JP2018129991A - Method of manufacturing stator for rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance an adhesive force of a foam adhesive part of insulation paper to coil winding to be higher than that to a stator core.SOLUTION: Heating is performed so that a temperature rise rate of coil winding 11 becomes lower than that of a stator core 20. An expansion ratio of a first portion 31 of a foam adhesive part 30a that is adjacent to the coil winding 11, is set to be lower than that of a second portion 32 of the foam adhesive part 30a that is adjacent to the stator core 20.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a method for manufacturing a stator for a rotating electrical machine.

  2. Description of the Related Art Conventionally, an invention relating to a stator for a rotating electrical machine, particularly an improvement of an insulation structure between a stator core and a coil winding is known (see Patent Document 1 below).

  Patent Document 1 discloses a rotating electrical machine including a stator core having a slot, a coil winding inserted and disposed in the slot, and an insulating paper that electrically insulates the stator core and the coil winding in the slot. A stator for a motor having the following characteristics is disclosed.

  In the stator for a rotating electrical machine disclosed in Patent Document 1, a foamed adhesive portion is provided in the portion of the insulating paper corresponding to both axial end portions of the slot. The foamed adhesive portion is for fixing the coil winding to the stator core by expansion and adhesion caused by heating after assembling the insulating paper and the coil winding to the stator core (the same document, (See claim 1).

  According to the stator for a rotating electrical machine disclosed in Patent Document 1, the foamed adhesive portion provided in the end region of the insulating paper expands and develops stickiness by heating after the coil winding and the insulating paper are assembled to the stator core. As a result, the coil winding is bonded and fixed to the stator core at the axial end of the slot (see the same document, paragraph 0007, etc.).

JP, 2006-52226, A

  In general, the surface of a coil winding of a stator for a rotating electrical machine is a smooth surface having a low roughness and coated with lubricating oil for the purpose of reducing friction when the coil winding is inserted into a stator core, for example. Therefore, in the conventional stator for a rotating electrical machine, the adhesive force for the coil winding of the foamed adhesive portion that adheres and fixes the coil winding to the stator core is likely to be lower than the adhesive force for the stator core.

  Further, in a conventional stator for a rotating electrical machine, the foamed adhesive part is expanded by heating after the coil winding and the insulating paper are assembled to the stator core, thereby expressing the adhesiveness. However, since the heat capacity of the coil winding is smaller than the heat capacity of the stator core, the temperature of the coil winding is likely to rise higher than the temperature of the stator core. It tends to be higher than the expansion ratio of the portion adjacent to the stator core. Since the adhesive force of the foamed adhesive portion decreases as the expansion ratio increases, the adhesive force of the foamed adhesive portion to the coil winding may be lower than the adhesive force of the foamed adhesive portion to the stator core.

  The present invention has been made in view of the above problems, and has the object of making the adhesive force of the foamed adhesive portion of the insulating paper to the coil winding higher than the adhesive force of the foamed adhesive portion of the insulating paper to the stator core. An object of the present invention is to provide a method for manufacturing a stator for a rotating electrical machine.

  In order to achieve the above object, a method for manufacturing a stator for a rotating electrical machine according to the present invention includes a coil insertion step of inserting a coil winding into a slot of a stator core with insulating paper having foamed adhesive portions on both sides, and the coil insertion. A coil bonding step of bonding the coil winding to the stator core by expansion and stickiness caused by heating of the foam bonding portion after the step, wherein the coil bonding step includes: The coil winding is heated so that the heating rate of the coil winding is slower than the heating rate of the stator core, and the foaming magnification of the first portion of the foamed adhesive portion adjacent to the coil winding is adjacent to the stator core. The expansion ratio is lower than the expansion ratio of the second portion of the foamed adhesive portion.

  In the method for manufacturing a stator for a rotating electrical machine according to the present invention, when a coil winding is inserted into a slot of the stator core in the coil insertion step, an insulating paper is interposed between the stator core and the coil winding. This insulating paper has foamed adhesive portions on both sides. The foamed adhesive portions on both sides of the insulating paper expand by melting and foaming by heating and exhibit adhesiveness.

  The foamed adhesive portions provided on both surfaces of the insulating paper are divided into two layers, for example, a first portion and a second portion with the insulating paper interposed therebetween. Therefore, when insulating paper is interposed between the stator core and the coil winding, for example, the first portion of the foamed adhesive portion provided on one surface of the insulating paper is adjacent to the coil winding and the other of the insulating paper is The 2nd part of the foaming adhesion part provided in the surface will be in the state adjacent to the stator core.

  Further, in the method for manufacturing a stator for a rotating electrical machine according to the present invention, in the coil bonding process after the coil insertion process, the stator core and the coil winding are heated so that the foamed bonded portions on both sides of the insulating paper interposed between them. Heat. As a result, the foamed adhesive part is melted to cause expansion and tackiness, and then the temperature of the foamed adhesive part is lowered and solidified, thereby allowing the coil winding to pass through the insulating paper and the foamed adhesive part on both sides thereof. Is bonded and fixed to the stator core. Here, the adhesive strength of the foamed adhesive part tends to decrease when the foaming ratio of the foamed adhesive part increases, and increases when the foaming ratio of the foamed adhesive part decreases.

  Therefore, in the method for manufacturing a stator for a rotating electrical machine according to the present invention, in the coil bonding step, heating is performed so that the temperature increase rate of the coil winding is slower than the temperature increase rate of the stator core. As a result, the temperature increase rate of the first part of the foamed adhesive part adjacent to the coil winding is slower than the temperature increase rate of the second part of the foamed adhesive part adjacent to the stator core, and the foaming ratio of the first part is reduced to the first. It can be made lower than the expansion ratio of two parts. Thereby, the adhesive force of the 1st part of the foaming adhesion part with respect to coil winding can be made higher than the adhesive force of the 2nd part of the foaming adhesion part with respect to a stator core.

  As described above, in the method for manufacturing a stator for a rotating electrical machine according to the present invention, in the coil bonding step, heating is performed so that the temperature increase rate of the coil winding is slower than the temperature increase rate of the stator core. Thereby, the foaming ratio of the 1st part of the foaming adhesion part adjacent to a coil winding can be made lower than the foaming ratio of the 2nd part of the foaming adhesion part adjacent to a stator core. Therefore, according to the method for manufacturing a stator for a rotating electrical machine of the present invention, the adhesive force of the foamed adhesive portion of the insulating paper to the coil winding can be made higher than the adhesive force of the foamed adhesive portion of the insulating paper to the stator core.

The flowchart of the manufacturing method of the stator for rotary electric machines which concerns on embodiment of this invention. Schematic of the coil bonding process shown in FIG. The cross-sectional enlarged view of the coil and stator core which are shown in FIG. FIG. 4 is an enlarged cross-sectional view of a coil and a stator core shown in FIG. 3. FIG. 5 is an enlarged cross-sectional view of insulating paper interposed between a coil and a stator core shown in FIG. 4. The graph which shows the temperature increase rate of a coil winding and a stator core in a coil adhesion | attachment process. The expanded sectional view corresponding to Drawing 5 of insulating paper after the end of a coil adhesion process. The graph which shows the temperature increase rate of the coil winding and the stator core in the conventional manufacturing method. The expanded sectional view after the heating of the insulating paper in the conventional manufacturing method.

  Hereinafter, an example of an embodiment of a method for manufacturing a stator for a rotating electrical machine according to the present invention will be described with reference to the drawings.

  FIG. 1 is a flowchart of a manufacturing method S100 for a stator for a rotating electrical machine according to an embodiment of the present invention. FIG. 2 is a schematic diagram of the coil bonding step S2 after the coil insertion step S1 shown in FIG. FIG. 3 is a schematic enlarged cross-sectional view of the coil 10 and the stator core 20 shown in FIG. 4 is an enlarged cross-sectional view of the coil 10 and the stator core 20 shown in FIG. FIG. 5 is a schematic enlarged cross-sectional view of the insulating paper 30 interposed between the coil 10 and the stator core 20 shown in FIG.

  A manufacturing method S100 for a rotating electrical machine stator according to the present embodiment includes a coil insertion step S1 for inserting the coil winding 11 into the slot 21 of the stator core 20 and a coil bonding step S2 for bonding the coil winding 11 to the stator core 20. Have. The manufacturing method S100 of the present embodiment can include other processes such as a manufacturing process of the stator core 20 and a manufacturing process of the coil 10 in addition to the processes shown in FIG. The steps other than those shown in FIG. 1 can be the same as the conventional method for manufacturing a stator for a rotating electrical machine, and thus the description thereof is omitted here.

  The coil insertion step S1 is a step of inserting the coil winding 11 into the slot 21 of the stator core 20 with the insulating paper 30 interposed as shown in FIG. By this coil insertion step S1, the coil winding 11 is inserted into the slot 21 of the stator core 20 as shown in FIG. 3, and the insulating paper 30 is inserted between the stator core 20 and the coil winding 11 as shown in FIG. Intervene. Here, the surface of the coil winding 11 is a smooth surface having a low roughness for the purpose of reducing friction when the coil winding 11 is inserted into the stator core 20, for example, and is coated with lubricating oil.

  Although not shown in FIGS. 3 and 4, the insulating paper 30 interposed between the stator core 20 and the coil winding 11 has foamed adhesive portions 30 a on both sides as shown in FIG. 5. The insulating paper 30 can be composed of, for example, a sheet material or a film material made of an insulating resin. The foaming adhesive portions 30a on both sides of the insulating paper 30 expand by melting and foaming by heating and exhibit adhesiveness.

  The foamed adhesive portion 30a can be formed by applying a material that expands and expands when heated, such as an epoxy-based foamed resin material, to the surface of the resin sheet material constituting the insulating paper 30. . Alternatively, the foamed adhesive portion 30a may be formed by bonding or integrating a sheet material formed of a resin material exhibiting such foamability and adhesiveness to the insulating paper 30.

  The foamed adhesive portions 30a provided on both surfaces of the insulating paper 30 are divided into two layers, for example, a first portion 31 and a second portion 32 with the insulating paper 30 interposed therebetween. Therefore, when the insulating paper 30 is interposed between the stator core 20 and the coil winding 11, for example, the first portion 31 of the foamed adhesive portion 30 a provided on one surface of the insulating paper 30 is adjacent to the coil winding 11. Then, the second portion 32 of the foamed adhesive portion 30 a provided on the other surface of the insulating paper 30 is in a state adjacent to the stator core 20. Here, the first portion 31 and the second portion 32 of the foamed adhesive portion 30a may have different components, properties, and characteristics, but in the present embodiment, the first portion 31 and the second portion 32 of the foamed adhesive portion 30a. Portion 32 has the same components, properties and characteristics. After completion of the coil insertion step S1, a coil bonding step S2 is performed as shown in FIG.

  The coil bonding step S2 is a step in which the coil winding 11 is bonded to the stator core 20 by expansion and tackiness generated by heating the foamed bonding portions 30a on both sides of the insulating paper 30 after the coil insertion step S1. In the coil bonding step S2, by heating the stator core 20 and the coil winding 11, the foamed bonding portions 30a on both sides of the insulating paper 30 interposed therebetween are heated. More specifically, as shown in FIG. 2, for example, by passing an alternating current through a coil C for induction heating arranged around the stator core 20, the stator core 20 is induction-heated from the outside and connected to a power source. By energizing the coil winding 11 via the wiring L, the coil winding 11 is heated by the electric resistance of the coil winding 11.

  And the foaming adhesion part 30a is heated with the stator core 20 and the coil winding 11 which were heated up, and the foaming adhesion part 30a is melted, and expansion | swelling and adhesiveness are produced. Thereafter, heating of the stator core 20 and the coil winding 11 is stopped, and the temperature of the foamed adhesive portion 30a is lowered and solidified, so that the coil winding 11 is made to pass through the insulating paper 30 and the foamed adhesive portions 30a on both sides thereof. The stator core 20 is bonded and fixed. Here, the adhesive force of the foam adhesive part 30a tends to decrease when the foaming ratio of the foam adhesive part 30a increases, and increases when the foaming ratio of the foam adhesive part 30a decreases. The coil winding 11 has a heat capacity smaller than that of the stator core 20, and the coil winding 11 is doubly heated by heating by direct energization and dielectric heating by the coil C for dielectric heating. Is more likely to rise than the temperature of the stator core 20.

  FIG. 8 is a graph showing an example of the temperature increase rate of the stator core and the coil winding in the conventional method for manufacturing a stator for a rotating electrical machine. In FIG. 8, the horizontal axis represents time [s], the vertical axis represents temperature [° C.], the solid line represents the heating time and temperature of the coil winding, and the broken line represents the heating time and temperature of the stator core. FIG. 9 is an enlarged cross-sectional view corresponding to FIG. 5 showing a state in which the coil winding 911 is joined to the stator core 920 via the insulating paper 930 having the foamed adhesive portions 930a on both surfaces in the conventional rotating electrical machine stator. .

  As described above, the heat capacity of the coil winding 911 is smaller than the heat capacity of the stator core 920. Therefore, as shown in FIG. 8, the temperature of the coil winding 911 is about 135 from about 25 [° C.] to about 160 [° C.] in about 90 [s] less than 100 [s], for example. The temperature has risen by about [° C]. That is, the heating rate of the coil winding 911 is about 1.5 [° C./s]. On the other hand, as shown in FIG. 8, the temperature of the stator core 920 is increased by about 70 [° C.] from about 25 [° C.] to about 95 [° C.] in about 90 [s], for example. Stay on. The temperature increase rate of the stator core 920 is about 0.78 [° C./s], which is lower than the temperature increase rate of the coil winding 911.

  In the conventional method for manufacturing a stator for a rotating electrical machine, as described above, the temperature increase rate of the coil winding 911 is faster than the temperature increase rate of the stator core 920, and the temperature of the coil winding 911 is reduced to the temperature of the stator core 920 in a short time. It becomes hotter than. Then, the temperature of the portion adjacent to the coil winding 911 of the foam adhesive portion 930a becomes higher than the temperature of the portion adjacent to the stator core 920 of the foam adhesive portion 930a. The coil winding 911 and the stator core 920 are bonded to each other while the foam beads contained in the foam bonding portion 930a are foamed to fill the gap between the coil winding 911 and the stator core 920. At this time, it is conceivable that the foaming magnification of the portion adjacent to the coil winding 911 of the foamed adhesive portion 930a is higher than the foaming magnification of the portion adjacent to the stator core 920 of the foamed adhesive portion 30a.

  In the conventional stator for a rotating electrical machine, when the expansion ratio of the portion adjacent to the coil winding 911 of the foamed adhesive portion 930a is higher than the expansion ratio of the portion adjacent to the stator core 920, adjacent to the coil winding 911 of the foamed adhesive portion 930a. The density and strength of the portion to be reduced are lower than the density and strength of the portion adjacent to the stator core 920. In this case, the adhesive force with respect to the coil winding 911 in the portion adjacent to the coil winding 911 of the foamed adhesive portion 930a having a higher expansion ratio is greater than the adhesive force with respect to the stator core 920 in the portion adjacent to the stator core 920 of the foamed adhesive portion 930a. May also decrease.

  Furthermore, as described above, the surface of the coil winding 911 is a smooth surface with a low roughness for the purpose of reducing friction when the coil winding 911 is inserted into the stator core 920, for example, and is coated with lubricating oil. . For this reason, in the conventional stator for a rotating electrical machine, the foamed adhesive portion 930 a that adheres and fixes the coil winding 911 to the stator core 920 is more likely to have a lower adhesive force to the coil winding 911 than an adhesive force to the stator core 920. In order to solve such a problem in the conventional stator for a rotating electrical machine, the manufacturing method S100 for a stator for a rotating electrical machine of the present embodiment is characterized by a coil bonding process S2 after the coil insertion process S1.

  More specifically, in the stator manufacturing method S100 of the present embodiment, the coil insertion in which the coil winding 11 is inserted into the slot 21 of the stator core 20 with the insulating paper 30 having the foamed adhesive portions 30a on both sides is interposed. In the point which has process S1, it is common with the conventional manufacturing method. Further, the present manufacturing method S100 is common to the conventional manufacturing method in that the coil winding 11 is bonded to the stator core 20 by the expansion and tackiness caused by heating of the foam bonding part 30a in the coil bonding step S2.

  However, this manufacturing method S100 is a conventional manufacturing method in that, in the coil bonding step S2, the stator core 20 is induction-heated from the outside, for example, so that the temperature increase rate of the coil winding 11 is slower than the temperature increase rate of the stator core 20. It is different from the method. Further, in this manufacturing method, in the coil bonding step S <b> 2, the expansion ratio of the first portion 31 of the foam bonding portion 30 a adjacent to the coil winding 11 is set to the foaming ratio of the second portion 32 of the foam bonding portion 30 a adjacent to the stator core 20. It differs from the conventional manufacturing method in that it is lower than the magnification.

  FIG. 6 is a graph showing an example of the temperature increase rate of the coil winding 11 and the stator core 20 in the coil bonding step S2 of the manufacturing method S100 shown in FIG. This manufacturing method is characterized in that the stator core 20 is heated so that the temperature increase rate of the coil winding 11 is slower than the temperature increase rate of the stator core 20 in the coil bonding step S2. For example, as shown in FIG. 2, the value of the current passed through the induction heating coil C arranged around the stator core 20 and the value of the current passed through the coil winding 11 are controlled. More specifically, for example, the value of the current flowing through the coil C for induction heating is increased from the conventional value, and the value of the current flowing through the coil winding 11 is decreased from the conventional value.

  Thereby, in this manufacturing method, the temperature increase rate of the coil winding 11 shown in FIG. 6 is lower than the temperature increase rate of the coil winding 911 in the conventional manufacturing method shown in FIG. More specifically, the temperature of the coil winding 11 is increased by about 100 [° C.] from about 25 [° C.] to about 125 [° C.] in about 90 [s], for example. The temperature after this temperature rise is about 35 [° C.] lower than the temperature of the conventional coil winding 911. That is, the temperature increase rate of the coil winding 11 is about 1.1 [° C./s], which is about 0.4 [° C./s] lower than the temperature increase rate of the conventional coil winding 911. .

  Further, in the present manufacturing method S100, the temperature increase rate of the stator core 20 shown in FIG. 6 is increased compared to the temperature increase rate of the stator core 920 in the conventional manufacturing method shown in FIG. More specifically, the temperature of the stator core 20 is increased by about 115 [° C.] from about 25 [° C.] to about 140 [° C.] in about 90 [s], for example. The temperature after the warming is about 40 [° C.] higher than the conventional temperature. That is, the temperature increase rate of the stator core 20 is about 1.28 [° C./s], which is about 0.5 [° C./s] higher than the temperature increase rate of the conventional stator core 920, and in the coil bonding step S2. The temperature rise rate of the coil winding 11 is increased by about 0.18 [° C./s].

  That is, in the manufacturing method S100 of the stator for a rotating electrical machine of the present embodiment, the temperature of the coil winding 11 is made lower than the temperature of the stator core 20 by making the temperature increase rate of the coil winding 11 slower than the temperature increase rate of the stator core 20. Can also be lowered. Thereby, the temperature of the 1st part 31 of the foaming adhesion part 30a adjacent to the coil winding 11 can be made lower than the temperature of the 2nd part 32 of the foaming adhesion part 30a adjacent to the stator core 20, and the 1st part The expansion ratio of 31 can be made lower than the expansion ratio of the second portion 32.

  As described above, the foamed adhesive portions 30a on both sides of the insulating paper 30 are heated by the coil winding 11 and the stator core 20, so that they expand by being melted and foamed, and exhibit adhesiveness. Then, the coil winding 11 is bonded and fixed to the stator core 20 via the insulating paper 30 and the foam adhesive portions 30a on both sides thereof by lowering the temperature of the foam adhesive portion 30a to solidify or solidify. Here, the adhesive force of the foam adhesive part 30a tends to decrease when the foaming ratio of the foam adhesive part 30a increases, and increases when the foaming ratio of the foam adhesive part 30a decreases.

  Therefore, as described above, the stator manufacturing method S100 of the present embodiment heats the coil winding 11 so that the temperature increase rate of the coil winding 11 is slower than the temperature increase rate of the stator core 20 in the coil bonding step S2. . Thereby, the expansion ratio of the first part 31 can be made lower than the expansion ratio of the second part 32. Therefore, the adhesive force of the first portion 31 of the foamed adhesive portion 30 a to the coil winding 11 can be made higher than the adhesive force of the second portion 32 of the foamed adhesive portion 30 a to the stator core 20.

  As described above, in the manufacturing method S100 for a stator for a rotating electrical machine according to the embodiment, the adhesive force of the foamed adhesive portion 30a of the insulating paper 30 to the coil winding 11 is used to bond the foamed adhesive portion 30a of the insulating paper 30 to the stator core 20. Can be higher than power. Therefore, for example, for the purpose of reducing friction when the coil winding 11 is inserted into the stator core 20, even when the surface of the coil winding 11 is a smooth surface and the lubricating oil is applied, the foaming of the insulating paper 30 is performed. The adhesive force of the adhesive portion 30a to the coil winding 11 can be made equal to or higher than the adhesive force to the stator core 20.

  The embodiment of the present invention has been described in detail with reference to the drawings, but the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

DESCRIPTION OF SYMBOLS 11 Coil winding, 20 Stator core, 21 Slot, 30 Insulating paper, 31 1st part, 30a Foam adhesion part, 32 2nd part, S1 coil insertion process, S2 coil adhesion process, S100 Manufacturing method of stator for rotary electric machine

Claims (1)

A coil insertion step of inserting a coil winding into a slot of the stator core with insulating paper having foam adhesive portions on both sides, and the stator core due to expansion and stickiness caused by heating of the foam adhesive portion after the coil insertion step A method of manufacturing a stator for a rotating electrical machine, comprising: a coil bonding step of bonding the coil winding to
In the coil bonding step, the coil winding is heated so that the temperature increase rate of the coil winding is slower than the temperature increase rate of the stator core, and the foaming magnification of the first portion of the foam bonding portion adjacent to the coil winding is A method for manufacturing a stator for a rotating electrical machine, wherein the foaming ratio of the second portion of the foamed adhesive portion adjacent to the stator core is lower.

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