JP2020089098A - Stator manufacturing method - Google Patents

Abstract

To sufficiently protect a weld between the end of a lead wire and the end of a power line.SOLUTION: A stator manufacturing method includes a first step of injecting a thermosetting resin into a cap in which a porous sponge-like porous member having a hollow portion and a notch formed in the inner surface of the hollow portion is disposed inside, a second step of inserting a weld between the end of a lead wire and the end of a power line in the hollow portion of the porous member of the cap filled with thermosetting resin, and a third step of heating the thermosetting resin by heating with the weld inserted in the hollow portion.SELECTED DRAWING: Figure 13

Description

The present invention relates to a stator manufacturing method, and more particularly, to a stator manufacturing method including a stator core, a stator coil, and a power line.

Conventionally, as a method of manufacturing this type of stator, a method of manufacturing a stator including a stator core (stator core) and a stator coil (stator coil) has been proposed (see, for example, Patent Document 1). The stator coil is wound around a stator core and is configured by connecting the tips of two U-shaped rectangular conductor wires. In this manufacturing method, a cap is attached to the connection between the tips of the two rectangular conductors. This cap is formed of a prepreg sheet obtained by impregnating an inner layer and an outer layer out of three layers of an inner layer, an intermediate layer, and an outer layer with a thermosetting resin to make a semi-cured state. It is formed into a box by mounting it in a mold and curing it by heating. By mounting the cap thus formed on the connection portion and filling the gap between the connection portion and the cap with the resin, the resin is prevented from flowing out of the cap by the inner layer and the outer layer.

JP-A-2000-4553

By the way, in a stator including a stator coil having a lead wire that is drawn to the outside of the stator core, and a power line in which the lead wire and the ends are welded to each other, when the welded part between the ends has low strength against vibration. There is. As a method of increasing the strength of the welded portion, a method of covering the welded portion with the above-mentioned box-shaped cap and filling the gap between the connection portion and the cap with resin such as resin may be considered. However, when the resin is filled in the gap between the connection portion and the cap to fill the gap, it may not be possible to sufficiently fill the gap. In this case, the cap may not be able to sufficiently fix the welded part, and the welded part may not be sufficiently protected from vibration during use of the stator (during operation of the motor incorporating the stator).

The stator manufacturing method of the present invention mainly aims to sufficiently protect the welded portion between the end portion of the lead wire and the end portion of the power line.

The stator manufacturing method of the present invention employs the following means in order to achieve the main object described above.

The stator manufacturing method of the present invention is
A method of manufacturing a stator, comprising: a stator core; a stator coil having a lead wire that is drawn to the outside of the stator core; the stator coil being wound around the stator core; and a power line in which the lead wire and end portions are welded to each other. hand,
A first step of injecting a thermosetting resin into a cap having a porous sponge-like porous member having a hollow portion and a notch formed in the inner surface of the hollow portion, and
A second step of inserting a welded portion of the end portion of the lead wire and the end portion of the power line into the hollow portion of the porous member of the cap into which the thermosetting resin is injected;
A third step of heating the thermosetting resin by heating with the welding portion inserted in the hollow portion;
The main point is to provide.

In this method for manufacturing a stator of the present invention, a thermosetting resin is injected into a cap in which a porous sponge-like porous member having a hollow portion and having a notch formed in the inner surface of the hollow portion is arranged inside. .. The injected thermosetting resin spreads throughout the porous member due to the capillary phenomenon. Then, the welded portion between the end of the lead wire and the end of the power line is inserted into the hollow portion of the cap into which the thermosetting resin has been injected. Since the notch is formed on the inner surface of the hollow portion, when the welded portion is inserted into the hollow portion, the inner surface is deformed by the notch, and the welded portion can be easily inserted into the porous member. Then, the thermosetting resin is cured by heating with the welded portion inserted in the hollow portion. Thereby, the welded portion can be sufficiently fixed with the thermosetting resin. As a result, the welded portion can be sufficiently protected.

In such a stator manufacturing method of the present invention, the height of the porous member in the axial direction of the stator core is formed to be higher than an upper limit of a predetermined range that is a height range that the welded portion can take. You may. In this way, even if the axial height of the weld relative to the stator core fluctuates, it is possible to cover the weld from the tip to a sufficient height with the thermosetting resin, and the weld is sufficient with the thermosetting resin. Can be fixed to. Thereby, the welded portion can be sufficiently protected.

It is a side view which shows the outline of the external appearance which looked at the stator 10 manufactured by the manufacturing method as one Example of this invention from the side surface. FIG. 2 is a top view showing an outline of an external appearance of the stator 10 when viewed from the upper side of FIG. 1. FIG. 3 is a perspective view showing an outline of an external appearance of the stator 10 when viewed from an angle. It is explanatory drawing for demonstrating the welding part WL of the leader line 16u and the power line 18u. It is a top view which shows the outline of the external appearance which looked at the cap 20 from the upper direction in FIG. It is a bottom view which shows the outline of the external appearance which looked at the cap 20 from the downward direction in FIG. It is a side view which shows the outline of the external appearance which looked at the cap 20 from the downward direction of FIG. It is a side view which shows the outline of the external appearance which looked at the cap 20 from the right direction of FIG. It is a top view which shows the outline of the external appearance which looked at the cap 30 from the upper direction in FIG. It is a bottom view which shows the outline of the external appearance which looked at the cap 30 from the downward direction in FIG. It is a side view which shows the outline of the external appearance which looked at the cap 30 from the downward direction of FIG. It is a side view which shows the outline of the external appearance which looked at the cap 30 from the right direction of FIG. It is a flow chart which shows an example of a cap attaching process. FIG. 4 is a bottom view for explaining the outline of the state of the cap 20 to which the porous member 40 is attached. It is sectional drawing which shows the outline of the cross section in AA ahead of FIG. It is an explanatory view showing a state in which a thermosetting resin is injected into the porous member 40. It is explanatory drawing which shows a mode that the welding part WL of the leader lines 16u-16w and the power lines 18u-18w is inserted in each porous member 40.

Next, modes for carrying out the present invention will be described using examples.

FIG. 1 is a side view schematically showing the outer appearance of a stator 10 manufactured by a manufacturing method according to an embodiment of the present invention, as viewed from the side. FIG. 2 is a top view showing the outline of the external appearance of the stator 10 as viewed from above in FIG. FIG. 3 is a perspective view showing the outline of the outer appearance of the stator 10 when viewed from an angle. In FIG. 3, the caps 20 and 30 are omitted for the sake of explanation. FIG. 4 is an explanatory diagram for explaining a welded portion WL between the lead wire 16u and the power line 18u. FIG. 5 is a top view showing the outline of the appearance of the cap 20 as viewed from above in FIG. 1. FIG. 6 is a bottom view showing the outline of the outer appearance of the cap 20 as seen from the lower side in FIG. 1. FIG. 7 is a side view schematically showing the outer appearance of the cap 20 as viewed from the lower side of FIG. FIG. 8 is a side view schematically showing the appearance of the cap 20 as viewed from the right side of FIG. FIG. 9 is a top view showing the outline of the outer appearance of the cap 30 as viewed from above in FIG. 1. FIG. 10 is a bottom view showing the outline of the outer appearance of the cap 30 as viewed from below in FIG. 1. FIG. 11 is a side view showing the outline of the outer appearance of the cap 30 as viewed from the lower side of FIG. 9. FIG. 12 is a side view showing the outline of the outer appearance of the cap 30 as viewed from the right side of FIG. 9.

The stator 10 is combined with a rotor (not shown) to form a three-phase AC generator/motor, and is used, for example, as a motor/generator for running electric vehicles and hybrid vehicles. As shown in FIGS. 1 and 2, the stator 10 includes a stator core 12, a three-phase (U-phase, V-phase, W-phase) stator coil 14, and caps 20 and 30.

As shown in FIG. 3, the stator core 12 is configured by laminating a plurality of non-oriented electrical steel sheets formed into an annular shape by, for example, press working. The stator core 12 includes a plurality of teeth T protruding inward in the radial direction at intervals in the circumferential direction, and a plurality of core slots Cs (not shown) formed between the teeth T adjacent to each other.

The three-phase stator coil 14 is formed by a flat conductor wire covered with an insulating film, and as shown in FIGS. 1 to 3, two coil ends 14a and 14b are formed from the upper and lower end surfaces of the stator core 12 in the axial direction of FIG. Are wound around the plurality of teeth T of the stator core 12 by concentrated winding or distributed winding so as to project outward. From the coil end 14a, three lead wires 16u to 16w, which are the end portions of each of the three-phase stator coils, are drawn to the outside of the stator core 12 and are bent upward in FIGS. 1 and 3. As for the lead wires 16u to 16w, as shown in FIG. 4, the insulating film at the tip end Epd is peeled off to expose the rectangular conductor. The ends Epd of the lead lines 16u to 16w are welded to the ends Epp of the power lines 18u to 18w by laser welding outside the stator core 12. The ends of the power lines 18u to 18w opposite to the ends Epp are connected to the stator terminals 19u to 19w. The coil end 14b is coated with a resin coat.

As shown in FIGS. 5 to 12, the caps 20 and 30 are formed of resin in a box shape as a whole, and are formed so that the substantially cylindrical receiving portions 22 a, 22 b and 32 stand upright from the bottom surface B. There is. The cap 20 covers the welded portion WL between the tip end Epd of the lead wires 16v and 16u and the end portion Epp of the power lines 18u and 18v from above in the bottom view of FIG. 1 and the tip portion Epd of the lead wires 16u and 16v. The power lines 18u and 18v are fixed to the welded portion WL with the ends Epp. The cap 30 covers the welded portion WL between the tip end Epd of the lead wire 16w and the end portion Epp of the power line 18w from above in FIG. 1, and the tip portion Epd of the lead wire 16w and the end portion Epp of the power line 18w are covered. It is fixed to the welded part WL.

Here, a cap attaching step of attaching the caps 20 and 30 to each welding portion WL, which is a part of the manufacturing process of the stator 10, will be described. FIG. 13 is a flowchart showing an example of the cap attaching process. In the cap attaching step, first, the step of attaching the porous member 40 to the receiving portions 22a, 22b, 32 of the caps 20, 30 is executed (step S100). FIG. 14 is a bottom view for explaining the outline of the state of the cap 20 to which the porous member 40 is attached. FIG. 15 is a cross-sectional view showing an outline of a cross section taken along the line AA in FIG. The porous member 40 is formed of a porous sponge-like material (for example, sponge) into a cylindrical shape as a whole. The porous member 40 includes a hollow portion 42, and the depth of the inner surface of the hollow portion 42 from the inner surface of the hollow portion 42 in the radial direction of the porous member 40 extends from the upper surface to the lower surface in FIG. 15 of the porous member 40. A plurality of notches C of dc are formed. The hollow portion 42 is formed with an inner diameter Ri into which the welded portion WL can be inserted while sliding on the inner surface of the hollow portion 42. A height h of the porous member 40 in the axial direction of the stator core 12 is higher than an upper limit hmax of a predetermined range obtained by an experiment or an analysis as a range of a height that the welded portion WL can take, and a hollow portion 42 is formed in the hollow portion 42 as described later. The caps 20 and 30 are formed to have a height that does not interfere with peripheral members when the welded portion WL is inserted.

Then, a thermosetting resin (for example, resin) is injected into the porous member 40 from the nozzle Nz of the resin injection device (step S110). FIG. 16 is an explanatory diagram showing a state where the thermosetting resin is injected into the porous member 40. As shown, the caps 20 and 30 are arranged so that the openings of the receiving portions 22a, 22b, and 32 face upward. Then, the thermosetting resin is injected from above so as to fill the porous member 40 and the caps 20 and 30. At this time, the entire porous member 40 is filled with the thermosetting resin due to the capillary phenomenon.

When the thermosetting resin is injected in this manner, the stator core 12 is moved by a predetermined amount in a state where the welded portions WL of the lead wires 16u to 16w and the power lines 18u to 18w are in the downward direction (the stator core 12 is upside down in FIG. 3). The welded portions WL of the leader lines 16u to 16w and the power lines 18u to 18w are inserted into the hollow portions 42 of each porous member 40 while moving downward by hd (step S120), and the thermosetting resin is heated. After curing (step S130), this process is completed. FIG. 17 is an explanatory diagram showing how the welded portions WL of the lead lines 16u to 16w and the power lines 18u to 18w are inserted into each porous member 40. In step S120, the predetermined amount hd is capped at the tip of each welded portion WL even if there are variations in the axial height of the stator core 12 of each welded portion WL between the lead wires 16u to 16w and the power lines 18u to 18w. As a movement amount that does not abut the bottom surface B of 20, 30 and is deep enough to fix each welded portion WL and that can be inserted into the hollow portion 42, as a value determined in advance by experiments or analysis. There is. In step S120, since the plurality of cuts C are formed on the inner surface of the hollow portion 42, the inner surface is deformed by the plurality of cuts C when the welding portion WL is inserted into the hollow portion 42, and the welded portion WL is easily perforated. It can be inserted into the quality member 40. Then, in step S130, the caps 20 and 30 and the porous member 40 are heated in a state where the thermosetting resin is spread to cure the thermosetting resin, so that the tip of the welded portion WL (the lower end in FIG. 17) is sufficient. The height can be covered with a thermosetting resin, and the welded portion WL can be sufficiently fixed to the caps 20 and 30 with a thermosetting resin. Thereby, the welded portion WL can be sufficiently protected.

According to the method for manufacturing the stator 10 of the embodiment described above, the cap in which the porous sponge-like porous member 40 having the hollow portion 42 and having the notch C formed in the inner surface of the hollow portion 42 is arranged inside A thermosetting resin is injected into the insides of 20, 30 and the welding portion WL is inserted into the hollow portion 42 of the porous member 40 of the caps 20 and 30 into which the thermosetting resin is injected, and the welding portion WL is inserted into the hollow portion 42. The welding portion WL can be sufficiently protected by heating in the inserted state to cure the thermosetting resin.

In the method of manufacturing the stator 10 of the embodiment, the height h of the porous member 40 is set higher than the upper limit hmax. However, the height h of the porous member 40 may be lower than the upper limit hmax.

In the method of manufacturing the stator 10 according to the embodiment, the depth dc is formed on the inner surface of the hollow portion 42 from the inner surface of the hollow portion 42 in the radial direction of the porous member 40 from the upper surface to the lower surface in FIG. A plurality of notches C are formed. However, the notch C formed in the inner surface of the hollow portion 42 may be formed to a predetermined depth higher than the upper surface to the lower surface in FIG. Further, the notch C does not necessarily have to be formed in plural, and may be formed in one.

Correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problem will be described. In the embodiment, the step S100 corresponds to the "first step", the step S110 corresponds to the "second step", and the step S120 corresponds to the "third step".

The correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problem is the same as that of the embodiment described in the section of means for solving the problem. This is an example for specifically explaining the mode for carrying out the invention, and does not limit the elements of the invention described in the column of means for solving the problem. That is, the interpretation of the invention described in the column of means for solving the problem should be made based on the description in that column, and the embodiment is the invention of the invention described in the column of means for solving the problem. This is just a specific example.

Although the embodiments for carrying out the present invention have been described above with reference to the embodiments, the present invention is not limited to these embodiments, and various embodiments are possible within the scope not departing from the gist of the present invention. Of course, it can be implemented.

INDUSTRIAL APPLICABILITY The present invention can be used in the stator manufacturing industry and the like.

10 stator, 12 stator core, 14 stator coil, 14a, 14b coil end, 16u-16w lead wire, 18u-18w power line, 19u-19w stator terminal, 20,30 cap, 22a, 22b, 32 receiving part, 40 porous Member, 42 Hollow part, B bottom face, C notch, Cs core slot, Epd, Epp end part, T tooth, WL weld part.

Claims (1)

A method of manufacturing a stator, comprising: a stator core; a stator coil having a lead wire that is drawn to the outside of the stator core; the stator coil being wound around the stator core; and a power line in which the lead wire and end portions are welded to each other. hand,
A first step of injecting a thermosetting resin into a cap having a porous sponge-like porous member having a hollow portion and a notch formed in the inner surface of the hollow portion, and
A second step of inserting a welded portion of the end portion of the lead wire and the end portion of the power line into the hollow portion of the porous member of the cap into which the thermosetting resin is injected;
A third step of heating the thermosetting resin by heating with the welding portion inserted in the hollow portion;
And a method for manufacturing a stator.