JP2019221114A - Manufacturing method of armature - Google Patents

Abstract

To provide a manufacturing method of an armature capable of preventing such a situation that multiple segment conductors are difficult to be placed on the armature core, in the armature where legs of the multiple segment conductors are joined.SOLUTION: In a manufacturing method of a stator 100, a first leg 110, a second leg 120, and a third leg 130 placed adjacently to the first leg 110 on one side in the radial direction are placed so that a position of the second leg 120 at an other side tip 71 becomes a position Pa3 in the radial direction deviated to the other side in the radial direction for a joint position Pa1 of the first leg 110 in the radial direction, and while moving relatively so that the first leg 110 and the third leg 130, and the second leg 120 approach relatively in the axial direction, the other side tip 71 is moved and guided to the joint position Pa1 in the radial direction, by an other side inclination face 72 provided in the second leg 120, thus joining the first and second legs 110, 120.SELECTED DRAWING: Figure 17

Description

  The present invention relates to a method for manufacturing an armature.

  BACKGROUND ART Conventionally, a method of manufacturing an armature including an armature core provided with a plurality of slots extending in a central axis direction is known (for example, see Patent Document 1).

  Patent Document 1 discloses a method of manufacturing a rotating electrical machine stator (hereinafter, referred to as “stator”) including a stator core provided with a plurality of slots extending in an axial direction. In this manufacturing method, the legs of the one-side conductor segment and the legs of the other-side conductor segment that are axially opposed to each other are inserted into the slot in the axial direction and joined to each other. In this case, the leg portion of the one-side conductor segment is disposed between the ends of the leg portions of the leg portion of the other-side conductor segment disposed on both sides in the radial direction of the other-side conductor segment axially facing the one-side conductor segment. One conductor segment is inserted into the slot such that the tip of the conductor passes in the axial direction.

Japanese Patent No. 5962607

  However, in the stator described in Patent Literature 1, for example, in the process of inserting the leg portion of the other-side conductor segment into the slot, the leg portion of the leg portion of the other-side conductor segment approaches each other in the radial direction. May be deformed (curved), or the distance between the tip portions may be relatively small due to a dimensional error of the other conductor segment. It is also conceivable that deformation (curvature) or dimensional error of the one-side conductor segment may occur. In these cases, when the leading end of the one-side conductor segment passes in the axial direction between the leading ends of the other-side conductor segments in the radial direction, the leading end of the one-side conductor segment becomes the leading end of the other-side conductor segment. Then, it is considered that there is a case where mechanical interference (jam) occurs. As a result, in the stator (armature) described in Patent Literature 1, the legs (the armatures) of the one-side conductor segment are caused by mechanical interference between the tip of the one-side conductor segment and the tip of the other-side conductor segment. There is a problem that it is difficult to dispose the second leg) and the leg (first leg) of the other conductor segment on the stator core (armature core).

  SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems, and one object of the present invention is to provide an armature in which legs of a plurality of segment conductors are joined to each other by using a plurality of segment conductors. An object of the present invention is to provide a method of manufacturing an armature that can prevent the armature from being difficult to be arranged.

  In order to achieve the above object, a method for manufacturing an armature according to one aspect of the present invention includes an armature core provided with a plurality of slots extending in an axial direction and overlapping with the slot when viewed in the axial direction. In the joining region which is a region, comprising a coil portion in which legs of a plurality of segment conductors arranged to face each other in the axial direction are joined, a method for manufacturing an armature, comprising: A first leg that is a leg, a second leg that is a leg that is joined at a joining position with the first leg in a joining region, and one of the first leg and the armature core in a radial direction. The third leg, which is a leg on one side in the axial direction, is disposed adjacent to the side, and the position of the distal end provided on one radial portion of the second leg is the third leg. Arrange so that it is shifted to the other side in the radial direction with respect to the joint position of one leg. After the step of performing and the step of disposing, the guide provided on the second leg is relatively moved so that the first leg, the third leg, and the second leg approach each other in the axial direction. The step of moving and guiding the tip of the second leg located at the position shifted to the other side in the radial direction to the joining position, and the step of moving and guiding the first leg and the second leg. And joining them.

  In the armature manufacturing method according to one aspect of the present invention, as described above, the position of the distal end provided on one radial side of the second leg is determined by the joining position of the first leg. The first leg, the second leg, and the third leg are arranged so as to be shifted to the other side in the radial direction with respect to the second leg and the radial direction of the second leg. The distance (spacing) in the radial direction with respect to the third leg portion disposed on one side of the second member can be made relatively large. For this reason, even when the second leg or the third leg is deformed or has a dimensional error, the second leg and the third leg are relatively large in the radial direction (interval), so that the second leg or the third leg is relatively large. When the two legs are moved to the joint region, the distal end provided on one radial side of the second leg and the distal end of the third leg mechanically interfere (be caught). Can be prevented. As a result, it is possible to prevent the plurality of segment conductors from being difficult to arrange on the armature core. Also, the guide portion provided on the second leg portion moves and guides the distal end portion of the second leg portion located at the position shifted to the other side in the radial direction to the joining position, so that the second leg portion is moved to the second position. It can be guided to an appropriate radial position for joining with one leg. As a result, it is possible to appropriately join the legs while preventing the plurality of segment conductors from being difficult to arrange on the armature core.

  According to the present invention, as described above, in the armature in which the leg portions of the plurality of segment conductors are joined, it is possible to prevent the plurality of segment conductors from being difficult to arrange on the armature core.

It is a top view showing composition of a stator (rotary electric machine) by one embodiment of the present invention. It is a perspective view showing composition of a stator by one embodiment of the present invention. 1 is an exploded perspective view of a stator according to an embodiment of the present invention. It is a top view showing the composition of the stator core by one embodiment of the present invention. FIG. 2 is a cross-sectional view illustrating a configuration of a segment conductor and slot insulating paper according to an embodiment of the present invention. It is a perspective view showing composition of the 2nd coil assembly by one embodiment of the present invention. FIG. 4 is a cross-sectional view of a position (a) where the insulating member of the segment conductor is not provided and a position (b) where the insulating member is provided according to the embodiment of the present invention. It is the figure (a) which looked at the general conductor by one embodiment of the present invention in the diameter direction, and the figure (b) which looked at in the peripheral direction. It is the figure which looked at the state where the segment conductor by one embodiment of the present invention was arranged in the slot in the direction of an axis. FIG. 2 is a diagram showing a part of a cross section taken along line 1000-1000 in FIG. 1. It is a figure for showing composition of one side slope and the other side slope by one embodiment of the present invention. 5 is a flowchart for explaining a stator manufacturing process according to an embodiment of the present invention. It is a figure for explaining the segment conductor preparation process by one embodiment of the present invention. FIG. 5 is a diagram for explaining a segment conductor arrangement step according to one embodiment of the present invention. It is a figure for explaining a bonding agent application process by one embodiment of the present invention. FIG. 4 is a diagram for explaining a process of arranging slot insulating paper in a slot according to an embodiment of the present invention. FIG. 5 is a view for explaining a step of arranging the first coil assembly in the slot according to the embodiment of the present invention. It is a figure for explaining movement of the 2nd leg in a movement guidance process by one embodiment of the present invention. It is a figure for explaining guidance by one side slope and the other side slope in a movement guidance process by one embodiment of the present invention. It is sectional drawing along the radial direction for demonstrating the process which presses a segment conductor with a pressing jig and wall part by one Embodiment of this invention. FIG. 7 is a diagram illustrating a configuration of a stator according to a first modification of the embodiment of the present invention. It is a figure showing the composition of the stator by the 2nd modification of one embodiment of the present invention. It is a figure showing the composition of the stator by the 3rd modification of one embodiment of the present invention.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[Strator structure]
The structure of the stator 100 according to the present embodiment will be described with reference to FIGS. As shown in FIG. 1, the stator 100 has an annular shape around a center axis C1. The stator 100 is an example of the “armature” in the claims.

  In the present specification, the “axial direction” means a direction (Z direction) along a central axis C1 of the stator 100 (a rotation axis of the rotor 101), as shown in FIG. The “circumferential direction” means the circumferential direction of the stator 100 (A direction). The “radial direction” means the radial direction (R direction) of the stator 100. The “radially inward” means a direction toward the center axis C1 along the radial direction (the direction of the arrow R1), and the “radially outward” means a direction away from the central axis C1 along the radial direction ( (Direction of arrow R2).

  The stator 100 forms a part of the rotary electric machine 102 together with the rotor 101. The rotating electric machine 102 is configured as, for example, a motor, a generator, or a motor / generator. The stator 100 is arranged radially outside the rotor 101, as shown in FIG. That is, in the present embodiment, the stator 100 forms a part of the inner rotor type rotating electric machine 102.

  As shown in FIGS. 2 and 3, the stator 100 includes a stator core 10, slot insulating paper 20, and a coil unit 30. The coil unit 30 includes a first coil assembly 30a and a second coil assembly 30b. Further, the coil section 30 includes a plurality of segment conductors 40. The stator core 10 is an example of the “armature core” in the claims.

(Structure of stator core)
The stator core 10 has a cylindrical shape with the central axis C1 (see FIG. 1) as the central axis. Stator core 10 is formed, for example, by stacking a plurality of electromagnetic steel sheets (for example, silicon steel sheets) in the axial direction. As shown in FIG. 4, the stator core 10 includes a back yoke 11 having an annular shape as viewed in the axial direction, and a plurality of slots 12 provided radially inside the back yoke 11 and extending in the axial direction. . The stator core 10 is provided with a plurality of teeth 13 on both sides of the slot 12 in the circumferential direction.

  The slot 12 is a portion (hole) surrounded by a wall portion 11a of the back yoke 11 provided radially outward of end surfaces 65 and 75 described later and a circumferential side surface 13a of the two teeth 13. The slot 12 is provided with an opening 12a that is provided radially inward of end surfaces 63 and 73 described later and that opens radially inward. The slots 12 are open on both sides in the axial direction. The teeth 13 are formed so as to protrude radially inward from the back yoke 11, and have protrusions 13 b that form the openings 12 a of the slots 12 at radially inner ends. Here, "inside the slot 12" means an area between the end face 10a and the end face 10b in the axial direction, and means an area (space) overlapping the slot 12 when viewed in the axial direction. is there. “Inside the slot 12” is an example of the “joining region” in the claims.

  The opening 12a has an opening width W1 in the circumferential direction. Here, the opening width W1 corresponds to the distance between the tips of the projections 13b of the teeth 13 (the distance along the circumferential direction of the stator core 10). The width W2 of the portion of the slot 12 where the coil portion 30 and the slot insulating paper 20 are arranged is larger than the opening width W1. That is, the slot 12 is configured as a semi-open type slot. Here, the width W2 corresponds to the distance between the circumferential side surfaces 13a of the teeth 13 arranged on both sides in the circumferential direction of the slot 12. The width W2 of the slot 12 is substantially constant in the radial direction.

(Structure of slot insulating paper)
The slot insulating paper 20 is disposed between the teeth 13 and the segment conductor 40 as shown in FIG. The slot insulating paper 20 includes a joint covering portion 21. For example, the joint covering portion 21 is formed such that a radially inner side of the joint 80 of the segment conductor 40 arranged closest to the opening 12a side of the slot 12 among the plurality of segment conductors 40 arranged in the radial direction. It is configured to cover.

  More specifically, the slot insulating paper 20 is made of, for example, a sheet-like insulating member such as aramid paper or a polymer film, and has a function of ensuring insulation between the segment conductor 40 (coil portion 30) and the stator core 10. . The slot insulating paper 20 is formed between the segment conductor 40 and the circumferential side surface 13a of the tooth 13 and between the segment conductor 40 and the wall portion 11a which are arranged at the outermost radial direction of the plurality of segment conductors 40. It is located between them. The slot insulating paper 20 is disposed so as to integrally cover the periphery of the plurality of segment conductors 40 arranged in the radial direction when viewed in the direction of arrow Z2. The slot insulating paper 20 can ensure insulation between the plurality of segment conductors 40 and the stator core 10. Further, as shown in FIG. 2, the slot insulating paper 20 includes a collar portion 22 (cuff portion) that protrudes axially outward on both sides in the axial direction from the slot 12 and that is formed by folding back.

(Structure of coil part)
As shown in FIG. 2, the coil section 30 has a long leg 51 a and a short leg 51 b joined to each other in the plurality of segment conductors 40 arranged in the slot 12 so as to face each other in the axial direction. Specifically, the coil section 30 is configured such that a first coil assembly 30a provided on the arrow Z2 direction side and a second coil assembly 30b provided on the arrow Z1 direction side are It is formed by being joined inside. As shown in FIG. 3, the first coil assembly 30a and the second coil assembly 30b are each formed in an annular shape around the same central axis C1 (see FIG. 1) as the stator core 10.

  The coil unit 30 is configured as, for example, a wave-wound coil. The coil unit 30 is configured as an 8-turn coil. That is, as shown in FIG. 5, the coil unit 30 is configured such that eight segment conductors 40 are arranged in the slot 12 in the radial direction (in parallel). The coil unit 30 is configured to generate magnetic flux while supplying current in the axial direction and current in the circumferential direction by supplying three-phase AC power from a power supply unit (not shown). Have been. For example, the coil units 30 are connected (connected) by three-phase Y connection.

  Here, in the same slot 12, for example, only the segment conductors 40 of the same phase among the plurality of segment conductors 40 are arranged. That is, in the same slot 12, the segment conductor 40 of any one phase of the U phase, the V phase, or the W phase is arranged. This makes it possible to prevent the thickness t1 of the insulating coating 40a of the segment conductor 40 in the radial direction and the thickness t2 (see FIG. 7) of the insulating member 90 from increasing.

(Structure of coil assembly)
As shown in FIG. 6, the second coil assembly 30b includes a plurality of (for example, three) power line connection segment conductors 41 (hereinafter, referred to as “power conductors 41”) as the segment conductors 40 and the segment conductors 40. (For example, two) segment conductors 42 for connection to neutral point (hereinafter referred to as “neutral point conductor 42”), and power conductor 41 and neutral point conductor 42 of plural segment conductors 40. And a plurality of general conductors 43 constituting the coil unit 30. Further, the first coil assembly 30a (see FIG. 3) (the coil on the non-lead side) includes a plurality of general conductors 43. Preferably, the first coil assembly 30a is composed of only a plurality of general conductors 43, and all of the power conductor 41 and the neutral conductor 42 provided on the stator 100 are connected to the second coil assembly 30b (lead-side coil). It is provided in.

(Structure of segment conductor)
As shown in FIG. 7A, the segment conductor 40 is configured as a rectangular conducting wire having a substantially rectangular cross section. Specifically, the segment conductor 40 is provided with an insulating coating 40a (a coating agent such as polyimide) having a thickness t1 on a conductor surface 40c of a conductor main body 40b made of a conductive material (metal material such as copper or aluminum). It is formed.

  As shown in FIG. 8, the segment conductor 40 includes a pair of long leg portions 51 a and short leg portions 51 b disposed in the slots 12, and a coil end portion 52. The long leg portion 51a and the short leg portion 51b mean, for example, a portion (slot accommodating portion or linear portion) disposed axially inside the slot 12 from the axial position of the end face 10a or 10b of the stator core 10, The coil end portion 52 is formed continuously with the long leg portion 51a and the short leg portion 51b, and means a portion disposed outside the end face 10a or 10b of the stator core 10 in the axial direction. The long leg 51a and the short leg 51b are formed, for example, linearly along the axial direction. Further, the coil end portion 52 has a bent portion 52a having a bent shape bent in the axial direction, and has an offset portion radially offset in the bent portion 52a as shown in FIG.

  Here, in the present embodiment, the pair of long leg portions 51a and short leg portions 51b have different axial lengths. Specifically, the axial length L1 of the long leg 51a is larger than the axial length L2 of the short leg 51b. Note that the axial lengths L1 and L2 are the length of the long leg 51a and the length of the short leg 51b from the other end 71 to the axial position corresponding to the axial end face 10a of the stator core 10. means. The axial lengths L1 and L2 are smaller than the axial length L3 of the stator core 10. Note that the axial length L3 of the stator core 10 means a distance (interval) between the end faces 10a and 10b in the axial direction. For example, the axial length L1 is greater than half the axial length L3, and the axial length L2 is smaller than half the axial length L3. That is, the long leg portion 51a is disposed so as to exceed (straddle) the axial center of the slot 12. Note that the length L1 is an example of the “first length” in the claims. The length L2 is an example of the “second length” in the claims.

  The general conductor 43 has a substantially U shape or a substantially J shape when viewed from the radial inside. As shown in FIG. 9, the general conductor 43 connects the pair of long legs 51 a and short legs 51 b arranged in different slots 12 (joining regions) with the long legs 51 a and short legs 51 b. And a coil end portion 52. The long leg 51a and the short leg 51b of the power conductor 41 and the long leg 51a and the short leg 51b of the neutral conductor 42 are the same as the long leg 51a and the short leg 51b of the general conductor 43. Therefore, the description is omitted.

  For example, the long leg 51a of the first general conductor 43 in which the short leg 51b is disposed in the first (No. 1) slot 12 is the first leg provided on the arrow A1 direction side of the first slot 12. 2 (No. 2). The long leg 51a of the second general conductor 43 in which the short leg 51b is disposed in the second (No. 2) slot 12 is provided on the second slot 12 on the arrow A1 direction side. 3 (No. 3). In the second slot 12, the long legs 51a of the first general conductor 43 and the short legs 51b of the second general conductor 43 are alternately arranged in the radial direction.

  As shown in FIG. 6, the power conductor 41 is formed by electrically connecting (joining) the long leg 51a or the short leg 51b to the power terminal member. The power conductor 41 has a function of introducing power from the power supply unit (not shown) to the coil unit 30. For example, three power conductors 41 are provided, one for each phase. The neutral point conductor 42 is formed by electrically connecting (joining) the long leg portion 51a or the short leg portion 51b and the neutral point coil end portion 42a. For example, a plurality of (two in the example of FIG. 6) neutral conductors 42 are provided. The neutral point conductor 42 has a function of electrically connecting a neutral point side end of each phase.

  Here, as shown in FIG. 10, one of the plurality of segment conductors 40 that is arranged on one side in the axial direction (the side in the arrow Z2 direction) is referred to as a one-side segment conductor 60, and The segment conductor 40 arranged on the other side in the axial direction (the side in the direction of the arrow Z1) is defined as the other-side segment conductor 70. That is, the first coil assembly 30a is configured by the one-side segment conductor 60, and the second coil assembly 30b is configured by the other-side segment conductor 70. The one-side segment conductor 60 is an example of the “first segment conductor” in the claims. The other segment conductor 70 is an example of the “second segment conductor” in the claims.

<Configuration of First to Fifth Legs>
In the present embodiment, the segment conductor 40 is inclined with respect to a plane orthogonal to the axial direction (a plane parallel to the end face 10a or 10b) and faces outward in the radial direction, and functions as a guide when the stator 100 is manufactured. It includes a one-sided segment conductor 60 having a one-sided inclined surface 62 and an end surface 63 that is a surface on the opposite side of the one-sided inclined surface 62 in the radial direction and is a surface along the axial direction. Further, the segment conductor 40 is inclined with respect to a plane orthogonal to the axial direction, faces inward in the radial direction, and has the other inclined surface 72 functioning as a guide portion at the time of manufacturing the stator 100 and the other inclined surface 72. The other segment conductor 70 has an end surface 75 which is a surface opposite to the direction and is a surface along the axial direction. That is, the segment conductor 40 is formed in a shape capable of receiving a load when pressed in the radial direction.

  Here, in the present embodiment, one of the short legs 51 b constituting the one-side segment conductor 60 is defined as the first leg 110. In the slot 12, the long leg 51 a of the other-side segment conductor 70 joined to the first leg 110 in the state where it is arranged at the radial joining position Pa 1 and the axial joining position Pb 1 is attached to the second leg. It is assumed to be a unit 120. That is, the first leg 110 and the second leg 120 are arranged to face each other in the axial direction. The radial joining position Pa1 means a radial position of the other end portion 71 of the second leg 120 when the first leg 110 and the second leg 120 are joined. I do.

  In the present embodiment, of the plurality of long legs 51a constituting the one-side segment conductor 60, the long legs 51a are arranged radially outside the first leg 110, and are arranged radially adjacent to the first leg 110. The long leg 51a is referred to as a third leg 130, and the long leg 51a disposed radially inside the first leg 110 and adjacent to the first leg 110 in the radial direction is referred to as a fourth leg 140. And The short leg portion 51b of the plurality of short leg portions 51b constituting the other-side segment conductor 70, which is arranged adjacent to the second leg portion 120 in the radial direction, is referred to as a fifth leg portion 150.

  The fourth leg 140 and the fifth leg 150 are joined to each other in a state where they are arranged at the radial joining position Pa2 and the axial joining position Pb2. Here, the radial joining position Pa2 is located radially inward of the radial joining position Pa1 by approximately the radial width W11 of the segment conductor 40 (see FIG. 11). Further, the joint position Pb2 in the axial direction is located on the axial direction Z1 direction side of the joint position Pb1 in the axial direction.

  Further, the long leg portions 51a and the short leg portions 51b of the one-side segment conductor 60 are arranged alternately in the radial direction in the same slot 12 (in the same joining region). Further, the long leg portions 51a and the short leg portions 51b of the other segment conductor 70 are arranged alternately in the radial direction in the same slot 12 (in the same joining region). In other words, in the same slot 12, the plurality of segment conductors 40 are arranged so that the joint portions 80 of the long leg portions 51a and the short leg portions 51b are not radially adjacent to each other.

  As shown in FIG. 11, in the present embodiment, one-side inclined surfaces 62 are provided on the long leg portions 51 a and the short leg portions 51 b of the one-side segment conductor 60. That is, the first leg 110, the third leg 130, and the fourth leg 140 are provided with one-side inclined surfaces 62. In addition, the other long side portion 51a and the short side portion 51b of the other side segment conductor 70 are provided with the other side inclined surface 72. That is, the second leg 120 and the fifth leg 150 are provided with the other-side inclined surface 72.

  The one-side tip 61 which is the tip of the one-side inclined surface 62 on the side of the arrow Z1 is disposed in a radially inner portion 60a of the one-side segment conductor 60 (the one-side inclined surface 62). . The other-side tip 71, which is the tip of the other-side inclined surface 72 on the arrow Z2 direction side, is disposed on a radially outer portion 70a of the other-side segment conductor 70 (the other-side inclined surface 72). . The one-side inclined surface 62 is arranged such that the one-side tip portion 61 is disposed in the radially outer portion 60a and the one-side root portion 64 is disposed in the radially outer portion 60b. It is configured as a facing surface facing outward and facing the other inclined surface 72 in the radial direction and the axial direction. Also, the other-side inclined surface 72 is arranged such that the other-side distal end portion 71 is disposed on the radially outer portion 70a and the other-side root portion 74 is disposed on the radially inner portion 70b. It is configured as a facing surface facing inward and facing the one side inclined surface 62 in the radial direction and the axial direction.

  Here, the portion 60a means a portion radially inward of the radial center of the one-side segment conductor 60. In addition, the portion 60b means a portion radially outward of the radial center of the one-side segment conductor 60. Further, the one-side root portion 64 is an end of the one-side inclined surface 62 on the arrow Z2 direction side, and is a boundary between the one-side inclined surface 62 and the radially outer end surface 65. In addition, the portion 70 a means a portion radially outside the radial center of the other segment conductor 70. The portion 70b means a portion radially inward of the radial center of the other-side segment conductor 70. Further, the other-side root 74 is an end of the other-side inclined surface 72 on the arrow Z1 direction side, and is a boundary between the other-side inclined surface 72 and the radially inner end surface 73. The end face 75 is a radially outer end face of the other segment conductor.

  In addition, as shown in FIG. 11, the one-side tip 61 and the other-side tip 71 are each formed in, for example, a flat surface (chamfered shape) orthogonal to the axial direction.

  The one side inclined surface 62 and the other side inclined surface 72 are engaged. Specifically, the one-side inclined surface 62 includes an engagement convex portion 66. Further, the other side inclined surface 72 includes an engagement recess 76. The engagement projection 66 is formed so as to protrude radially outward. The engagement concave portion 76 is formed so as to face the engagement convex portion 66 in the radial direction and to be depressed outward in the radial direction. The engaging projection 66 and the engaging recess 76 are arranged to engage in the radial direction. That is, each of the one-side inclined surface 62 and the other-side inclined surface 72 has a key-shaped portion.

  A joint 80 is formed between the one-side inclined surface 62 and the other-side inclined surface 72. For example, the joining portion 80 is made of a joining agent 180. For example, the one-side inclined surface 62 and the other-side inclined surface 72 are electrically and mechanically connected (joined) by electrically joining the conductive material included in the joining agent 180 to the conductor main body of the segment conductor 40. ing. Thus, the joining portion 80 (the joining agent 180) has a function of fixing the plurality of separate segment conductors 40 to each other and conducting the plurality of separate segment conductors 40 to each other. For example, the conductive material included in bonding agent 180 is a metal material such as silver or copper. Preferably, the bonding agent 180 is a paste-like bonding agent (silver nanopaste) containing, as conductive particles, metal particles obtained by reducing silver to a nanometer level or a micrometer level in a solvent. Further, the bonding agent 180 contains a member (volatile agent) that evaporates when heated, and the member that evaporates decreases the volume of the bonding agent 180 by heating, and is inclined on one side. It has a function of bringing the surface 62 and the other-side inclined surface 72 close to each other.

  In addition, between the portion near the one-side root portion 64 of the one-side inclined surface 62 and the portion near the other-side tip portion 71 of the other-side inclined surface 72 (in the radial direction and the axial direction), A gap CL capable of absorbing a dimensional error or the like between the side segment conductor 60 and the other side segment conductor 70 is provided.

  Here, the end face 63 is disposed radially inward of the end face 73. The end face 75 is arranged radially outside the end face 65. That is, the end face 63 is arranged at a position offset radially inward from the end face 73. That is, the end face 75 is arranged at a position offset radially outward from the end face 65.

(Structure of insulating member)
As shown in FIG. 10, an insulating member 90 is provided in the coil unit 30. An insulating member 90 is provided at the joint position Pb1 or Pb2 in the axial direction of the segment conductors 40 adjacent in the radial direction in the long leg portion 51a. For example, the insulating member 90 is formed by winding a sheet-like insulating material such as polyimide on the insulating coating (outer periphery). For example, as shown in FIG. 7B, the insulating member 90 has a radial thickness t2. The thickness t2 is smaller than the thickness t1 of the insulating coating 40a, for example.

[Method of manufacturing stator]
Next, a method for manufacturing the stator 100 according to the present embodiment will be described. FIG. 12 shows a flowchart for explaining each manufacturing process of the stator 100.

(Segment conductor preparation process)
First, in step S1, a plurality of segment conductors 40 are prepared. Specifically, as shown in FIG. 6, a power conductor 41, a neutral conductor 42, and a general conductor 43 (see FIG. 8) constituting other portions of the coil unit 30 are prepared.

  In the present embodiment, prior to the segment conductor arranging step (S6), the long leg portion 51a whose axial length is the length L1, and the length L2 whose axial length is smaller than the length L1. A plurality of segment conductors 40 having short legs 51b are prepared. Specifically, one-side segment conductor 60 and the other-side segment conductor 70 are prepared.

  More specifically, as shown in FIGS. 13 and 14, a pair of long leg portions 51 a and short leg portions 51 b disposed in different slots 12 (joining regions) and including the first leg portion 110, and the first leg portion A one-side segment conductor 60 having a first coil end portion 152 that is a coil end portion 52 that connects a pair of long leg portions 51a and short leg portions 51b including the wire 110 is prepared (formed). Also, a pair of long leg portions 51a and short leg portions 51b arranged in different slots 12 and including the second leg portions 120 and a pair of long leg portions 51a and short leg portions 51b including the second leg portions 120 are provided. The pair of long legs 51a including the first leg 110 and the pair of long legs 51a including the first leg 110 are so set that the distance D2 in the direction is smaller than the circumferential distance D1 of the pair of long legs 51a and the short legs 51b including the first leg 110. The other-side segment conductor 70 having the second coil end portion 252 which is the coil end portion 52 connecting the short leg portion 51b is prepared (formed).

  The axial height h1 of the first coil end portion 152 is smaller than the axial height h2 of the second coil end portion 252. The axial height h1 refers to the axial length from the axial top 152a (the vertex on the arrow Z2 direction side) of the first coil end 152 to the long leg 51a or the short leg 51b. The axial height h2 means the axial length from the axial top 252a of the second coil end portion 252 (the vertex on the arrow Z2 direction side) to the long leg 51a or the short leg 51b. I do. That is, the height h2 of the second coil end portion 252 is larger than the height h1 because the distance D2 is smaller than the distance D1. The total length of the one-side segment conductor 60 (the sum of the length of the long leg 51a and the short leg 51b and the length of the first coil end 152) and the total length of the other segment conductor 70 (the long leg 51a and the short The sum of the length of the leg 51b and the length of the first coil end 152) is substantially equal. Note that the distances D1 and D2 are described as meaning the distance along the circumferential direction between the inner end faces in the circumferential direction of the long leg 51a and the short leg 51b.

  As shown in FIG. 15, in the present embodiment, the other side inclined surface 72 as the other guide portion that is inclined with respect to the plane orthogonal to the axial direction and that faces the other side in the radial direction, The other-side segment conductor 70 including the second leg 120 and the fifth leg 150 having the end surface 75 that is the surface on the opposite side in the radial direction and the surface along the axial direction is formed. More specifically, a second leg 120 provided with an engagement recess 76 that engages with the first leg 110, and a fifth leg provided with an engagement recess 76 that engages with the fourth leg 140. And the other side segment conductor 70 including the first and second segment conductors 150 is prepared.

  Also, a fourth leg 140 provided with an engagement projection 66 engaged with the fifth leg 150 and a first leg provided with an engagement projection 66 engaged with the second leg 120. One-sided segment conductor 60 including 110 and third leg 130 is prepared.

(Insulation member placement process)
In step S2, as shown in FIG. 8, the insulating member 90 is attached to a position corresponding to the axial position Pb1 or Pb2 on the outer periphery of the insulating coating of the long leg 51a of the segment conductor 40. For example, as shown in FIG. 7, an insulating member 90 having a radial thickness t2 is attached to each long leg 51a of the plurality of segment conductors 40. For example, a tape-shaped (film-shaped) insulating member 90 is arranged at least radially outside the long leg 51a, and is wound around the entire circumference of the long leg 51a.

(Bonding agent application process)
In step S3, as shown in FIG. 15, the bonding agent 180 is applied to at least one of the one-side inclined surface 62 and the other-side inclined surface 72. Preferably, the bonding agent 180 is applied to both the one-side inclined surface 62 and the other-side inclined surface 72.

(Coil assembly forming process)
In step S4, as shown in FIGS. 2 and 3, an annular first coil assembly 30a including the one-side segment conductor 60 and an annular second coil assembly 30b including the other-side segment conductor 70 are formed. For example, when the plurality of general conductors 43 are arranged in the plurality of slots 12 (the completed state of the stator 100), the annular first coil assembly 30a is formed so as to have a substantially similar arrangement relationship. You. In addition, the power conductor 41, the neutral conductor 42, and the plurality of general conductors 43 of each of the three phases are arranged in a circle so that they have substantially the same arrangement relationship as when they are arranged in the plurality of slots 12. An annular second coil assembly 30b is formed.

  Here, as shown in FIG. 3, the outer diameter φ2 of the second coil assembly 30b composed of the other segment conductor 70 prepared in step S1 is equal to the first coil assembly 30a composed of the one segment conductor 60. Is smaller than the outer diameter φ1.

(Slot insulating paper placement process)
In step S5, as shown in FIG. 16, the slot insulating paper 20 is arranged in each of the plurality of slots 12. The slot insulating paper 20 is arranged in a state where the inner side in the radial direction is closed. Further, as shown in FIG. 3, the arranged slot insulating paper 20 is held in the slot 12 by the collar portions 22 on both axial sides.

(Segment conductor placement process)
In step S6, the plurality of segment conductors 40 are arranged at positions overlapping the slots 12 when viewed from the axial direction. Specifically, as shown in FIG. 3, the second coil assembly 30b is disposed on the side (for example, immediately above) the direction of the arrow Z1 with respect to the stator core 10. Further, the first coil assembly 30a is disposed on the side (for example, directly below) of the stator core 10 in the direction of the arrow Z2.

  Here, as shown in FIG. 17, in the present embodiment, the first leg 110 is joined to the first leg 110 at a radial joining position Pa1 in the slot 12 (joining region) in the slot 12 (joining region). The leg part 120 and the third leg part 130 arranged adjacent to the first leg part 110 on the radially outer side of the first leg part 110 form a part 70a of the second leg part 120 (see FIG. 11). Is arranged such that the position of the other end portion 71 provided at the position is a radial position Pa3 shifted radially inward with respect to the radial joining position Pa1 of the first leg 110. For example, with the second leg 120 along the axial direction, the entire second leg 120 is disposed at the radial position Pa3.

  Specifically, as shown in FIG. 18, in the present embodiment, by using the one-side segment conductor 60 and the other-side segment conductor 70 prepared in the segment conductor preparing step (S1), the second leg 120 is used. Is disposed at a radial position Pa3 shifted radially inward with respect to the radial joining position Pa1. Further, the second leg portion 120 is positioned at a position where the shift width W21 of the other end portion 71 of the second leg portion 120 to the other side in the radial direction with respect to the radial joining position Pa1 is larger than the thickness t2 of the insulating member 90. Is arranged. Further, in the present embodiment, the engaging concave portion 76 of the second leg portion 120 is disposed radially outside the engaging convex portion 66 of the fourth leg portion 140, and the other end of the second leg portion 120 on the other side. 71 are arranged at a radial position Pa3 shifted radially inward with respect to the radial joining position Pa1. That is, at this time, the radial position Pa3 where the other end portion 71 of the second leg portion 120 is arranged is radially inward of the insulating member 90 (see FIG. 17) and radially larger than the fourth leg portion 140. It is located outside in the direction. For example, the shift width W21 is half the radial width W11 of the long leg 51a or the short leg 51b. Further, for example, the radial position Pa3 is a radially intermediate point between the one end portion 61 of the third leg portion 130 and the one end portion 61 of the fourth leg portion 140.

  Further, in the present embodiment, as shown in FIG. 17, the one end portion 61 of the first leg portion 110 as the short leg portion 51b is disposed at the radial joining position Pa1, and as shown in FIG. One end 61 of the third leg 130 as the long leg 51a is disposed radially outside the first leg 110, and the other end 71 of the second leg 120 as the long leg 51a is Are arranged at a radial position Pa3 shifted radially inward with respect to the radial joining position Pa1.

(Movement guidance process)
In step S <b> 7, the first leg 110 to the fifth leg 150 are moved into the slot 12, and the second leg 120 is moved to the radial position Pa <b> 3 by the one-side inclined surface 62 and the other-side inclined surface 72. To the joining position Pa1 in the radial direction. That is, in the present embodiment, the first leg 110, the second leg 120, and the third leg 120 are arranged such that the first leg 110 and the third leg 130 and the second leg 120 approach each other in the axial direction. The part 130 is moved relatively.

  Specifically, in the present embodiment, first, as shown in FIG. 17, the first coil assembly 30a is translated (moved linearly) in the direction of arrow Z1 with respect to the stator core 10, so that the first coil assembly 30a is moved. Each of the long leg portions 51a and the short leg portions 51b of the one-side segment conductor 60 is inserted into each slot 12 (the slot 12 in which the slot insulating paper 20 is disposed).

  Thereafter, the second coil assembly 30b is translated (moved linearly) in the direction of the arrow Z2 with respect to the stator core 10, so that the long leg portions 51a and the short leg portions 51b of the other segment conductor 70 of the second coil assembly 30b. Is inserted into each slot.

  Here, as shown in FIG. 18, in the present embodiment, the other end portion 71 of the second leg 120 is located at a radial position Pa <b> 3 shifted radially inward with respect to the radial joining position Pa <b> 1. In such a state, the intermediate point between the one end portion 61 of the fourth leg portion 140 and the one end portion 61 of the third leg portion 130 is preferably set in the radial direction. The first leg portion 110 to the fifth leg portion 150 are guided to move so that the portion 71 passes. That is, at the time when the axial positions of the other end portion 71 of the second leg portion 120, the one end portion 61 of the third leg portion 130, and the one end portion 61 of the fourth leg portion 140 become substantially the same. , The distance D11 (interval) between the other end 71 of the second leg 120 and the one end 61 of the third leg 130, the other end 71 of the second leg 120, and the fourth leg. The distance D12 (interval) between the one end portion 61 of the portion 140 and the one end portion 61 is substantially the same.

  Thereafter, as shown in FIG. 19, in the present embodiment, the other-side inclined surface 72 of the second leg 120 is brought into contact with the one-side inclined surface 62 of the fourth leg 140, thereby forming the other-side inclined surface 72. By being moved in the direction along the inclination direction (E direction), the other end portion 71 of the second leg 120 is guided to move from the radial position Pa3 to the radial joining position Pa1.

  For example, when the other inclined surface 72 of the second leg 120 abuts the one inclined surface 62 of the fourth leg 140, the second leg 120 is moved in the direction of arrow E with respect to the fourth leg 140. (Between the arrow Z2 direction and the arrow R2 direction). Here, since the engaging concave portion 76 is disposed radially outside (the first leg portion 110 side) of the engaging convex portion 66, the engaging concave portion 76 and the engaging convex portion 66 do not engage with each other. The radial position of the second leg 120 is guided by the one-side inclined surface 62 and the other-side inclined surface 72.

  Then, as shown in FIG. 11, the one-side inclined surface 62 of the first leg 110 and the other-side inclined surface 72 of the second leg 120 are radially opposed to each other. The engagement protrusion 66 and the engagement recess 76 of the second leg 120 are in a state of being engaged in the radial direction. At this time, at least a portion between the one-side inclined surface 62 and the other-side inclined surface 72 is filled with the bonding agent 180. Further, the end face 65 is arranged (offset state) so as to protrude radially beyond the end face 75. Further, the insulating member 90 is placed at a position radially adjacent to either the one-side inclined surface 62 or the other-side inclined surface 72.

(Joining process)
In step S8, the one-side inclined surface 62 and the other-side inclined surface 72 are joined. In detail, as shown in FIG. 10, at least the bonding agent 180 is heated and cured by a heating device (not shown) while the long leg portion 51 a and the short leg portion 51 b are pressed by the pressing jig 160. By doing so, the one-side inclined surface 62 and the other-side inclined surface 72 are joined.

  Specifically, the pressing jig 160 moves outward in the radial direction, and the pressing force is applied to portions near the one-side inclined surface 62 and the other-side inclined surface 72 of the segment conductor 40 (near the axial positions Pb1 and Pb2). By the transmission, the plurality of segment conductors 40 arranged in the radial direction are pressed in the slot 12. As shown in FIG. 20, a pressing jig 160 is disposed in the opening 12a of the slot 12 (inside of the slot 12 in the radial direction). Thus, the plurality of segment conductors 40 (the plurality of long leg portions 51a and the short leg portions 51b) arranged in the radial direction are sandwiched on both sides in the radial direction by the pressing jig 160 and the wall portion 11a of the stator core 10. It will be in a state where it has The pressing jig 160 generates a pressing force (load) on the plurality of segment conductors 40 arranged in the radial direction outward in the radial direction, so that a reaction force is generated from the wall portion 11a toward the inside in the radial direction. The plurality of segment conductors 40 arranged in the radial direction are pressed from both sides in the radial direction.

  Further, as shown in FIG. 10, the pressing jig 160 presses the long leg 51a radially outward while contacting the end surface 63 of the segment conductor 40 arranged radially inward. At this time, since the end surface 75 is arranged (offset) radially outward from the end surface 65, the one-side inclined surface 62 and the other-side inclined surface 72 are pressed against each other.

  Then, while the one-side inclined surface 62 and the other-side inclined surface 72 are pressed against each other, the bonding agent 180 is heated to a curing temperature or higher by a heating device (for example, a heater, hot air, or the like) to be cured. 80 are formed and mechanically connected. Then, the one-side inclined surface 62 and the other-side inclined surface 72 are electrically connected by the conductive material (silver or the like) included in the bonding agent 180 (the bonding portion 80). Then, in all the slots 12, all the segment conductors 40 facing each other are joined. Thereby, the coil part 30 of a wave winding shape is formed. Thereafter, as shown in FIG. 2, the stator 100 is completed. In addition, as shown in FIG. 1, the rotating electric machine 102 is manufactured by combining the stator 100 and the rotor 101.

[Effects of the above embodiment]
In the above embodiment, the following effects can be obtained.

  In the above embodiment, the position of the tip portion (71) provided on the radially one-side portion (70a) of the second leg portion (120) is determined by the joint position (Pa1) of the first leg portion (110). ), The first leg (110), the second leg (120), and the third leg (130) are arranged so as to be shifted to the other side in the radial direction (Pa3). The distance (interval) (D11) in the radial direction between the second leg (120) and the third leg (130) arranged on one side in the radial direction of the second leg (120) is relatively large. Can be. For this reason, even when the second leg (120) or the third leg (130) has a deformation or a dimensional error, the radial movement of the second leg (120) and the third leg (130) in the radial direction. Since the distance (interval) (D11) is relatively large, when the second leg (120) is moved to the joint area (12), a portion of the second leg (120) on one side in the radial direction is used. It is possible to prevent the tip portion (71) provided at (70a) and the tip portion (61) of the third leg (130) from mechanically interfering (being caught). As a result, it is possible to prevent the plurality of segment conductors (40) from being difficult to arrange on the armature core (10). Further, the distal end (71) of the second leg (120) located at the position (Pa3) shifted to the other side in the radial direction by the guide portion (72) provided on the second leg (120), By guiding the movement to the joining position (Pa1), the second leg (120) can be guided to a radial position (Pa1) suitable for joining the first leg (110). As a result, the leg portions (51a, 51b) can be appropriately joined together while preventing the plurality of segment conductors (40) from being difficult to arrange on the armature core (10).

  Further, in the above embodiment, the second leg (120) is inclined with respect to a plane orthogonal to the axial direction, and has an inclined surface (72) as a guide (72) facing the other side in the radial direction. Including the inclined surface (72) and the end surface (75) that is the surface on the opposite side in the radial direction and is the surface along the axial direction, the step of guiding the movement (S7) is performed by the second leg (120). The inclined surface (72) is the first leg (110) or one leg (51a) in the axial direction, and is disposed adjacent to the first leg (110) on the other side in the radial direction. By contacting at least one of the fourth leg portions (140), the distal end of the second leg portion (120) is moved in a direction (the direction of arrow E) along the inclination direction of the inclined surface (72). The part (71) is moved from the position (Pa3) shifted to the other side in the radial direction to the joining position (Pa1). A guide to step (S7). With such a configuration, when viewed in the axial direction, the second leg (120) and the first leg (110) or the fourth leg (140) are located at a position (Pa3) where they overlap. Even when the second leg (120) is relatively moved in the axial direction, the inclined surface (72) of the second leg (120) abuts on the first leg (110) or the fourth leg (140) and slides with each other. It can be moved (moved along an inclined direction (the direction of arrow E in FIG. 19)). As a result, the tip (71) of the second leg (120) mechanically interferes with the first leg (110) or the fourth leg (140), and relatively moves in the axial direction. Can be prevented, and the tip (71) of the second leg (120) can be appropriately guided to the joint position (Pa1).

  Further, in the above embodiment, prior to the disposing step (S6), a pair of legs (51a, 51b) including the first leg (110), which are disposed in the mutually different joining regions (12), and the first leg A first segment conductor (60) having a first coil end portion (152) connecting a pair of legs (51a, 51b) including a portion (110); The circumferential distance (D2) between the pair of legs (51a, 51b) including the second leg (120) and the pair of legs (51a, 51b) including the second leg (120) is the first. A pair of legs (51a, 51b) including the second leg (120) so as to be smaller than a circumferential distance (D1) between the pair of legs (51a, 51b) including the leg (110). And a second coil end portion (252) for connecting The method further includes a step (S1) of preparing a segment conductor (70), and the arranging step (S6) includes using the prepared first segment conductor (60) and the prepared second segment conductor (70). This is a step (S6) of arranging the tip (71) of the second leg (120) at a position (Pa3) that is shifted to the other side in the radial direction with respect to the joining position (Pa1). According to this structure, the prepared first leg (110) of the first segment conductor (60) and the second leg (120) of the second segment conductor (70) are connected to the joining region (12). If it is arranged at a position (Pa3) that overlaps with the slot (12) when viewed in the axial direction, the second leg (120) is not moved or deformed in the radial direction, and the second leg (120) is not moved. The tip portion (71) can be easily arranged at a position (Pa3) shifted to the other side in the radial direction with respect to the joining position (Pa1) (the radial position of the first leg (110)). . In the case where the second leg (120) is moved or deformed in the radial direction during the disposing step (S6), a device or the like for moving or deforming the second leg (120) in the radial direction is required. In this case, it is considered that a manufacturing facility for arranging the second leg (120) becomes complicated and large. On the other hand, in the above embodiment, the second leg portion (120) is moved or deformed in the radial direction by using the second segment conductor (70) having a relatively small circumferential distance (D2). No equipment is required. As a result, it is possible to prevent the manufacturing facilities of the armature (100) from becoming complicated and large.

  Further, in the above embodiment, the step of guiding the movement (S7) is performed at the position (Pa3) where the tip (71) of the second leg (120) is shifted to the other side in the radial direction with respect to the joining position (Pa1). ), The tip of the fourth leg (140) which is the leg (51a) on one side in the axial direction and is arranged adjacent to the first leg (110) on the other side in the radial direction. Guiding the movement of the second leg (120) so that the tip (71) of the second leg (120) passes between the radial direction of the tip (61) and the tip (61) of the third leg (130). (S7). Here, when the tip (71) of the second leg (120) is arranged at a position (Pa3) shifted to the other side in the radial direction with respect to the joining position (Pa1), the second leg (120) The radial distance between the distal end (71) and the distal end (61) of the fourth leg (140) is reduced by the deviation width (W21). On the other hand, if it comprises like the said embodiment, the front-end | tip part (71) of a 2nd leg part (120) will be the front-end | tip part (61) of a 4th leg part (140), and the 3rd leg part ( 130) between the tip (61) of the second leg (120) and the tip (61) of the fourth leg (140). Can be prevented.

  Further, in the above embodiment, the step of guiding the movement (S7) is performed at a radially intermediate point between the tip (61) of the fourth leg (140) and the tip (61) of the third leg (130). This is a step (S7) of guiding the movement of (Pa3) so that the tip (71) of the second leg (120) passes. Here, when the tip (71) of the second leg (120) passes through a position other than the radial midpoint (Pa3), the tip (71) of the second leg (120) is The distance between one of the tip (61) of the fourth leg (140) and the tip (61) of the third leg (130) is different from that of the tip (61) of the fourth leg (140). It is smaller than half the distance between the third leg (130) and the tip (61). On the other hand, according to the above embodiment, the distance (D12) between the tip (71) of the second leg (120) and the tip (61) of the fourth leg (140), and The distance (D11) between the tip (71) of the second leg (120) and the tip (61) of the third leg (130) is determined by the distance (D11) between the tip (61) of the fourth leg (140). The distance (D11 + D12) between the third leg (130) and the tip (61) can be reduced to approximately one half. As a result, even if the second leg (120) is curved or deformed in either one of the radial direction and the other direction, the position other than the radial intermediate point (Pa3) is moved to the second position. The second leg (120), the fourth leg (140) and the third leg (130) mechanically interfere with each other as compared with the case where the tip (71) of the leg (120) passes. Can be prevented.

  In the above embodiment, the second leg (120) is provided with the engagement recess (76) that engages with the first leg (110), and the fourth leg (140) is An engaging projection (66) is provided which engages with a fifth leg (150), which is a leg (51b) arranged adjacent to the other side in the radial direction of the second leg (120). In the disposing step (S6), the engaging concave portion (76) is disposed on one side in the radial direction from the engaging convex portion (66), and the distal end portion (71) of the second leg portion (120) is This is a step (S6) of disposing at a position (Pa3) shifted to the other side in the radial direction with respect to the joining position (Pa1). According to this structure, even if the second leg (120) is arranged at a position (Pa3) shifted to the other side in the radial direction with respect to the joining position (Pa1), the engagement of the second leg (120) is maintained. The engagement recess (76) and the engagement protrusion (66) of the fourth leg (140) can be prevented from being erroneously engaged. As a result, the engagement concave portion (76) of the second leg portion (120) and the engagement convex portion (66) of the fourth leg portion (140) are prevented from being erroneously engaged, and the engagement concave portion (76) is prevented. 76), the second leg (120) and the first leg (110) can be engaged, and the engagement leg (66) allows the fourth leg (140) and the fifth leg (150) to engage. ) Can be engaged.

  In the above embodiment, the step of guiding the movement (S7) includes placing the first leg (110) and the third leg (130) in the slot (12) as the joining area (12) in the other axial direction. After being inserted toward the side, the second leg (120) is inserted into the slot (12) toward one side in the axial direction, so that the second leg (120) is shifted to the other side in the radial direction by the guide portion (72). The step (S7) of moving and guiding the tip (71) of the second leg (120) located at the position (Pa3) to the joining position (Pa1). According to this structure, since the wall (13a) of the teeth (13) and the wall (11a) of the back yoke (11) are surrounded, the legs (51a, Even in the slot (12) where it is not easy to hold the 51b), the tip of the second leg (120) is located at the position (Pa3) shifted to the other side in the radial direction by the guide portion (72). (71) can be easily moved and guided to the joining position (Pa1).

  Further, in the above embodiment, the third leg (130) is provided with the insulating member (90) on the other side in the radial direction, and the arranging step (S6) is performed by the second leg (120). At the position (Pa3) where the deviation width (W21) of the tip portion (71) to the other side in the radial direction with respect to the joining position (Pa1) is larger than the thickness (t2) of the insulating member (90), the second leg portion is provided. This is the step (S6) of arranging (120). With this configuration, the third leg (130), the first leg (110) provided on the other radial side of the third leg (130), and the second leg are formed by the insulating member (90). The insulation performance between the portion (120) and the joint (80) can be ensured. And even when the insulating member (90) is provided on the third leg (130), mechanical interference between the second leg (120) and the insulating member (90) can be prevented. . As a result, it is possible to prevent the insulating member (90) from being torn or peeled off from the third leg (130), so that the third leg (130), the first leg (110), and the second leg can be prevented. The insulation performance with the part (120) can be more reliably ensured.

  Further, in the above embodiment, prior to the disposing step (S6), the long leg (51a) having the first length (L1) in the axial direction and the first leg (51a) having the first length (L1). The method further comprises a step (S1) of preparing a plurality of segment conductors (40) having a short leg (51b) having a second length (L2) smaller than (L1), and the step of arranging (S6) The tip (61) of the first leg (110) as the short leg (51b) is arranged at the joint position (Pa1), and the third leg (130) as the long leg (51a) is placed. The distal end (61) is arranged on one side in the radial direction of the first leg (110), and the distal end (71) of the second leg (120) as the long leg (51a) is connected to the joint position ( This is a step (S6) of disposing at a position (Pa3) shifted to the other side in the radial direction with respect to Pa1). According to this structure, the joint position (Pb1) between the first leg (110) and the second leg (120) and the joint position between the third leg (130) and another leg (51b). The position in the axial direction with respect to (Pb2) can be arranged at a different position. Therefore, the joint position (Pb1) between the first leg (110) and the second leg (120) and the joint position (Pb2) between the third leg (130) and the other leg (51b) are different. However, the insulation performance between the joints (80) can be more easily ensured as compared with the case where the positions in the axial direction are the same and they are arranged adjacent to each other in the radial direction. As a result, the tip (71) of the second leg (120) and the tip (61) of the third leg (130) mechanically interfere with each other while ensuring insulation performance between the joints (80). Can be prevented.

[Modification]
It should be noted that the embodiments disclosed this time are illustrative in all aspects and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description of the embodiments, and includes all modifications (modifications) within the scope and meaning equivalent to the terms of the claims.

<First Modification>
For example, in the above embodiment, as shown in FIG. 17, in the segment conductor arranging step (S6), the radial position of the entire second leg 120 is shifted from the radial joining position Pa1 to the radial position Pa3. However, the present invention is not limited to this. For example, by inclining the second leg 120 in the radial direction with respect to the axial direction as in the method of manufacturing the stator 100 according to the first modification shown in FIG. Only the other end portion 71 of the leg portion 120 and the vicinity of the other end portion 71 may be shifted to the radial position Pa3.

<Second modification>
Further, in the above-described embodiment, as shown in FIG. 19, an example is shown in which the second leg 120 is provided with the other-side inclined surface 72 as a guide, but the present invention is not limited to this. For example, as in the stator 200 according to the second modification shown in FIG. 22, the guide portion of the second leg 220 may be formed by an arcuate surface (R surface) 272. Accordingly, in the movement guiding step, the arc-shaped surface 272 of the second leg 220 and the arc-shaped surface 262 of the fourth leg 240 come into contact with each other. Is moved from the radial position Pa3 to the radial joining position Pa1 and guided.

<Third modification>
Further, in the above embodiment, as shown in FIG. 19, an example is shown in which the second leg portion 120 is provided with the engaging concave portion 76 and the fourth leg portion 140 is provided with the engaging convex portion 66. It is not limited to this. For example, like the stator 300 according to the third modified example shown in FIG. 23, the second leg portion 320 is provided with the other inclined surface 372 that is flat along the inclined direction in which the engagement recess is not provided, and The leg 340 may be provided with a flat one-sided inclined surface 362 along the inclined direction in which the engaging projection is not provided.

<Other modified examples>
In the above embodiment, the example in which the armature of the present invention is configured as a stator has been described, but the present invention is not limited to this. For example, the armature of the present invention may be configured as a rotor having a rotor core and a coil (segment conductor).

  Further, in the above-described embodiment, an example is described in which the stator is configured such that one side in the radial direction is radially outside and the other side in the radial direction is radially inside, but the present invention is not limited to this. For example, the stator may be configured such that one side in the radial direction is radially inward and the other radial side is radially outward.

  Further, in the above embodiment, the example in which the bonding portion is formed of the bonding agent (silver nanopaste) has been described, but the present invention is not limited to this. For example, the joining portion may be formed by welding the segment conductors or using brazing or the like without using a joining agent.

  Further, in the above embodiment, the example in which the opening is formed radially inside the stator has been described, but the present invention is not limited to this. For example, the opening may be formed radially outside the stator.

  Further, in the above embodiment, an example in which the coil is formed as a wave-wound coil has been described, but the present invention is not limited to this. For example, the coils may be formed as distributed winding coils or concentrated winding coils.

  Further, in the above embodiment, the example in which the cross-sectional shape of the segment conductor is formed in a rectangular shape is shown, but the present invention is not limited to this. That is, the cross-sectional shape of the segment conductor may be formed into a shape (circular shape, elliptical shape, etc.) other than the rectangular shape.

  Further, in the above embodiment, an example is described in which the slot is configured to be semi-open (the opening width is smaller than the width of the slot), but the present invention is not limited to this. For example, if the characteristics of the stator (armature) are not significantly affected, the slot may be configured as a fully open type slot having an opening width equal to the width of the slot. It should be noted that semi-open is more preferable than fully open in terms of the characteristics of the stator.

  Further, in the above embodiment, an example in which the segment conductors of only the same phase are arranged in the same slot has been described, but the present invention is not limited to this. For example, a plurality of segment conductors of different phases may be arranged in the same slot.

  Further, in the above-described embodiment, an example is shown in which the long leg portions and the short leg portions are alternately arranged in the same slot in the radial direction, but the present invention is not limited to this. For example, in the same slot, only a plurality of long legs or a plurality of short legs may be arranged in the radial direction without being alternately arranged in the radial direction.

  Further, in the above embodiment, the first leg and the second leg are moved into the slot (axially inside the axial end face of the stator core), and the first leg and the second leg are moved inside the slot. Although an example of joining the parts has been described, the present invention is not limited to this. For example, at a position (joining area) where the slot overlaps with the slot when viewed in the axial direction, the first leg and the second leg are disposed axially outside the axial end face of the stator core in the axial direction. The first leg and the second leg may be joined.

  Further, in the above embodiment, the example in which the short leg portion is configured as the slot accommodating portion has been described, but the present invention is not limited to this. That is, the short leg portion is a part of the segment conductor, and is not disposed in the slot but extends along the axial direction at a position overlapping the slot when viewed in the axial direction (for example, a linear shape). ) May be configured.

  Further, in the above embodiment, the example in which the coil assembly forming process is provided in the manufacturing process of the stator has been described, but the present invention is not limited to this. That is, after preparing the segment conductors, a step of arranging the segment conductors individually or in plurals in the joining region (for example, in the slot) without forming the first coil assembly and the second coil assembly may be performed. Good.

  Further, in the above embodiment, in the segment conductor arranging step, after arranging the one-side segment conductor (the first leg) in the joint area, the other-side segment conductor (the first leg conductor) arranged at a position radially displaced from the joint position. Although the example in which the two legs are guided to move to the joining area has been described, the present invention is not limited to this. That is, in the segment conductor arranging step, the joining position and the distal end of the second leg may be relatively displaced in the radial direction, and the radial arrangement position of the second leg may be the radial direction in the completed state of the stator. And the radial position of the first leg may be shifted from the radial direction of the completed stator. Further, in the segment conductor arranging step, the radial arrangement positions of both the first leg and the second leg may be shifted from the radial position of the completed state of the stator.

  Further, in the above embodiment, in the movement guide step, the other end of the second leg is set to the radially intermediate point between the one end of the third leg and the one end of the fourth leg. Although an example of moving so as to pass is shown, the present invention is not limited to this. That is, in the movement guiding step, the other end of the second leg is moved from the joint position other than the radially intermediate point between the one end of the third leg and the one end of the fourth leg. It may pass through a position shifted in the direction.

  Further, in the above embodiment, the example in which the insulating member arranging step is provided in the stator manufacturing step has been described, but the present invention is not limited to this. That is, even when the joint portion is provided, the insulating member may not be provided (provided) on the segment conductor if the insulation distance from the segment conductor adjacent in the radial direction is secured.

  Further, in the above-described embodiment, an example in which the segment conductor is provided with the long leg portion and the short leg portion (an example in which the segment conductor is formed so as to have a J-shape) is shown, but the present invention is not limited to this. That is, the pair of legs may be configured to have substantially the same axial length, and the segment conductor may be formed to have a substantially U-shape.

  In the above-described embodiment, an example has been described in which the distance between the pair of legs including the second leg is made smaller than the distance between the pair of legs including the first leg in the segment conductor preparing step. However, the present invention is not limited to this. For example, in the segment conductor preparing step, the distance between the pair of legs including the second leg is formed substantially equal to the distance between the pair of legs including the first leg, Then, the second leg (the other segment conductor) is deformed so that the distance between the pair of legs including the second leg is smaller than the distance between the pair of legs including the first leg. May be.

DESCRIPTION OF SYMBOLS 10 Stator core (armature core) 12 Slot 30 Coil part 40 Segment conductor 51a Long leg 51b Short leg 60 One segment conductor (1st segment conductor)
61 One-side tip 62 One-side inclined surface 63, 75 End surface 66 Engagement convex 70 Other-side segment conductor (second segment conductor)
70a portion (one radial portion of the second leg portion)
71 Tip on the other side (tip of second leg) 72 Slope on the other side (guide)
74 Engaging recess 90 Insulating member 100, 200, 300 Stator (armature)
110 First leg 120, 220, 320 Second leg 130 Third leg 140, 240, 340 Fourth leg 150 Fifth leg 271 Tip (tip of second leg)
272 arcuate surface (guide)

Claims (9)

An armature core provided with a plurality of slots extending in the axial direction, and a plurality of segments arranged facing the axial direction in a joining area which is an area overlapping with the slot when viewed in the axial direction. A method for manufacturing an armature, comprising: a coil portion in which legs of a conductor are joined.
A first leg that is the leg on one side in the axial direction; a second leg that is the leg joined at a joint position with the first leg in the joint region; A third leg which is disposed adjacent to one side of the armature core in the radial direction and which is the leg on one side in the axial direction; A step of arranging such that the position of the tip provided on one side in the direction is shifted to the other side in the radial direction with respect to the joint position of the first leg,
After the arranging step, the first and third legs and the second leg are provided on the second leg while relatively moving so as to approach each other in the axial direction. A step of moving and guiding the tip of the second leg located at a position shifted to the other side in the radial direction by the guiding portion to the joining position;
Joining the first leg and the second leg after the step of moving and guiding the armature. The second leg portion is inclined with respect to a plane orthogonal to the axial direction, and has an inclined surface as the guide portion facing the other side in the radial direction, and a surface on the opposite side of the inclined surface and the radial direction. And including an end surface that is a surface along the axial direction,
In the step of guiding the movement, the inclined surface of the second leg is the first leg or the leg on one side in the axial direction, and the first leg and the other in the radial direction. By contacting at least one of the fourth legs disposed adjacent to the side, the distal end of the second leg is moved in the direction along the inclination direction of the inclined surface, thereby moving the tip of the second leg into the diameter. The method for manufacturing an armature according to claim 1, wherein the step of moving and guiding the armature from a position shifted to the other side in the direction to the joining position. Prior to the arranging step, a pair of the leg portions including the first leg portion, which are arranged in the joining regions different from each other, and a first coil end portion connecting the pair of leg portions including the first leg portion A first segment conductor, a pair of legs including the second leg disposed in the joining region different from each other, and a circumferential direction of the pair of legs including the second leg. And a second coil end that connects the pair of legs including the second leg so that a distance between the pair of legs including the first leg is smaller than a circumferential distance between the pair of legs including the first leg. Having a step of preparing the second segment conductor,
The arranging step includes, by using the prepared first segment conductor and the second segment conductor, moving the distal end of the second leg to the other side in the radial direction with respect to the joining position. The method for manufacturing an armature according to claim 1, wherein the method is a step of disposing the armature at a shifted position.   In the step of guiding the movement, the tip of the second leg is located at a position shifted to the other side in the radial direction with respect to the joining position, and the tip of the second leg is positioned on one side in the axial direction. The second leg extends between the distal end of the fourth leg disposed adjacent to the first leg and the other side in the radial direction and the distal end of the third leg. The method for manufacturing an armature according to any one of claims 1 to 3, wherein the step of guiding the movement is performed such that a tip portion of a leg portion passes.   The step of guiding the movement is performed such that the tip of the second leg passes through the radially intermediate point between the tip of the fourth leg and the tip of the third leg. The method for manufacturing an armature according to claim 4, which is a step of guiding. The second leg is provided with an engagement recess that engages with the first leg.
The fourth leg is provided with an engagement projection that engages with a fifth leg, which is the leg disposed adjacent to the other side of the second leg in the radial direction,
The arranging step includes arranging the engaging concave portion on one side in the radial direction with respect to the engaging convex portion, and moving a distal end portion of the second leg portion in the radial direction with respect to the joining position. The method for manufacturing an armature according to claim 4, wherein the method is a step of disposing the armature at a position shifted to the side.   The step of guiding the movement includes inserting the first leg and the third leg into the slot as the joining area toward the other side in the axial direction, and then inserting the second leg into the slot. The guide portion moves the distal end of the second leg, which is located at a position shifted to the other side in the radial direction, into the joining position by being inserted toward one side in the axial direction. The method for manufacturing an armature according to any one of claims 1 to 6, which is a step of performing. The third leg is provided with an insulating member on the other side in the radial direction,
The arranging step includes arranging the second leg at a position where a deviation width of the distal end of the second leg from the joining position to the other side in the radial direction is larger than a thickness of the insulating member. The method of manufacturing an armature according to any one of claims 1 to 7, which is a step of performing. Prior to the arranging step, a long leg portion having the axial length of the first length, and a short leg portion having the second axial length smaller than the first length. Having a step of preparing the plurality of segment conductors,
The disposing step includes disposing a distal end of the first leg as the short leg at the joint position, and moving a distal end of the third leg as the long leg to the first leg. And disposing the distal end of the second leg as the long leg at a position shifted to the other side in the radial direction with respect to the joining position. An armature manufacturing method according to any one of claims 1 to 8.

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