided cores (e.g., a divided core 6 in an embodiment described later) having teeth 12) in the embodiment;
A stator manufacturing method for manufacturing a stator of a rotating electrical machine including a coil wound around the teeth of the split core (for example, a coil 2 in an embodiment described later),
The coil is wound around the teeth beyond an imaginary line (for example, a virtual line L1 in an embodiment described later) drawn along a circumferential end surface of the back yoke (for example, a circumferential end surface 11ac in the embodiment described later). A coil winding step (for example, a coil winding step S1 in an embodiment described later);
A heating step of heating the split core around which the coil is wound (for example, a heating step S2 in an embodiment described later);
A stator manufacturing method comprising: a compression step of pressing the heated coil in the circumferential direction (for example, a compression step S3 in an embodiment described later).

Invention of Claim 2 is a stator manufacturing method of Claim 1, Comprising:
An angle (for example, an angle β in an embodiment described later) of a pressing surface (for example, a pressing surface 20a in an embodiment described later) of a compression jig (for example, a compression jig 20 in an embodiment described later) used in the compression step is A back yoke inclination angle formed by an intermediate line (for example, an intermediate line L2 in an embodiment described later) and the imaginary line connecting the circumferential intermediate portion of the back yoke and the axis of the stator. The stator manufacturing method is slightly larger than the back yoke inclination angle α) in the embodiments described later.

Invention of Claim 3 is a stator manufacturing method of Claim 2, Comprising:
The stator manufacturing method, wherein an angle of the pressing surface is 1 ° to 3 ° larger than an angle of inclination of the back yoke.

The invention according to claim 4 is the stator manufacturing method according to any one of claims 1 to 3,
The method for manufacturing a stator, wherein a heating temperature in the heating step is 150 ° C to 250 ° C.

The invention according to claim 5 is the stator manufacturing method according to any one of claims 1 to 4,
In the compression step, the heated coil is simultaneously pressed from both sides in the circumferential direction.

  According to the first aspect of the present invention, since the spreadability of the winding material can be enhanced by applying heat to the coil winding material in the heating process, the coil is wound on the teeth beyond the virtual line in the coil winding process. Even if the coil is wound, the coil is expanded and plastically deformed by a compression process, so that the coil can be stored in the slot at a high density while avoiding interference between adjacent coils. Thereby, the space factor of a coil can be improved.

  According to the invention of claim 2, the angle of the pressing surface of the compression jig used in the compression process is formed by the intermediate line of the split core connecting the circumferential intermediate portion of the back yoke and the axis of the stator and the virtual line. By making it slightly larger than the back yoke inclination angle, the space factor of the coil can be further improved.

  According to the invention of claim 3, the space factor of the coil can be further improved by increasing the angle of the pressing surface by 1 ° to 3 ° larger than the back yoke inclination angle.

  According to invention of Claim 4, a coil can be suitably extended by the heating temperature in a heating process being 150 to 250 degreeC.

  According to the invention of claim 5, in the compression step, the coil can be spread without being biased on both sides in the circumferential direction by simultaneously pressing the heated coil from both sides in the circumferential direction. In addition, the work time can be shortened.

It is a front view of the stator of one embodiment of the present invention. It is a perspective view of the division | segmentation core with which the insulator was mounted | worn. It is sectional drawing of the division | segmentation core of one Embodiment of this invention. It is a flowchart which shows an example of the manufacturing method of the stator of this invention. It is a schematic diagram explaining the compression process of FIG. It is a principal part enlarged view of FIG. It is a schematic diagram explaining the deformation | transformation of the coil in a compression process. It is sectional drawing of two adjacent division | segmentation cores among the stator cores which arranged the division | segmentation core in the annular | circular shape. It is sectional drawing of two adjacent split cores among the stator cores which arranged the conventional split core in the annular | circular shape.

  Hereinafter, a stator manufacturing method according to an embodiment of the present invention will be described with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

  First, a stator according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a front view of a stator according to an embodiment of the present invention, and FIG. 2 is a perspective view of a split core to which an insulator is attached.

  The stator 1 according to the present embodiment is used in an inner rotor type rotating electrical machine in which a rotor (not shown) is rotatably provided on an inner peripheral portion, and a stator core 3 is fixed to a housing 4 as shown in FIG. Yes.

  The stator core 3 is configured by assembling a plurality of divided cores 6 in an annular shape. In each divided core 6, an insulator 10 is mounted on a core body 7 having a substantially T shape in a front view, and a coil 2 is wound around a coil winding portion 16 of the insulator 10. The coil 2 is a so-called rectangular wire that uses copper as a winding material and has a rectangular cross section.

  From the stator core 3, the coil 2 is drawn out to the outside in the radial direction of the housing 4, and power supply terminals 5 U, 5 V of corresponding phases are respectively provided at end portions on the power supply side of the U-phase, V-phase, and W-phase coils 2. And 5W are connected. One end side of each coil 2 wound around the core body 7 is grouped for each phase and connected to the corresponding phase feed terminals 5U, 5V, and 5W, and the other end side of each coil 2 is connected to the middle point. The units 15 are connected to each other. Therefore, in the stator 1 of this embodiment, the coils 2 of each phase are connected by Y-shaped connection.

  The core body 7 is configured by laminating a plurality of magnetic plates 8 such as electromagnetic steel plates in the axial direction. Referring also to FIG. 3, the core body 7 includes a back yoke 11 that forms an annular region on the outer peripheral side of the stator core 3, and teeth that protrude from the inner peripheral side of the back yoke 11 toward the radially inner side of the stator core 3. 12 and a magnetic inlet / outlet portion 13 provided at the extending end of the tooth 12.

  The back yoke 11 has a pair of flanges 11 a that protrudes on both sides along the circumferential direction of the stator core 3, and the magnetic input / output portion 13 similarly has a pair of protrusions that protrude on both sides along the circumferential direction of the stator core 3. It has a flange 13a. In the following description, the circumferential end surfaces of the flanges 11a on both sides may be referred to as the circumferential end surface 11ac, and the circumferential end surfaces of the flanges 13a may be referred to as the circumferential end surface 13ac.

  The teeth 12 are formed in a rectangular shape whose cross section perpendicular to the extending direction is long in the axial direction. In the following description, end surfaces on both sides in the circumferential direction of the teeth 12 may be referred to as side end surfaces 12a.

  The coil winding portion 16 of the insulator 10 includes a side wall 16 a that covers the side end surfaces 12 a on both sides of the teeth 12 of the core body 7, a front wall 16 b that covers the front side end surface of the teeth 12, and a rear wall that covers the rear side end surfaces of the teeth 12. 16c, an outer flange 16d that covers the lower surface of the flange portion 11a on the back yoke 11 side, and an inner flange 16e that covers the upper surface side of the flange portion 13a on the magnetic input / output portion 13 side.

  A slot SLT (see FIG. 8) in which the coil 2 is accommodated is formed between the teeth 12 and 12 of the adjacent divided cores 6 and 6 by assembling the plurality of divided cores 6 thus configured in an annular shape. Is done.

Next, the stator manufacturing method of this embodiment is demonstrated based on FIGS.
As shown in FIG. 4, the stator manufacturing method of the present embodiment includes a coil winding step S1, a heating step S2, a compression step S3, and a stator assembly step S4.

  In the coil winding step S1, as shown in FIG. 3, the outer circumference of the tooth 12 is more specifically exceeded beyond the virtual line L1 drawn along the circumferential end surface 11ac which is the circumferential end surface of the flange portion 11a of the back yoke 11. Specifically, the coil 2 is wound around the coil winding portion 16 of the insulator 10.

  Note that the space surrounded by the side end surface 12a of the tooth 12, the lower surface of the flange portion 11a, the upper surface of the flange portion 13a, and the virtual line L1 is wound around the adjacent divided coil after the divided core 6 is assembled. This is a space where the coils 2 are not interfered with each other. That is, if the coil 2 is wound without crossing the virtual line L1 in the circumferential direction, the coils 2 do not interfere with each other after the split core 6 is assembled.

Here, the winding amount of the coil 2 around the teeth 12 will be described in detail.
As an example, it is assumed that a rectangular wire coil having a rectangular cross section of 0.9 mm × 2 mm is used. In the split core 6 of a predetermined size, the winding of the coil 2 into the slot SLT is 10 steps in all stages, and the number of turns is reduced from the upper layer to the lower layer portion in accordance with the inclination of the virtual line L1, and the virtual line A total of 55 turns can be wound within a range not exceeding L1.

  On the other hand, when the present invention is applied and the imaginary line L1 is wound, the upper layer is wound twice on one side by more than two turns on one side and the lower layer is wound on three sides by one turn more on one side, The number of turns was 55 + 7 × 2 + 1 × 3 for a total of 72 turns, which was wound 17 turns more on one side than when not exceeding the virtual line L1.

  That is, the number of windings of the coil 2 in the slot is 72/55 as compared with the case where the virtual line L1 is not exceeded, which is about 1.3 times. Thus, in consideration of the spreadability of the coil 2 in the compression step S3 described later, it is preferable to wind the coil 2 1.2 to 1.4 times more than usual.

  In the heating step S2, the split core 6 around which the coil 2 is wound in the coil winding step S1 is heated, for example, in a thermostatic bath. In the present embodiment, the winding material of the coil 2 is copper, and the heating in the heating step S2 is intended to improve the spreadability of copper.

  Specifically, since copper has high spreadability by applying heat, the circumferential direction of the coil 2 is compressed in a high-temperature environment by compressing the circumferential direction of the coil 2 in the compression step S3 to be described later using the characteristics. The compressed portion of the winding of coil 2 is expanded in the axial direction and deformed.

  The heating temperature in heating process S2 of this embodiment becomes like this. Preferably it is 150 to 250 degreeC, More preferably, it is 180 to 220 degreeC. When the winding material of the coil 2 is copper, 190 ° C. is most preferable from the viewpoint of the spreadability of copper.

In the compression step S3, the coil 2 heated in the heating step S2 is pressed in the circumferential direction by a press machine, for example.
Specifically, as shown in FIGS. 5 and 6, using a compression jig 20 having an inclined pressing surface 20 a, pressure is applied simultaneously from both sides in the circumferential direction of the split core 6, and the coil 2 is pressed. Compress.

  By pressing in the compression step S3, as shown in FIG. 7, the coil 2 pressed along the circumferential direction is plastically deformed so as to move in the axial direction due to its spreadability. Here, the angle β of the pressing surface 20a of the compression jig 20 used in the compression step S3 is such that the split core 6 connecting the circumferential middle portion of the back yoke 11 and the axis O of the stator 1 as shown in FIG. The back yoke inclination angle α (see also FIG. 1) formed by the intermediate line L2 and the virtual line L1 is set slightly larger.

  In the present embodiment, the angle β of the pressing surface 20a is set to be 1 ° to 3 ° larger in the circumferential direction than the back yoke inclination angle α. Note that the angle β of the pressing surface 20a of the compression jig 20 determines the amount by which the coil 2 is compressed, that is, the amount by which the coil 2 is crushed in the circumferential direction, so that the winding amount of the coil 2 beyond the virtual line L1 is taken into consideration. Determined. Thereby, the coil 2 can be accommodated in the virtual line L1 with high density by spreading and plastically deforming the coil 2.

  In the stator assembly step S4, the split cores 6 on which the coils 2 are pressed in the compression step S3 are arranged in an annular shape as shown in FIG. In this case, the coil 2 wound around the split core 6 does not interfere with the coil 2 wound around the adjacent split core 6 as described above, and there is almost no gap in the slot SLT. That is, it is accommodated with a high space factor. Subsequently, the stator core 3 in which the divided cores 6 are arranged is press-fitted and fixed to the housing 4 as shown in FIG. 1 to complete the stator 1.

  As described above, according to the present embodiment, by applying heat to the winding material of the coil 2 in the heating step S2, the spreadability of the winding material can be improved. Even if the coil 2 is wound around the tooth 12 beyond the line L1, the coil 2 can be accommodated in the virtual line L1 with high density by spreading and plastically deforming the coil 2 in the compression step S3. Therefore, the coil 2 can be wound 1.2 to 1.4 times more than usual, and the space factor of the coil 2 can be preferably improved.

  Further, the angle β of the pressing surface 20a of the compression jig 20 used in the compression step S3 is determined by the intermediate line L2 and the virtual line L1 of the split core 6 that connects the circumferential intermediate portion of the back yoke 11 and the axis of the stator 1. The space factor of the coil 2 can be further improved by making it slightly larger than the formed back yoke inclination angle α.

  Moreover, the space factor of a coil can be improved more by making the angle of the press surface 20a 1 to 3 degrees larger than the back yoke inclination angle.

  Moreover, the coil 2 can be suitably extended by the heating temperature in heating process S2 being 150 to 250 degreeC.

  Moreover, in the compression process S3, since the heated coil 2 is simultaneously pressed by the compression jig 20 from both sides in the circumferential direction, the coil 2 can be spread without deviation in the circumferential direction. In addition, the work time can be shortened.

In addition, this invention is not limited to embodiment mentioned above, A deformation | transformation, improvement, etc. are possible suitably.
For example, in the embodiment, the winding material of the coil 2 is copper, but any other material may be used as long as it can obtain an appropriate spreadability by pressing in the compression process.

2 Coil 3 Stator core 6 Split core 11 Back yoke 11ac Circumferential end surface (circumferential end surface)
12 Teeth 20 Compression jig 20a Pressing surface L1 Virtual line L2 Intermediate wire S1 Coil winding step S2 Heating step S3 Compression step α Back yoke inclination angle β Pressing surface angle

Claims (5)

A stator core constituted by dividing a split core having a predetermined radial width and extending in an arc shape into a circular arc, and teeth protruding radially inward from a circumferential intermediate portion of the back yoke. When,
A stator manufacturing method for manufacturing a stator of a rotating electrical machine comprising a coil wound around the teeth of the split core,
A coil winding step of winding the coil around the teeth beyond an imaginary line drawn along a circumferential end surface of the back yoke;
A heating step of heating the split core around which the coil is wound;
And a compression step of pressing the heated coil in the circumferential direction. The stator manufacturing method according to claim 1,
The angle of the pressing surface of the compression jig used in the compression step is an inclination of the back yoke formed by the intermediate line of the divided core connecting the circumferential intermediate part of the back yoke and the axis of the stator and the virtual line. A stator manufacturing method that is slightly larger than the angle. The stator manufacturing method according to claim 2,
The stator manufacturing method, wherein an angle of the pressing surface is 1 ° to 3 ° larger than an angle of inclination of the back yoke. It is a stator manufacturing method of any one of Claims 1-3,
The method for manufacturing a stator, wherein a heating temperature in the heating step is 150 ° C to 250 ° C. It is a stator manufacturing method of any one of Claims 1-4,
In the compression step, the heated coil is simultaneously pressed from both sides in the circumferential direction.

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