JP2020054077A - Method of manufacturing stator coil - Google Patents

Abstract

To reduce connection defects of conductor segments in a method for manufacturing a stator coil.SOLUTION: The method includes: a position setting step of setting an upper conductor segment assembly 10 at a set position where a long leg 43 and a short leg 46 of an upper conductor segment face lower teeth 18 of a lower stator core 16; a rotating step of rotating the upper conductor segment assembly 10 to move to a connection position where a tip 45 and a coupling member 50 face each other; and a connection step of connecting each tip 45 to each coupling member 50 in a lump by moving the upper conductor segment assembly 10 toward a lower conductor segment assembly 15 at the connection position.SELECTED DRAWING: Figure 11

Description

  The present invention relates to a method for manufacturing a stator coil, and more particularly, to a method for manufacturing a stator coil by connecting ends of a plurality of conductor segments collectively.

  Generally, in a stator of a rotating electric machine, a stator coil is wound around a stator core. As a stator coil, a coil formed by connecting a plurality of conductor segments is known. Patent Literature 1 proposes a method in which a substantially U-shaped conductor segment is inserted into a slot from both ends in the axial direction of a stator core, and the conductor segments are joined to each other in the slot to manufacture a stator coil.

  In the manufacturing method described in Patent Literature 1, first, a binding material containing conductive particles is applied to a tip end surface of a conductor segment. Then, a plurality of conductor segments are inserted from one side into the plurality of slots, and a plurality of conductor segments are inserted into the plurality of slots also from the other side. Then, the tip surfaces of the conductor segments are pressed against each other and heated to cure the bonding material and connect the plurality of conductor segments at once.

JP 2015-23773 A

  The manufacturing method of the related art described in Patent Document 1 has a problem that a large manufacturing apparatus is required to heat the conductor segments to harden the binder, and the manufacturing apparatus becomes large. For this reason, a manufacturing method of connecting the conductor segments by inserting the ends of the conductor segments into a tubular coupling member made of a conductive material instead of the bonding material has been studied.

  However, when inserting the end of the conductor segment into the coupling member, if the coupling member and the conductor segment are misaligned, the conductor segment and the coupling member interfere with each other, and the insulating film of the conductor segment is damaged, In some cases, the ring member is deformed and connection failure of the conductor segments occurs.

  Therefore, an object of the present invention is to reduce the connection failure of a conductor segment in a method of manufacturing a stator coil for connecting ends of a conductor segment using a coupling member.

  The method of manufacturing a stator coil according to the present invention is a method of manufacturing a stator coil, comprising: inserting a plurality of first conductor segments into the first slots from one axial end of a first stator core having a plurality of first slots; A first end of one conductor segment and a plurality of second slots corresponding to the plurality of first slots of the first stator core, the second slots being combined with the first stator core in the axial direction to form a stator core; The coupling members of the second conductor segment assembly into which a plurality of second conductor segments each having a coupling member attached to the second end portion from the other end side in the axial direction of the two stator cores are inserted are collectively connected. A method for manufacturing a stator coil, wherein each first end of the first conductor segment and each coupling member of the second conductor segment are paired. A position setting step of setting the first conductor segment assembly at a setting position in which each of the first ends faces the teeth between the second slots of the second stator core so as to be displaced in a circumferential direction from a connection position to be connected. A rotation step of rotating one or both of the first conductor segment assembly and the second conductor segment assembly to move the first conductor segment assembly from the set position to the connection position; A connecting step of moving the first conductor segment assembly and the second conductor segment assembly so as to approach each other in the axial direction and collectively connecting the first ends to the coupling members. , Is included.

  In this way, each first end of the first conductor segment and each coupling member of the second conductor segment are displaced in the circumferential direction from the connection position where they face each other, and each first end is located in the second slot of the second stator core. By setting the first conductor segment assembly at a setting position opposed to the teeth between the first conductor segment, each first end of the first conductor segment can be set at a position that does not interfere with each coupling member of the second conductor segment. . Then, the first conductor segment assembly is moved in the circumferential direction by the rotating process to correct the relative position shift between each first end of the first conductor segment and each coupling member of the second conductor segment, thereby correcting each first conductor segment. A connection position where one end and each coupling member face each other. Then, the first conductor segment assembly is moved toward the second conductor segment assembly at the connection position, and each first end is collectively connected to each coupling member. This allows each first end to be inserted into each coupling member without any deviation in the relative position between each first end and each coupling member, so that each first end interferes with each coupling member. As a result, it is possible to prevent the insulating films of the first and second conductor segments from being damaged and the coupling member from being deformed. Thereby, connection failure of the conductor segments can be reduced.

  ADVANTAGE OF THE INVENTION This invention can reduce the poor connection of a conductor segment in the manufacturing method of the stator coil which connects the edge part of a conductor segment using a coupling member.

It is a perspective view which shows the process of inserting an upper conductor segment into the upper slot of an upper stator core. It is a perspective view of an upper conductor segment assembly. It is a perspective view which shows the process of inserting a lower conductor segment into the lower slot of a lower stator core. It is a perspective view of a lower conductor segment assembly. It is a perspective view which shows the assembled stator coil. It is a perspective view of an upper conductor segment. It is a perspective view of a lower conductor segment. It is sectional drawing of the connection part of an upper conductor segment and a lower conductor segment. A perspective view (a) showing the upper and lower conductor segment assemblies in a state where the upper conductor segment assembly is set at a set position, and a circumferential development view (b) ((a)) of a plane cross section of the upper and lower conductor segments. FIG. A perspective view (a) showing the lower conductor segment assembly in a state where the upper conductor segment assembly is slightly rotated leftward from the set position, and a circumferential development view (b) of a plane cross section of the upper and lower conductor segments. It is (circumferential direction development figure of B view of (a)). FIG. 9A is a perspective view showing the lower conductor segment assembly in a state where the upper conductor segment assembly is further rotated leftward from the state shown in FIG. 9, and the circumferential development of a plane cross section of the upper and lower conductor segments. It is a figure (b) (circumferential direction development figure of C view of (a)). A perspective view (a) showing the lower conductor segment assembly when the upper conductor segment assembly is rotated to the connection position, and a circumferential development view (b) ((a)) of a plane cross section of the upper and lower conductor segments. FIG. It is explanatory drawing which shows the process of inserting the front-end | tip of each upper conductor segment of an upper-conductor segment assembly into the coupling member attached to the front-end | tip of a lower conductor segment in the manufacturing process of the stator coil of a comparative example.

  Hereinafter, a method for manufacturing the stator coil 20 of the present embodiment will be described with reference to the drawings. In the method of manufacturing the stator coil 20 of the present embodiment, first, as shown in FIG. 1, a plurality of upper conductor segments 40 are inserted into the upper slots 12 from the upper end surface 11A of the upper stator core 11 having the plurality of upper slots 12. Then, the upper conductor segment assembly 10 shown in FIG. 2 is assembled. Next, as shown in FIG. 3, a plurality of lower conductor segments 30 each having a coupling member 50 attached to a distal end 35 are inserted from the lower end surface 16B side of the lower stator core 16 having a plurality of lower slots 17. The lower conductor segment assembly 15 shown in FIG. 4 is assembled. Then, the upper conductor segment assembly 10 is set on the lower conductor segment assembly 15, and each tip 45 of each upper conductor segment 40 and each coupling member 50 of the lower conductor segment 30 are collectively connected. And the stator coil 20 and the stator 100 shown in FIG.

  Here, the upper slot 12, the upper stator core 11, the side of the upper end face 11A, the upper conductor segment 40, the tip 45, and the upper conductor segment assembly 10 are respectively a first slot, a first stator core, and an axial direction according to claim 1. One end, a first conductor segment, a first end, and a first conductor segment assembly. Similarly, the lower slot 17, the lower stator core 16, the side of the lower end face 16B, the lower conductor segment 30, the tip 35, and the lower conductor segment assembly 15 are respectively a second slot, a second stator core, and an axial direction according to claim 1. The other end corresponds to the second conductor segment, the second end, and the second conductor segment assembly.

<Components of the stator>
First, the members forming the stator 100 and the stator coil 20 will be described with reference to FIGS. 1 to 8, and then the manufacturing process of the stator coil 20 will be described.

  As shown in FIG. 1, the upper stator core 11 has a plurality of upper teeth 13 projecting radially inward from the inner peripheral surface of the substantially annular yoke. An upper slot 12, which is a space for accommodating a part of the stator coil 20, is formed between the upper teeth 13 adjacent in the circumferential direction. As shown in FIG. 3, the lower stator core 16 also includes a yoke and lower teeth 18, and a lower slot 17 is formed between the lower teeth 18. The upper slot 12 and the upper teeth 13 of the upper stator core 11 are the same size as the lower slots 17 and the lower teeth 18 of the lower stator core 16 and are arranged at the same positions in the circumferential direction. As shown in FIG. 5, the upper stator core 11 is combined with the lower stator core 16 in the axial direction to form a stator core 25. The upper stator core 11 and the lower stator core 16 may be, for example, laminated steel sheets formed by laminating a plurality of electromagnetic steel sheets (for example, silicon steel sheets) in a thickness direction, or press-molding magnetic particles coated with insulation. A dust core may be used.

  The stator coil 20 is configured by connecting the upper conductor segment 40 and the lower conductor segment 30 so as to be wound around the teeth 13 and 18 of the upper stator core 11 and the lower stator core 16. The connection mode and the winding mode of the stator coil 20 may be appropriately selected according to the specifications of the rotating electric machine, and may be wound by distributed winding or concentrated winding.

  As shown in FIG. 6, the upper conductor segment 40 is composed of a plurality of upper conductor segments 41 formed in a substantially U shape. When the entire plurality of upper conductor segments 41 are shown, they are referred to as upper conductor segments 40.

  As shown in FIG. 6, the upper conductor segment 41 is formed by bending a coated conductive wire in which the surface of a rectangular wire 410 having a corner R made of a conductive material such as copper is covered with an insulating coating 46 into a substantially U-shape. It was done. The upper conductor segment 41 includes a long leg 43 parallel to each other, a short leg 44 shorter than the long leg 43, and a mountain-shaped connection 42 connecting the legs 43, 44. The insulating coating 46 is peeled off from the distal end 45 of each of the long leg 43 and the short leg 44 so as to be inserted into the coupling member 50.

  As shown in FIG. 7, the lower conductor segment 30 is formed by bending a rectangular wire 310 having an R at the corner into a substantially U-shape as in the case of the upper conductor segment 41, and forming the long leg portion 33, the short leg portion 34, and the connection portion 32. 3, a lower conductor segment 39 having two short legs 34 inserted into the outermost peripheral side of the lower slot 17, and It consists of a lower conductor segment (not shown) with two long legs 33 to be inserted. The outer surfaces of the lower conductor segments 31 and 39 are covered with an insulating coating 36.

  Similarly to the upper conductor segment 41, the distal end 35 of each of the long leg portion 33 and the short leg portion 34 has the outer dimensions smaller than those of the other portions because the insulating coating 36 is peeled off. A coupling member 50 is attached to each tip 35.

  As shown in FIG. 1, the long leg portion 43 and the short leg portion 44 of the upper conductor segment 41 are inserted into the upper slot 12 from the upper side, and are inserted into the lower slot 17 from the lower side as shown in FIG. The short legs 34 and the long legs 33 of the segments 31 and 39 are connected via a coupling member 50. Further, each of the connection portions 42 and 32 protrudes from the upper end surface 11A and the lower end surface 16B of the upper stator core 11 to form a coil end. Therefore, the lengths of the long leg portions 33, 43 and the short leg portions 34, 44 are such that the total length is substantially the same as the axial length of the upper slot 12 and the lower slot 17. The difference between the lengths of the long legs 33, 43 and the short legs 34, 44 is slightly shorter than the length of the coupling member 50.

  As shown in FIG. 8, the coupling member 50 is a quadrangular tubular member having a round corner at the corner of a conductive material such as copper. The outer surface is insulated and coated like the conductor segments 30 and 40. The inner diameter of the coupling member 50 is slightly smaller than the outer dimensions of the respective tips 35, 45 of the conductor segments 30, 40 from which the insulating coatings 36, 46 have been removed. For this reason, when each tip 35, 45 is inserted into the coupling member 50, the coupling member 50 fits into each tip. The outer dimensions of the coupling member 50 are substantially the same as the outer dimensions of the conductor segments 30, 40. For this reason, when the respective tips 35 and 45 are inserted into the coupling member 50, the outer surfaces of the coupling member 50 (the outer surfaces of the insulating coatings 36 and 46) and the legs 33, 34, 43 and 44 of the conductor segments 30 and 40. Is substantially flush with the outer surface.

<Manufacturing process of stator coil>
Hereinafter, the manufacturing process of the stator coil 20 of the embodiment will be described with reference to FIGS. 1 to 5 and FIGS.

  As shown in FIG. 1, a plurality of upper conductor segments 41 are inserted into the upper slots 12A and 12B from the upper end surface 11A side of the upper stator core 11 to assemble the upper conductor segment assembly 10 shown in FIG. As described above with reference to FIG. 6, the upper conductor segment 41 is formed by bending a covered conductive wire into a substantially U-shape, and includes a long leg 43, a short leg 44, and a connecting portion 42. The insulating coating 46 is peeled off from each end 45 of the long leg 43 and the short leg 44.

  The long legs 43 and the short legs 44 of the plurality of upper conductor segments 41 are inserted into the upper slots 12A and 12B so as to be alternately arranged in the radial direction. As shown in FIG. 9A, when the upper conductor segment 41 is inserted into the upper slots 12A and 12B, the long leg portion 43 of the upper conductor segment 41 has a front end 45 and a portion covered with the insulating coating 46 on the front end 45 side. 11 protrudes downward from the lower end surface 11B. Further, the tip 45 of the short leg portion 44 of the upper conductor segment 41 slightly protrudes downward from the lower end surface 11B of the upper stator core 11. As shown in FIG. 2, the connection part 42 forms an upper coil end.

  As shown in FIG. 3, a plurality of lower conductor segments 31, 39 are inserted into the lower slots 17A, 17B from the lower end face 16B side of the lower stator core 16 to assemble the lower conductor segment assembly 15 shown in FIG. . As described above with reference to FIG. 7, the lower conductor segment 31 is formed by bending a covered conductive wire into a substantially U-shape, and includes a long leg 33, a short leg 34, and a connecting portion 32. A coupling member 50 is attached to each end 35 of the long leg 33 and the short leg 34. The lower conductor segment 39 has two short legs 34.

  As shown in FIG. 3, the long legs 33 and the short legs 34 of the plurality of lower conductor segments 31 are inserted into the lower slots 17A and 17B so as to be alternately arranged in the radial direction. As shown in FIG. 9A, when the long leg portion 33 of the lower conductor segment 31 is inserted into the lower slots 17A and 17B, the coupling member 50 attached to the distal end 35 is moved from the upper end surface 16A of the lower stator core 16. It protrudes upward. The coupling member 50 attached to the distal end 35 of the short leg portion 34 of each of the lower conductor segments 31, 39 slightly protrudes upward from the upper end surface 16A of the lower stator core 16. As shown in FIG. 4, the connection part 32 forms a lower coil end.

  As shown in FIG. 9B, when the lower conductor segment 31 and the upper conductor segment 41 are inserted into the upper slot 12 and the lower slot 17, respectively, the radial position of the long leg 33 of the lower conductor segment 31 and the upper The radial positions of the short legs 44 of the conductor segments 41 are the same, and the radial positions of the short legs 34 of the lower conductor segments 31 and 39 are the same as the radial positions of the long legs 43 of the upper conductor segment 41. Become.

  Next, the upper conductor segment assembly 10 is set coaxially on the lower conductor segment assembly 15 shown in FIG. Then, as shown in FIG. 9A, each end 45 of the upper conductor segment 41 protruding from the lower end surface 11B of the upper stator core 11 is set to a set position facing the lower teeth 18 of the lower stator core 16 (position setting). Process).

  Then, the upper conductor segment assembly 10 is lowered toward the lower conductor segment assembly 15 until the tip 45 of the long leg 43 of the upper conductor segment 41 protruding from the lower end surface 11B is directly above the lower teeth 18 of the lower stator core 16. Let it. Then, as shown in FIG. 9A, the lower end of the insulating coating 46 of the long leg 43 of the upper conductor segment 41 and the upper end of the coupling member 50 attached to the long leg 33 of the lower conductor segment 31. Overlap in the axial direction. In this state, the long leg 43 of the upper conductor segment 41 and the coupling member 50 attached to the long leg 33 of the lower conductor segment 31 are separated from each other and do not interfere with each other.

  Next, as shown in FIG. 10A, the upper conductor segment assembly 10 is rotated leftward. Then, as shown in part E of FIG. 10B, the corner R of the side surface of the insulating coating 46 of the long leg 43 of the upper conductor segment 41 and the cup attached to the long leg 33 of the lower conductor segment 31. The corner R of the side surface of the ring member 50 comes into contact (rotation step).

  As shown in FIG. 11A, when the upper conductor segment assembly 10 is further rotated leftward, as shown in FIG. 11B, the insulating coating 46 of the long leg 43 of the upper conductor segment 41 becomes The coupling member 50 attached to the long leg 33 of the lower conductor segment 31 is moved in the radial direction. Accordingly, the long leg 43 of the upper conductor segment 41 moves in the radial direction, and the coupling member 50 attached to the tip 45 of the long leg 43 of the upper conductor segment 41 and the short leg 34 of the lower conductor segment 31. Is corrected. At the same time, the coupling member 50 attached to the long leg 33 of the lower conductor segment 31 moves in the radial direction, and the radius between the coupling member 50 and the tip 45 of the short leg 44 of the upper conductor segment 41 is changed. Directional misalignments are corrected.

  Then, as shown in FIG. 12A, the upper conductor segment assembly 10 is further rotated leftward to the connection position. In the connection position, as shown in FIG. 12B, the tip 45 of the long leg 43 of the upper conductor segment 41 and the coupling member 50 attached to the short leg 34 of the lower conductor segment 31 face each other, The coupling member 50 attached to the long leg 33 of the conductor segment 31 and the tip 45 of the short leg 44 of the upper conductor segment 41 face each other.

  In this state, the upper conductor segment assembly 10 is moved toward the lower conductor segment assembly 15. Then, the tips 45 of the long legs 43 of the upper conductor segment 41 are inserted into the plurality of coupling members 50 attached to the short legs 34 of the plurality of lower conductor segments 31. At the same time, the tips 45 of the short legs 44 of the plurality of upper conductor segments 41 are inserted into the plurality of coupling members 50 attached to the long legs 33 of the plurality of lower conductor segments 31.

  Thereby, the plurality of tips 45 of the plurality of upper conductor segments 41 and the plurality of coupling members 50 are connected together (connection step).

  Then, the stator coil 20 and the stator 100 as shown in FIG. 5 can be assembled.

  According to the method of manufacturing the stator coil 20 of the present embodiment described above, the corner R of the side surface of the insulating coating 46 of the long leg 43 of the upper conductor segment 41 is attached to the tip 35 of the long leg 33 of the lower conductor segment 31. The radius of the long leg 43 of the upper conductor segment 41 and the radius of the coupling member 50 attached to the long leg 33 of the lower conductor segment 31 by contacting the corner R of the coupling member 50. After correcting the displacement of the directional position, the upper conductor segment assembly 10 is moved toward the lower conductor segment assembly 15 so that the respective tips 45 of the upper conductor segments 40 are collectively attached to the respective coupling members 50 of the lower conductor segment 30. And insert.

  Next, a method for manufacturing the stator coil 20 of the comparative example will be described with reference to FIG. As shown in FIG. 13, in the method of manufacturing the stator coil 20 of the comparative example, the upper conductor segment assembly 10 is mounted without correcting the relative displacement of the upper conductor segment 40 and the lower conductor segment 30 in the radial direction. By moving toward the lower conductor segment assembly 15, the respective distal ends 45 of the long leg portions 43 and the short leg portions 44 of the upper conductor segment 40 are collectively inserted into the respective coupling members 50 of the lower conductor segment 30. For this reason, as shown in part F of FIG. 13, the lower end surface of each insulating coating of the upper conductor segment 40 interferes with the upper end surface of each coupling member 50, and each insulating coating of the upper conductor segment 40 is damaged. The coupling member 50 may be deformed.

  On the other hand, in the method of manufacturing the stator coil 20 according to the present embodiment, the deviation between the radial position of the long leg 43 of the upper conductor segment 41 and the radial position of the long leg 33 of the lower conductor segment 31 is corrected. Then, the upper conductor segment assembly 10 is moved toward the lower conductor segment assembly 15 to insert the respective tips 45 of the upper conductor segment 40 into the respective coupling members 50 of the lower conductor segment 30 in a lump. It is possible to prevent the lower end surface of each insulating coating of the segment 40 from interfering with the upper end surface of each coupling member 50, thereby damaging the insulating coating 46 of the upper conductor segment 40 and deforming the coupling member 50. . For this reason, poor connection between the upper conductor segment 40 and the lower conductor segment 30 can be reduced.

  In the method of manufacturing the stator coil 20 of the present embodiment, the corner R of the side surface of the insulating coating 46 of the long leg 43 of the upper conductor segment 41 is attached to the tip 35 of the long leg 33 of the lower conductor segment 31. The upper conductor segment 41 or the long leg portion 43 of the upper conductor segment 41 or the coupling member 50 can be smoothly moved in the radial direction because the corner portion R of the coupling member 50 is brought into contact. For this reason, the radial position of the long leg 43 of the upper conductor segment 41 and the coupling member 50 of the long leg 33 of the lower conductor segment 31 are maintained without damaging the insulating coating 46 or deforming the coupling member 50. Can be corrected. Thus, poor connection between the upper conductor segment 40 and the lower conductor segment 30 can be reduced.

  In the embodiment described above, in the rotating step, the upper conductor segment assembly 10 is described as being rotated leftward, but is not limited thereto, and may be rotated rightward. Further, instead of the upper conductor segment assembly 10, the lower conductor segment assembly 15 may be rotated. Further, not one of the upper conductor segment assembly 10 and the lower conductor segment assembly 15 but both of them may be rotated in opposite directions.

  In the connection step, the description has been made assuming that the upper conductor segment assembly 10 is moved toward the lower conductor segment assembly 15. However, the present invention is not limited to this, and the upper conductor segment assembly 10 and the lower conductor segment assembly 15 may be connected to each other. The lower conductor segment assembly 15 may be moved upward if it is moved so as to be close to the axial direction.

  Reference Signs List 10 upper conductor segment assembly, 11 upper stator core, 11A, 16A upper end surface, 11B, 16B lower end surface, 12, 12A, 12B upper slot, 13 upper teeth, 15 lower conductor segment assembly, 16 lower stator core, 17, 17A, 17B Lower slot, 18 Lower teeth, 20 Stator coil, 25 Stator core, 30, 31, 39 Lower conductor segment, 32, 42 Connection, 33, 43 Long leg, 34, 44 Short leg, 35, 45 Tip, 36 , 46 insulating coating, 40 upper conductor segment, 50 coupling member, 100 stator, 310, 410 rectangular wire.

Claims (1)

A first end of each of the first conductor segments of a first conductor segment assembly in which a plurality of first conductor segments are inserted into the first slots from one axial end of a first stator core having a plurality of first slots; ,
A second stator core having a plurality of second slots corresponding to the plurality of first slots of the first stator core and being axially combined with the first stator core to constitute a stator core; A method for manufacturing a stator coil, comprising: connecting a plurality of coupling members of a second conductor segment assembly in which a plurality of second conductor segments each having a coupling member attached to an end thereof are inserted;
The first end of the first conductor segment and the coupling member of the second conductor segment are displaced in the circumferential direction from the connection position where they face each other, and the first end is the second end of the second stator core. A position setting step of setting the first conductor segment assembly at a setting position facing a tooth between two slots;
A rotating step of rotating one or both of the first conductor segment assembly and the second conductor segment assembly to move the first conductor segment assembly from the set position to the connection position;
At the connection position, the first conductor segment assembly and the second conductor segment assembly are moved so as to be close to each other in the axial direction, and the first ends are collectively connected to the coupling members. Connection process,
A method for manufacturing a stator coil, comprising: