JP2019205230A - Rotary electric machine stator manufacturing method - Google Patents

Abstract

To obtain a rotary electric machine stator manufacturing method for enabling downsizing by lowering the height of a coil end while enabling an electromagnetic design having a high degree of freedom by using a linear unit coil.SOLUTION: A linear unit coil 21 is inserted in dummy slots 52 of a dummy core 50. Projected portions, of the unit coil 21, from the dummy slots 52 are twisted in the circumferential direction. The ends, of the unit coil 21, twisted in the circumferential direction are joined together. A first joint wire 30 and a second joint wire 40 are mounted on the dummy core 50 from the radial direction such that joint portion 30c, 40c is located radially outside a joined portion 19 of the ends of the unit coil 21. Thereafter, the unit coil 21, the first joint wire 30, and the second joint wire 40 are transferred to a stator core 11. Projected portions of the unit coil 21, the first joint wire 30, and the second joint wire 40 from slots 14 are twisted in the circumferential direction. Ends of the projected portions twisted in the circumferential direction are joined together.SELECTED DRAWING: Figure 6E

Description

  The present invention relates to a method for manufacturing a stator of a rotating electric machine such as an electric motor or a generator, and more particularly to a method for forming a stator winding.

  The winding method of the stator winding of the rotating electrical machine includes a concentrated winding method in which a conductor wire is wound around each tooth, and a distributed winding method in which a conductor wire is wound across a plurality of teeth. In contrast to the concentrated winding method, the distributed winding method has a merit that vibration during operation of the rotating electrical machine can be reduced because the distribution of the rotating magnetic field becomes smooth.

  However, in the coil end portion of the distributed winding type stator winding, a plurality of conductor wires overlap each other. For this reason, the coil end portion becomes higher in the axial direction, which is an obstacle to downsizing of the rotating electrical machine.

  In view of such a situation, by optimizing the overlapping of the conductor wires at the coil end portion of the distributed winding type stator winding, the gap between the overlapping conductor wires is minimized, and the height of the coil end portion is reduced. Various methods for reducing the above have been proposed. For example, Patent Document 1 proposes a technique for optimizing the overlapping of wires in a coil end portion by dividing a coil for one phase into a plurality of U-shaped unit coils. Furthermore, Patent Document 2 proposes a technique for optimizing the overlap between wires in a coil end portion by dividing a coil for one phase into a plurality of linear unit coils.

  Here, when a U-shaped unit coil is used, the number of coils arranged in the slot is an even number. On the other hand, when a linear unit coil is used, the number of coils arranged in the slot can be set to an odd number, and there is an advantage that the degree of freedom in design of the rotating electrical machine is increased. In addition, when a linear unit coil is used, the number of welding points between the coils increases, but the shape of the unit coil itself is a simple linear shape, so it is possible to manufacture a highly accurate unit coil at high speed. It becomes.

  Patent Documents 1 and 2 refer to joining ends of adjacent unit coils after the coil ends are formed. However, in order to join the unit coils to form the stator winding, it may be necessary to join the ends of the ends of the unit coils that are not adjacent after the coil end molding. That is, depending on the design specifications of the rotating electrical machine, connection work such as forming a neutral point or connecting a group of coils in parallel may be performed on the coil end. Patent Document 3 discloses a technique for performing these connection operations on a coil end.

Japanese Patent No. 4200611 JP 2006-157993 A Japanese Patent No. 3807401

  In Patent Document 3, the length of the unit coil for neutral point connection is lengthened, the coil end is molded, and then the protrusion from the coil end of the unit coil for neutral point connection is bent once to wrap around the coil end. The ends of the unit coil for neutral point connection that were routed in the direction were joined together. However, when joining the end portions of the unit coils by welding or brazing, there is a risk that the insulating coating of the conductor wire constituting the coil end may be damaged by heating at the time of joining. Furthermore, the installation space of the holding part which hold | maintains the edge parts for neutral point connection was required at the time of joining. Therefore, it is necessary to separate the joint between the ends for neutral point connection from the coil end.

  Further, as in Patent Documents 1 and 2, when U-shaped and linear unit coils are used, the joint portions between the end portions of the unit coils are joint portions between the end portions for neutral point connection. It will be placed at a position directly below. Since there is no insulating coating at the joint between the end portions of the unit coil, it is necessary to secure the insulation distance by separating the joint between the end portions for neutral point connection from the coil end.

  As described above, in Patent Documents 1 to 3, there is a problem that the height of the joint portion between the end portions of the unit coil on the coil end is increased, and the axial length of the stator is increased.

  The present invention has been made to solve such a problem, and enables the electromagnetic design with a high degree of freedom using a linear unit coil, while reducing the height of the coil end and reducing the size. It is an object of the present invention to obtain a method for manufacturing a stator of a rotating electrical machine that can be made.

  A method of manufacturing a rotating electrical machine according to the present invention includes an annular stator core in which a plurality of slots are arranged at a constant pitch in the circumferential direction, and a stator winding attached to the stator core, The stator winding includes a plurality of linear unit coils inserted into each of the plurality of slots, and a joint line inserted into two or more slots among the plurality of slots. Has two or more straight portions inserted into each of the two or more slots, and a joint portion that connects one end portions in the axial direction of the two or more straight portions, and the shaft of the stator core. On one end side in the direction, axial end portions of the plurality of unit coils are joined to each other, and the joint portion is an axis of a joint portion at one axial end portion of the unit coil located between the two or more linear portions. Placed outside the direction On the other end side in the axial direction of the stator core, the other end portions in the axial direction of the plurality of unit coils, and the other end portion in the axial direction of the plurality of unit coils and the other end in the axial direction of the joint line. A stator of a rotating electrical machine in which a plurality of slots are joined to each of a plurality of dummy slots arranged in the same number as the plurality of slots at the constant pitch in the circumferential direction of the dummy core. Avoiding the insertion position of the straight line portion, mounting the plurality of unit coils in a row in the radial direction, and twisting the protruding portions of the plurality of unit coils protruding in the axial direction from the dummy slot in the circumferential direction A first twisting step, a first joining step for joining axial end portions of the plurality of unit coils twisted in the circumferential direction, and a joint portion of the joining portion at one end portion in the axial direction of the unit coil. Axial outside And inserting the joint wire into the dummy core by inserting the two or more straight portions into the insertion positions of the plurality of dummy slots from the radial direction so that the plurality of unit coils and the joints are positioned. A step of drawing a wire from the dummy core to one end side in the axial direction and mounting the wire to the plurality of slots of the stator core from one end side in the axial direction; and the plurality of units protruding from the plurality of slots to the other end side in the axial direction A second twisting step of twisting the coil and the protruding portion of the joint wire in the circumferential direction; a second joining step of joining the plurality of unit coils twisted in the circumferential direction and the other end portions of the joint wire in the axial direction; It is equipped with.

According to the present invention, since a linear unit coil is used, an electromagnetic design with a high degree of freedom is possible.
In addition, after joining the end portions of the unit coils in the axial direction using the dummy core, the joint wire is changed from the radial direction to the dummy core so that the joint portion is positioned outside the joint portion between the end portions of the unit coils in the axial direction. Wearing. Thereby, joining operations such as welding and brazing on the coil end on one axial end side are omitted. Therefore, there is no occurrence of damage to the insulating film of the conductor wire constituting the coil end by heating. The installation space for the holding portion that holds the ends for neutral point connection, which was necessary at the time of joining, becomes unnecessary. Furthermore, since the joint portion is covered with insulation, it is not necessary to separate the joint portion from the joint portion between the one end portions of the unit coils. As a result, the joint portion can be disposed close to the coil end, so that a stator with a reduced size can be manufactured.

It is a longitudinal cross-sectional view which shows the rotary electric machine which concerns on Embodiment 1 of this invention. It is a cross-sectional view which shows the principal part of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a longitudinal cross-sectional view which shows the principal part of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the surroundings of the 1st joint line of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the surroundings of the 2nd joint line of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the dummy core with which the unit coil was mounted | worn in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the state which attached the twist jig | tool to the unit coil with which the dummy core in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention was mounted | worn. It is a principal part expanded view which shows the state which has bent the unit coil with which the dummy core in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention was mounted | worn with the twist jig | tool. It is a principal part expanded view which shows the state which joined the front-end | tip parts of the unit coil with which it attached to the dummy core in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the state by which the 1st joint line was mounted | worn in the unit coil group joined in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the state by which the 2nd joint line was mounted | worn in the unit coil group joined in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part expanded view which shows the process in which the unit coil group joined in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention is mounted | worn to a stator core. It is a principal part expanded view which shows the state which mounted | wore the stator core with the unit coil group joined in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view which shows the 1st joint line in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a front view which shows the 2nd joint line in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the method of assembling the 2nd joint line in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the method of assembling the 2nd joint line in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a figure explaining the method of assembling the 2nd joint line in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a principal part perspective view which shows the state which attached the unit coil in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 2 of this invention to the dummy core. It is a principal part perspective view which shows the state which mounted | wore the dummy core with the spacer jig | tool in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 2 of this invention. It is a principal part expanded view which shows the state which attached the twist jig | tool to the unit coil with which the dummy core in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 2 of this invention was mounted | worn. It is a principal part expanded view which shows the state which has bent the unit coil with which the dummy core in the manufacturing method of the stator of the rotary electric machine which concerns on Embodiment 2 of this invention was mounted | worn with the twist jig | tool.

Embodiment 1 FIG.
1 is a longitudinal sectional view showing a rotary electric machine according to Embodiment 1 of the present invention. In addition, a longitudinal cross-sectional view is a cross-sectional view showing a cross section including the axis of the rotation shaft. Further, in this specification, for the sake of convenience, the direction parallel to the axis of the rotation axis is the axial direction (corresponding to the vertical direction in FIG. 1), and the direction orthogonal to the axis of the rotation axis is centered on the axis of the rotation axis. Is the radial direction (corresponding to the horizontal direction in FIG. 1), and the direction of rotation about the rotation axis is the circumferential direction.

  In FIG. 1, a rotating electrical machine 100 includes a housing 1 having a bottomed cylindrical frame 2 and a bracket 3 that closes an opening of the frame 2, a stator 10 housed and held inside a cylindrical portion 2a of the frame 2, a frame 2, and a rotor 5 fixed to a rotary shaft 6 rotatably supported by a bearing 4 via a bearing 4 and rotatably disposed on an inner diameter side of a stator 10. The frame 2 and the bracket 3 are made of a metal material such as iron or aluminum, and mechanically hold the rotor 5 and the stator 10 and serve as a heat dissipation path for the stator 10.

  The rotor 5 is fixed to a rotor core 7 that is fixed to a rotary shaft 6 that is inserted through the axial center position, and the rotor 5 is fixed to the outer peripheral surface of the rotor core 7 and is arranged at an equal pitch in the circumferential direction to constitute a permanent magnetic pole. A permanent magnet type rotor including a magnet 8. The rotor 5 is not limited to a permanent magnet rotor, but a squirrel-cage rotor in which a non-insulated rotor conductor is housed in a slot of a rotor core and both sides are short-circuited by a short-circuit ring, and an insulated conductor wire A wound rotor or the like that is mounted in a slot of the rotor core may be used.

  Next, the configuration of the stator 10 will be described. FIG. 2 is a cross-sectional view showing the main part of the stator of the rotating electrical machine according to the first embodiment of the present invention, and FIG. 3 shows the main part of the stator of the rotating electric machine according to the first embodiment of the present invention. FIG. 4 is a longitudinal sectional view, FIG. 4 is a main part development view showing the periphery of the first joint line of the stator of the rotating electrical machine according to Embodiment 1 of the present invention, and FIG. 5 is the rotating electrical machine according to Embodiment 1 of the present invention. It is a principal part expanded view which shows the 2nd joint line periphery of the stator of this. In addition, a cross-sectional view is a cross-sectional view showing a cross section orthogonal to the axis of the rotation shaft. The main part development view is a diagram in which the main part of the stator as viewed from the inner diameter side is linearly developed.

  Here, for convenience of explanation, it is assumed that the number of slots per phase per phase is 2, and the stator winding is a three-phase winding. Further, the storage position in the slot of the unit coil is defined as the first layer, the second layer, the third layer, and the fourth layer from the inner diameter side.

  As shown in FIGS. 2 to 5, the stator 10 includes an annular stator core 11 and a stator winding 20 attached to the stator core 11. The stator core 11 is manufactured by laminating and integrating magnetic thin plates such as electromagnetic steel plates, and protrudes radially inward from the inner peripheral wall surface of the core back 12 and each of the core backs 12, and so on in the circumferential direction. A plurality of teeth 13 arranged at an angular pitch. A space formed between the teeth 13 adjacent in the circumferential direction becomes a slot 14. Note that an insulator 16 for securing electrical insulation between the stator core 11 and the stator winding 20 is mounted in the slot 14. The insulator 16 is made of paper, resin, or a composite material thereof. Here, the insulator 16 is made in a sheet shape by sandwiching a polyimide film between meta-aramid fibers.

  The stator winding 20 includes a unit coil 21, a first joint line 30, and a second joint line 40 for neutral point connection. The unit coil 21 is linearly formed by a conductor having a rectangular cross section such as copper or aluminum coated with an insulating coating. Each slot 14 accommodates four unit coils 21 arranged in a row in the radial direction. The first joint wire 30 is formed in a U shape by a conductor having a rectangular cross section such as copper or aluminum coated with an insulating coating. The first joint wire 30 is accommodated in the slot 14 in place of the unit coil 21 accommodated in the first layer in the slot 14 at a plurality of locations. Although not shown, the first joint wire 30 is housed in the slot 14 in place of the unit coil 21 housed in the fourth layer of the slot 14 at a plurality of locations. The second joint line 40 is made of a conductor having a rectangular cross section such as copper or aluminum coated with an insulating coating, and is formed in a shape in which the ends of the three straight portions are connected by the joint portion 40c. The second joint wire 40 is accommodated in the slot 14 in place of the unit coil 21 accommodated in the first layer in the slot 14 at a plurality of locations.

  On one end side in the axial direction of the stator core 11, the projecting portions of the unit coil 21, the first joint line 30 and the second joint line 40 accommodated in the first layer in the slot 14 from the slot 14 are shown in FIG. 4. And in FIG. 5, it is bent so as to incline in the right direction. The protruding portion from the slot 14 of the unit coil 21 housed in the second layer in the slot 14 is bent so as to incline to the left in FIGS. 4 and 5. Although not shown, the protruding portion from the slot 14 of the unit coil 21 housed in the third layer in the slot 14 is bent so as to incline in the right direction in FIGS. 4 and 5. . The unit coil 21 housed in the fourth layer in the slot 14 and the protruding portion of the first joint line 30 from the slot 14 are bent so as to incline in the left direction in FIGS. 4 and 5.

  Here, one end of the unit coil 21 housed in the first layer of one slot 14 and the second layer of the slot 14 that is 6 slots away from the one slot 14 in the right direction in FIGS. 4 and 5 are housed. One end of the unit coil 21 is overlapped in the radial direction. One end of the unit coil 21 housed in the third layer of one slot 14 and the fourth layer of the slot 14 which is 6 slots away from the one slot 14 in the right direction in FIGS. 4 and 5. One end of the unit coil 21 overlaps in the radial direction. In this way, one end portions of the unit coils 21 accommodated in the first layer and the second layer of the pair of slots 14 separated by 6 slots overlap in the radial direction, and are accommodated in the third layer and the fourth layer. One end portions of the unit coils 21 are overlapped in the radial direction. The pair of slots 14 separated by six slots is a pair of slots 14 located on both sides of six teeth 13 that are continuous in the circumferential direction. An interval between slots 14 that are six slots apart is referred to as a six-slot interval.

  On the other end side in the axial direction of the stator core 11, the projecting portions of the unit coil 21, the first joint line 30 and the second joint line 40 accommodated in the first layer in the slot 14 from the slot 14 are illustrated in FIG. 4 and 5, it is bent so as to incline to the left. The protruding part from the slot 14 of the unit coil 21 accommodated in the second layer in the slot 14 is bent so as to incline in the right direction in FIGS. 4 and 5. Although not shown, the protruding portion of the unit coil 21 housed in the third layer in the slot 14 from the slot 14 is bent so as to incline to the left in FIGS. 4 and 5. . Projecting portions of the unit coil 21 and the first joint line 30 housed in the fourth layer in the slot 14 from the slot 14 are bent so as to incline in the right direction in FIGS. 4 and 5.

  Here, on the other end side in the axial direction of the stator core 11, the other ends of the unit coil 21, the first joint line 30, and the second joint line housed in the first layer of the pair of slots 14 separated by 6 slots are provided. And the other end of the unit coil 21 accommodated in the second layer overlap in the radial direction. The other end of the unit coil 21 housed in the third layer of the pair of slots 14 separated by 6 slots, and the other end of the unit coil 21 and the first joint wire 30 housed in the fourth layer Are overlapping in the radial direction.

  Then, on one end side in the axial direction of the stator core 11, one end portions of the unit coils 21 housed in the first layer and the second layer of the pair of slots 14 separated by 6 slots are welded. On the other end side in the axial direction of the stator core 11, the other end portions of the unit coils 21 housed in the first layer and the second layer of the pair of slots 14 separated by 6 slots are welded. As a result, two one-turn coils are formed in which the unit coils 21 housed in the first and second layers of the group of slots 14 arranged at intervals of 6 slots are connected in series. Yes. Note that the joining method is not limited to welding, and brazing, caulking, or the like may be used.

  Then, on the other axial end side of the stator core 11, the other end portions of the first joint wires 30 housed in the first layer of the pair of slots 14 separated by 6 slots are separated by 6 slots, respectively. The unit coil 21 accommodated in the second layer of the slot 14 is welded to the other end. As a result, two one-turn coils in which the unit coils 21 housed in the first layer and the second layer of the group of slots 14 arranged at intervals of 6 slots are connected in series are connected to the first joint line. 30 are connected in series to form a two-turn coil.

  Then, on one end side in the axial direction of the stator core 11, one end portions of the unit coils 21 housed in the third layer and the fourth layer of the pair of slots 14 separated by 6 slots are welded. On the other end side in the axial direction of the stator core 11, the other end portions of the unit coils 21 housed in the third layer and the fourth layer of the pair of slots 14 separated by 6 slots are welded. As a result, two one-turn coils are formed in which the unit coils 21 housed in the third and fourth layers of the group of slots 14 arranged at intervals of 6 slots are connected in series. Yes.

  Then, at the other axial end of the stator core 11, the other ends of the first joint wires 30 housed in the fourth layer of the pair of slots 14 separated by 6 slots are separated by 6 slots, respectively. The unit coil 21 housed in the third layer of the slot 14 is welded to the other end. As a result, two one-turn coils in which the unit coils 21 housed in the third layer and the fourth layer of the group of slots 14 arranged at intervals of 6 slots are connected in series are connected to the first joint line. 30 are connected in series to form a two-turn coil.

  In each of the groups of slots 14 arranged at intervals of 6 slots, one 2-turn coil configured by connecting unit coils 21 housed in the first layer and the second layer in series. And two one-turn coils configured by connecting the unit coils 21 housed in the third layer and the fourth layer in series are connected in series, respectively, and one four-turn coil is connected. A phase coil is configured. Thus, six four-turn phase coils are formed as a whole. Although not described, the connection between the two-turn coils can also be performed using the first joint wire 30.

  Further, on the other end side in the axial direction of the stator core 11, the other end portions of the second joint wires 40 housed in the first layer of the three slots 14 that are separated from each other by two slots are separated by a distance of 6 slots. The other end of the unit coil 21 housed in the second layer of the slot 14 is welded. As a result, three phase coils are star-connected to form a stator winding 20 composed of two sets of three-phase AC windings. The protruding portion of the unit coil 21 that protrudes from the slot 14 of the stator core 11 toward one end in the axial direction constitutes a coil end at one end in the axial direction of the stator winding 20. The projecting portions of the unit coil 21, the first joint wire 30, and the second joint wire 40 that protrude from the slot 14 of the stator core 11 toward the other axial end are coil ends on the other axial end side of the stator winding 20. Configure. The unit coil 21 includes a straight portion 21a housed in the slot 14, an inclined portion 21b that protrudes from the slot 14 and is inclined in the circumferential direction, and a joining tip portion 21c provided at the tip of the inclined portion 21b. .

  Next, a method for manufacturing the stator will be described. 6A is a main part development view showing a dummy core on which a unit coil is mounted in the method for manufacturing a stator of a rotating electrical machine according to Embodiment 1 of the present invention, and FIG. 6B is a rotation according to Embodiment 1 of the present invention. FIG. 6C is a main part development view showing a state where the twist jig is attached to the unit coil attached to the dummy core in the method for manufacturing the stator of the electric machine, and FIG. 6C shows the manufacture of the stator of the rotating electric machine according to Embodiment 1 of the present invention. FIG. 6D is a main part development view showing a state in which the unit coil mounted on the dummy core in the method is bent by a twist jig, and FIG. 6D is mounted on the dummy core in the method for manufacturing the stator of the rotating electric machine according to the first embodiment of the present invention. FIG. 6E is a main part development view showing a state in which the tip portions of the unit coils are joined together, and FIG. 6E is a diagram showing joined unit coils in the method of manufacturing a stator for a rotary electric machine according to Embodiment 1 of the present invention. FIG. 6F is a main part development view showing a state in which the first joint wire is attached to the group, and FIG. 6F shows the second joint connected to the unit coil group joined in the manufacturing method of the stator of the rotating electric machine according to the first embodiment of the present invention. FIG. 6G is a main part development view showing a state in which the wire is attached, and FIG. 6G shows a process of attaching the unit coil group joined to the stator core in the method for manufacturing a stator of a rotating electric machine according to Embodiment 1 of the present invention. FIG. 6H is a main part development view showing a state where the unit coil groups joined in the stator manufacturing method according to Embodiment 1 of the present invention are attached to the stator core. 7 is a front view showing a first joint line in the method for manufacturing a stator for a rotating electrical machine according to Embodiment 1 of the present invention, and FIG. 8 is a diagram for manufacturing the stator for a rotating electrical machine according to Embodiment 1 of the present invention. The second joint line in the method To a front view, FIG. FIGS. 9A-9C are views for explaining a method of assembling a second joint line in the manufacturing method of a stator of a rotary electric machine according to Embodiment 1 of the present invention. 6A to 6H show only the unit coil, the first joint line, and the second joint line that are attached to the first layer.

  Here, the dummy core 50 is configured by forming dummy slots 52 extending in the radial direction on an annular base 51 at an equiangular pitch in the circumferential direction. The dummy slots 52 have the same circumferential width as the slots 14 and are formed in the same number as the slots 14 of the stator core 11. The dummy slot 52 has openings on both sides in the radial direction and one side in the axial direction. In addition, the dummy core 50 may be made of a lump of iron or the like, or may be configured by assembling a plurality of divided dummy cores made of lump of iron or the like into an annular shape.

  The twist jig 55 has an insertion hole 57 into which the tip of the unit coil 21 is inserted on one surface of the ring-shaped base 56 in the axial direction on the same circumference at a one-slot pitch in the circumferential direction. The same number as the number is formed. The twist jig 55 corresponds to each of the group of unit coils 21 of the first layer, the group of unit coils 21 of the second layer, the group of unit coils 21 of the third layer, and the group of unit coils 21 of the fourth layer. It is comprised by four types of jig | tool which has a diameter to do.

  First, a linear unit coil 21 is manufactured by cutting a conductor wire having a rectangular cross section such as copper or aluminum coated with an insulating coating into a set length. Next, the insulating coating on both ends of the unit coil 21 is removed. Next, as shown in FIG. 6A, four unit coils 21 are inserted into each dummy slot 52 of the dummy core 50 in a row in a radial direction. At this time, the unit coil 21 is not inserted in the storage position of the first joint line 30 and the second joint line 40.

  Next, as shown in FIG. 6B, the twist jig 55 is attached to the unit coil 21 attached to the dummy core 50 from one end side in the axial direction. Specifically, the four types of twist jigs 55 are arranged coaxially and concentrically with the dummy core 50. And the front-end | tip part of the unit coil 21 of a 1st layer is inserted in each of the insertion hole 57 of the twist jig | tool 55 located in the innermost periphery. The tip of the second layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located second from the inner diameter side. The tip of the third layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located third from the inner diameter side. The tip of the unit coil 21 of the fourth layer is inserted into each of the insertion holes 57 of the twist jig 55 located on the outermost periphery.

  Next, the twist jig 55 located on the innermost circumference is rotated to one side in the circumferential direction while being brought close to the dummy core 50 (first twist process). Thereby, the protrusion part from the dummy slot 52 of the unit coil 21 inclines to the circumferential direction one side, as FIG. 5C shows. The inclined portion of the unit coil 21 becomes the inclined portion 21b. Next, the twist jig 55 positioned second from the inner diameter side is rotated toward the other side in the circumferential direction while being brought close to the dummy core 50 (first twist process). Next, the twist jig 55 positioned third from the inner diameter side is rotated to one side in the circumferential direction while being brought close to the dummy core 50 (first twist process). Further, the twist jig 55 located on the outermost periphery is rotated to the other side in the circumferential direction while being brought close to the dummy core 50 (first twist process). Thereby, the inclined part 21b of the unit coil 21 of the first layer and the third layer is inclined in the opposite direction to the inclined part 21b of the unit coil 21 of the second layer and the fourth layer.

  Next, the twist jig 55 is removed. As a result, the tip end portion 21c of the first layer unit coil 21 of one dummy slot 52 overlaps the tip end portion 21c of the second layer unit coil 21 of the dummy slot 52 that is spaced 6 slots away radially inward. . Further, the tip 21c of the third layer unit coil 21 of one dummy slot 52 overlaps the tip end 21c of the fourth layer unit coil 21 of the dummy slot 52, which is spaced 6 slots apart, radially inward. Therefore, as shown in FIG. 6D, the tip portions 21c of the unit coils 21 of the first layer and the second layer that overlap in the radial direction are welded (first joining step). Thereby, the unit coils 21 of the first layer and the second layer of each group of the dummy slots 52 arranged at intervals of 6 slots are connected by the joint portion 19. Furthermore, the tip portions 21c of the unit coils 21 of the third layer and the fourth layer that overlap in the radial direction are welded together (first joining step). As a result, the unit coils 21 of the third layer and the fourth layer of each group of the dummy slots 52 arranged at intervals of 6 slots are connected by the joint portion 19.

  Next, as shown in FIG. 6E, the first joint line 30 is inserted into the empty space in the first layer of the dummy slot 52 from the inner diameter side (joint line mounting step). Further, although not shown, the first joint wire 30 is inserted into the empty space of the fourth layer of the dummy slot 52 from the outer diameter side (joint wire mounting step).

  The first joint wire 30 is produced by bending a linear conductor wire produced by cutting a conductor wire having a rectangular cross section such as copper or aluminum coated with an insulating coating into a set length. As shown in FIG. 7, the first joint line 30 has a pair of parallel straight portions 30a, a U-shaped joint portion 30c, a pair of joint portions 30c, and a pair of straight portions 30a. It is comprised by the substantially U shape which consists of the parallel inclination part 30b. The insulating coating at the tip of the pair of straight portions 30a is removed. The pair of straight portions 30a are separated by 6 slots. As shown in FIG. 6E, the first joint line 30 is inserted into each of the two dummy slots 52 that are separated from each other by a distance of 6 slots between the pair of linear portions 30a. The pair of inclined portions 30 b are parallel to the inclined portion 21 b of the unit coil 21. Further, the joint portion 30 c extends in the circumferential direction, close to the joint portion 19, on the radially outer side of the joint portion 19 of the five unit coils 21 positioned between the pair of linear portions 30 a.

  Next, as shown in FIG. 6F, the second joint line 40 is inserted into the empty space in the first layer of the dummy slot 52 from the inner diameter side (joint line mounting step).

  Here, the 2nd joint line 40 is comprised by the three conductor wires 41, 42, and 43, as FIG. 8 shows. The three conductor wires 41, 42, 43 are formed by bending a linear conductor wire produced by cutting a conductor wire having a rectangular cross section such as copper or aluminum coated with an insulating film into a set length. Produced. As shown in FIGS. 9A and 9B, the conductor wires 41, 42, and 43 are such that one end of the straight portions 41a, 42a, and 43a and the other end of the L-shaped split joint portions 41c, 42c, and 43c are inclined portions 41b. , 42b, 43b, and is configured in a substantially L shape. The insulating coatings on both ends of the conductor wires 41, 42, 43 are removed. The lengths of the split joint portions 41c, 42c, and 43c are longer in the order of the split joint portion 43c, the split joint portion 42c, and the split joint portion 41c. The split joint portion 41c is displaced by 2d in the width direction of the conductor wire 41 with respect to the inclined portion 41b. The split joint portion 42c is displaced by d in the width direction of the conductor wire 42 with respect to the inclined portion 42b. Here, d is the width of the conductor lines 41, 42, 43. As shown in FIG. 9C, the three conductor wires 41, 42, and 43 are overlapped so that the split joint portions 41c, 42c, and 43c are in contact with the width direction of the conductor wires 41, 42, and 43, and the split joint portion 41c. , 42c, 43c are welded together at one end to be integrated. Here, the integrated divided joint portions 41c, 42c, and 43c are referred to as a joint portion 40c. Insulation is applied to the joint portion 18c of the joint portion 40c and the region where the insulating coating around it is removed. Examples of the insulation treatment include a method of applying an insulating paint, winding an insulating tape, and attaching an insulating tube. Thereby, the 2nd joint line 40 shown by FIG. 8 is produced. The joint 18 is covered with an insulating member 17.

  As shown in FIG. 6F, the second joint line 40 is inserted into each of the three dummy slots 52 that are spaced apart from each other by two slot intervals from the straight portions 41a, 42a, and 43a. The inclined portions 41b, 42b, 43b are parallel to the inclined portion 21b of the unit coil 21. Further, the joint portion 40c is a radial direction of the joint portion 19 of one unit coil 21 located between the straight portions 41a and 42a and the joint portion 19 of one unit coil 21 located between the straight portions 42a and 43a. The outer side extends in the circumferential direction in the vicinity of the joint 19. Here, the two second joint lines 40 are attached to the dummy core 50.

  Next, the assembly of the unit coil 21, the first joint line 30 and the second joint line 40 is pulled out from the dummy core 50 in the axial direction. Next, an insulator 16 is attached to each slot 14 of the stator core 11. Next, as shown in FIG. 6G, the assembly of the unit coil 21, the first joint wire 30 and the second joint wire 40 is attached to the stator core 11 from the outside in the axial direction. Four straight portions of the unit coil 21, the first joint line 30 and the second joint line 40 are inserted into each slot 14 in a row in a radial direction. 6H, the assembly of the unit coil 21, the first joint wire 30 and the second joint wire 40 is attached to the stator core 11 (the unit coil 21, the first joint wire 30 and the first joint wire 30). Step of mounting assembly of two joint lines 40). At this time, the straight portions of the unit coil 21, the first joint wire 30, and the second joint wire 40 protrude to the other axial end side of the stator core 11.

  Next, twist processing is performed on the straight portions of the unit coil 21, the first joint wire 30, and the second joint wire 40 protruding from the stator core 11 to the other axial end side by the twist jig 55 (second twist). Process). Note that the second twist process by the twist jig 55 is performed in the same manner as the first twist process shown in FIGS. 6B and 6C.

  That is, four types of twist jigs 55 are arranged on the other axial end side of the stator core 11, coaxially and concentrically with the stator core 11. And the front-end | tip part of the unit coil 21, the 1st joint line 30, and the 2nd joint line 40 of a 1st layer is inserted in each of the insertion hole 57 of the twist jig | tool 55 located in the innermost periphery. The tip of the second layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located second from the inner diameter side. The tip of the third layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located third from the inner diameter side. The fourth layer unit coil 21 and the first joint wire 30 are inserted into the insertion holes 57 of the twist jig 55 located on the outermost periphery.

  Next, the twist jig 55 located on the innermost circumference is rotated to one side in the circumferential direction while being brought close to the stator core 11. Thereby, the protrusion part from the slot 14 of the unit coil 21, the 1st joint line 30, and the 2nd joint line 40 inclines to the circumferential direction one side. Next, the twist jig 55 positioned second from the inner diameter side is rotated to the other side in the circumferential direction while being brought close to the stator core 11. Next, the twist jig 55 positioned third from the inner diameter side is rotated toward one side in the circumferential direction while being brought close to the stator core 11. Further, the twist jig 55 located on the outermost periphery is rotated to the other side in the circumferential direction while being brought close to the stator core 11. Thereby, the unit coil 21 of the first layer, the inclined part of the first joint line 30 and the second joint line 40, and the inclined part 21b of the unit coil 21 of the third layer are replaced with the inclined part of the unit coil 21 of the second layer and The unit coil 21 of the fourth layer and the inclined portion 21b of the first joint line 30 are inclined in the opposite direction.

  Next, the twist jig 55 is removed. As a result, the tip portions of the first layer unit coil 21, the first joint wire 30 and the second joint wire 40 of one slot 14 are aligned with the tip portions of the second layer unit coil 21 of the slot 14 which are separated by six slots. It overlaps radially inside. The tip of the third layer unit coil 21 in one slot 14 is radially inward with respect to the fourth layer unit coil 21 of the slot 14 and the tip of the first joint wire 30 that are separated by 6 slots. Overlap. Therefore, the first and second layer unit coils 21, the first joint wire 30, and the tip ends of the second joint wires 40 that overlap in the radial direction are welded together (second joining step). Furthermore, the unit coils 21 of the third layer and the fourth layer that overlap in the radial direction and the tips of the first joint wires 30 are welded together (second joining step).

  Here, the unit coil 21 and the first joint wire 30 each produce six-phase coils of four turns. Further, the second joint wire 40 produces a stator winding 20 composed of two sets of three-phase windings in which three phase coils are star-connected.

  According to the first embodiment, first, the unit coil 21, the first joint line 30 and the second joint line 40 are produced. Next, after the unit coil 21 is inserted into the dummy slot 52 of the dummy core 50, the protruding portion of the unit coil 21 from the dummy slot 52 is twisted in the circumferential direction. Next, after joining the end portions of the unit coil 21 twisted in the circumferential direction, the first joint wire 30 is positioned so that the joint portion 30 c is located radially outward of the joint portion 19 between the end portions of the unit coil 21. Is mounted on the dummy core 50 from the radial direction. Further, the second joint wire 40 is attached to the dummy core 50 from the radial direction so that the joint portion 40 c is positioned radially outward of the joint portion 19 between the end portions of the unit coil 21. Next, the assembly of the unit coil 21, the first joint wire 30, and the second joint wire 40 is pulled out from the dummy core 50 toward one end in the axial direction, and attached to the stator core 11 from one end in the axial direction. Next, the projecting portions of the unit coil 21, the first joint wire 30, and the second joint wire 40 that project from the slot 14 of the stator core 11 toward the other end in the axial direction are twisted in the circumferential direction. Next, the end portions of the unit coil 21, the first joint line 30 and the second joint line 40 twisted in the circumferential direction are joined together to manufacture the stator 10.

Thereby, joining operations such as welding and brazing on the coil end on one axial end side are omitted. Therefore, there is no occurrence of damage to the insulating film of the conductor wire constituting the coil end by heating. The installation space for the holding portion that holds the ends for neutral point connection, which was necessary at the time of joining, becomes unnecessary. Further, since the joint portions 30c and 40c are covered with insulation, it is not necessary to separate the joint portion from the joint portion between the end portions of the unit coils. As a result, the joint portions 30c and 40c can be disposed close to the coil end, so that the stator 10 with a reduced size can be manufactured.
Further, since the stator winding 20 using the linear unit coil 21 is manufactured, an electromagnetic design with a high degree of freedom is possible.

Embodiment 2. FIG.
10 is a perspective view of a main part showing a state in which a unit coil is mounted on a dummy core in a method for manufacturing a stator of a rotary electric machine according to Embodiment 2 of the present invention, and FIG. 11 relates to Embodiment 2 of the present invention. FIG. 12A is a perspective view of a principal part showing a state in which the spacer jig in the method for manufacturing a stator of a rotating electrical machine is mounted on a dummy core, and FIG. 12A is mounted on the dummy core in the method for manufacturing a stator of a rotating electrical machine according to Embodiment 2 of the present invention. FIG. 12B is a main part development view showing a state where the twist jig is attached to the unit coil, and FIG. 12B shows the unit coil attached to the dummy core in the method of manufacturing the stator of the rotating electric machine according to Embodiment 2 of the present invention. It is a principal part expanded view which shows the state bent with the jig | tool.

  In the second embodiment, except that the unit coil 21 is twisted by the twist jig 55 in a state where the spacer jig 60 is inserted into the empty space of the projecting portion of the unit coil 21 from the dummy core 50, the above-described embodiment is performed. The configuration is the same as in the first mode.

  In the second embodiment, as shown in FIG. 10, four unit coils 21 are inserted into each dummy slot 52 of the dummy core 50 in a row in a radial direction. At this time, the unit coil 21 is not inserted in the storage position of the first joint line 30 and the second joint line 40.

  Next, as shown in FIG. 11, the spacer jig 60 is inserted from the inner diameter side into the empty space of the protruding portion from the dummy core 50 of the unit coil 21 arranged in the first layer. The spacer jig 60 includes a plate-like spacer 60a inserted between the unit coils 21 and a shaft portion 60b. The spacer 60 a has a width equivalent to the width of the unit coil 21. The inclination angle of the unit coil 21 is set so that the empty space between the inclined portions 21 b of the unit coil 21 is not less than the width of the unit coil 21. The spacer jig 60 is installed so that the shaft center of the shaft portion 60b coincides with the radial direction in a state where the spacer 60a is inserted between the unit coils 21. The spacer jig 60 is held so that the shaft portion 60b can rotate around its axis.

  A spacer 60a of the spacer jig 60 is inserted from the outer diameter side into the space between the unit coils 21 arranged in the fourth layer. The spacer jig 60 is installed such that the shaft center of the shaft portion 60b coincides with the radial direction in a state where the spacer 60a is inserted between the unit coils 21. The spacer jig 60 is supported so that the shaft portion 60b can rotate around its axis. 11 shows a state in which the spacer 60a is inserted at the insertion position of the first joint line 30, but the spacer 60a is also inserted at the insertion position of the second joint line 40.

  Next, the twist jig 55 is attached to the unit coil 21 attached to the dummy core 50 from one end side in the axial direction, as shown in FIG. 12A. Specifically, the four types of twist jigs 55 are arranged coaxially and concentrically with the dummy core 50. And the front-end | tip part of the unit coil 21 of a 1st layer is inserted in each of the insertion hole 57 of the twist jig | tool 55 located in the innermost periphery. The tip of the second layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located second from the inner diameter side. The tip of the third layer unit coil 21 is inserted into each of the insertion holes 57 of the twist jig 55 located third from the inner diameter side. The tip of the unit coil 21 of the fourth layer is inserted into each of the insertion holes 57 of the twist jig 55 located on the outermost periphery.

  Next, the twist jig 55 located on the innermost circumference is rotated toward one side in the circumferential direction while being brought close to the dummy core 50. Thereby, the protrusion part from the dummy slot 52 of the unit coil 21 inclines to the circumferential direction one side, as FIG. 12B shows. At this time, the spacer jig 60 rotates around the axis of the shaft portion 60b, and the spacer 60a is inclined in conjunction with the bending of the protruding portion from the dummy slot 52 of the unit coil 21. Next, the twist jig 55 positioned second from the inner diameter side is rotated to the other side in the circumferential direction while being brought close to the dummy core 50. Next, the twist jig 55 positioned third from the inner diameter side is rotated to one side in the circumferential direction while being brought close to the dummy core 50. Further, the twist jig 55 located at the outermost periphery is rotated to the other side in the circumferential direction while being brought close to the dummy core 50. At this time, the spacer jig 60 mounted in the empty space between the unit coils 21 in the fourth layer rotates around the axis of the shaft portion 60b, and the spacer 60a bends the protruding portion from the dummy slot 52 of the unit coil 21. Tilt in conjunction with. Thereby, the inclined part 21b of the unit coil 21 of the first layer and the third layer is inclined in the opposite direction to the inclined part 21b of the unit coil 21 of the second layer and the fourth layer.

  Next, the twist jig 55 is removed, the tip portions 21c of the first layer and the second layer unit coils 21 overlapping in the radial direction are welded together, and the tip ends of the unit coils 21 of the third layer and the fourth layer overlapping in the radial direction. The parts 21c are welded together. Next, the spacer jig 60 is removed. Thereby, an empty space is formed between the inclined portions 21b of the unit coils 21 adjacent in the circumferential direction. The first joint line 30 and the second joint line 40 are attached using an empty space. Other steps are the same as those in the first embodiment.

  According to the second embodiment, twist processing is performed on the terminal portion of the unit coil 21 in a state where the spacer 60 a is inserted into the empty space between the protruding portions of the unit coil 21 from the dummy core 50. Therefore, even if the inclination angle is increased, a gap between the inclined portions 21b of the unit coil 21 sandwiching the spacer 60a is secured. That is, a gap for inserting the first joint wire 30 and the second joint wire 40 is secured between the inclined portions 21b of the unit coil 21. Thereby, the inclination part 21b of the unit coil 21 can be enlarged as much as possible, and the height of the coil end of the stator winding 20 including the first joint wire 30 and the second joint wire 40 can be reduced. Furthermore, the occurrence of poor mounting of the first joint line 30 and the second joint line 40 is suppressed.

  The spacer jig 60 is arranged such that the spacer 60a is inserted into the empty space between the protruding portions of the unit coil 21 from the dummy core 50, and the shaft center of the shaft portion 60b is in the radial direction. The spacer jig 60 is supported so as to be rotatable around the axis of the shaft portion 60b. Thereby, at the time of twist processing of the terminal portion of the unit coil 21, the spacer jig 60 rotates around the axis of the shaft portion 60b, and the spacer 60a is interlocked with the bending of the protruding portion from the dummy slot 52 of the unit coil 21. Tilt. As a result, the twist processing of the terminal portion of the unit coil 21 is performed smoothly, and the workability of the twist processing is improved.

In each of the above embodiments, four straight portions such as unit coils are arranged in one line in the slot, but the number of straight portions arranged in one row in the slot is limited to four. not,
What is necessary is just two or more.
In each of the above embodiments, each phase coil is configured by connecting four coils of one turn in series, but each phase coil is connected by connecting two coils of one turn in series. The two turn coils may be connected in parallel.

In each of the above embodiments, the phase coil is star-connected, but the phase coil may be delta-connected.
Further, in each of the above embodiments, the unit coil, the first joint line, and the second joint line are configured by a conductor wire having a rectangular cross section, but the cross sectional shape of the conductor wire is not limited to a rectangle, and may be, for example, a circle. .
Moreover, in each said embodiment, although the number of slots is formed in the ratio of 2 per phase for every pole, the number of slots per phase for every pole is not limited to 2, For example, 1 may be sufficient.
In the first embodiment, the stator winding is configured as a three-phase winding. However, the number of phases of the stator winding is not limited to three, and may be five or seven.

  11 Stator core, 14 slots, 19 joints, 20 stator windings, 21 unit coils, 30 1st joint wire, 40 2nd joint wire, 40c joint portion, 41a, 42a, 43a straight portion, 50 dummy core, 52 Dummy slot, 55 twist jig, 60a spacer.

Claims (5)

An annular stator core in which a plurality of slots are arranged at a constant pitch in the circumferential direction, and a stator winding attached to the stator core,
The stator winding includes a plurality of linear unit coils inserted into each of the plurality of slots, and joint wires inserted into two or more slots among the plurality of slots,
The joint line includes two or more straight portions inserted into the two or more slots, and a joint portion that connects one end portions in the axial direction of the two or more straight portions,
On one end side in the axial direction of the stator core, one end portions in the axial direction of the plurality of unit coils are joined together, and the joint portion is one end in the axial direction of the unit coil located between the two or more linear portions. Arranged on the outer side in the axial direction of the joint part,
On the other end side in the axial direction of the stator core, the other end portions in the axial direction of the plurality of unit coils, and the other end portion in the axial direction of the plurality of unit coils and the other end in the axial direction of the joint line. In the manufacturing method of the stator of the rotating electrical machine in which the part is joined,
The unit coils are arranged in a row in the radial direction so as to avoid the insertion positions of the two or more straight portions in each of the plurality of dummy slots arranged in the same number as the plurality of slots at the constant pitch in the circumferential direction of the dummy core. A plurality of side-by-side mounting steps;
A first twisting step of twisting the protruding portions of the plurality of unit coils protruding in the axial direction from the dummy slot in the circumferential direction;
A first joining step for joining axial ends of the plurality of unit coils twisted in the circumferential direction;
The two or more straight portions are inserted in the insertion positions of the plurality of dummy slots from the radial direction so that the joint portion is located on the outer side in the axial direction of the joint portion at one end portion in the axial direction of the unit coil. Attaching the joint line to the dummy core;
A step of drawing the plurality of unit coils and the joint wire from the dummy core to one end in the axial direction, and mounting the plurality of unit coils and the plurality of slots in the stator core from the one end in the axial direction;
A second twist step of twisting the plurality of unit coils projecting from the plurality of slots toward the other end in the axial direction and the projecting portion of the joint wire in the circumferential direction;
A second joining step for joining the plurality of unit coils twisted in the circumferential direction and the other axial ends of the joint lines;
A method of manufacturing a stator of a rotating electric machine comprising: In the first twisting step, circumferential twisting is performed for each group of axial projecting portions of the unit coils inserted at the same radial position in the plurality of dummy slots at once and in the radial arrangement order. Twist in the circumferential direction by alternately changing the direction,
In the second twist step, the twisting direction in the circumferential direction is collectively and in the radial arrangement order for each group of unit coil and joint wire protrusions inserted at the same radial position in the plurality of slots. The method for manufacturing a stator of a rotating electric machine according to claim 1, wherein the two are alternately twisted in the circumferential direction. Prior to the first twisting step, inserting a spacer between the protruding portions of the unit coils located on both sides in the circumferential direction of the insertion positions of the two or more linear portions;
The manufacturing method of the stator of the rotary electric machine of Claim 1 or Claim 2 further equipped with the process of removing the said spacer after the said 1st twist process.   The method for manufacturing a stator of a rotating electrical machine according to claim 3, wherein the spacer inserted between the projecting portions of the unit coils is rotatably held around an axis whose radial direction is the axial direction.   Prior to the step of attaching the dummy core to the joint core, the two or more conductor wires including the two or more straight portions and the split joint portions extending from the two or more straight portions are connected to the split joint portions. The stator of the rotating electrical machine according to any one of claims 1 to 4, wherein the end portions are joined to each other, and an insulation treatment is applied to a joint portion between the end portions of the split joint portion. Production method.

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