JP2020202611A - Manufacturing method for rotary electric machine - Google Patents

Abstract

To provide a manufacturing method for a rotary electric machine in which the number of components is reduced.SOLUTION: A manufacturing method for a rotary electric machine is for manufacturing a rotary electric machine that includes an annular stator core 6 in which a plurality of slots 15 are formed and that is formed so as to surround a center axis, a coil 5 that is mounted in the slots 15, a seal member that is formed on the stator core 6, and cooling jackets 6, 7 that are fixed to the stator core 6 with the seal member and that form a cooling passage in which a part of the coil 5 is disposed. The method includes the steps of: forming thermosetting resins 42, 43 on the stator core 6; covering a part of the coil 5 and bringing the cooling jackets 6, 7 into the thermosetting resins 42, 43; and curing the thermosetting resins 42, 43 by heat.SELECTED DRAWING: Figure 14

Description

The present disclosure relates to a method for manufacturing a rotary electric machine.

The rotary electric machine includes a stator formed in an annular shape and a rotor arranged in the stator. The stator includes a stator core formed in an annular shape and a coil mounted on the stator core.

The rotor is provided so as to rotate about the rotation center line. The stator core includes a first end surface and a second end surface arranged in the direction in which the rotation center line extends, and a slot extending in the direction in which the rotation center line extends is formed on the inner peripheral surface of the stator core.

The coil includes a portion located in the slot, a first coil end located on the first end face of the stator core, and a second coil end located on the second end face.

The rotary electric machine includes a first mold resin that covers the first coil end, a second mold resin that covers the second coil end, and a varnish that fixes the coil in the slot.

In the rotary electric machine configured as described above, an alternating current flows through the coil when the rotor is rotationally driven. When an alternating current flows through the coil, copper loss occurs in the coil and the coil becomes hot.

Therefore, various proposals have been made for rotary electric machines having a configuration for cooling the coil. For example, the rotary electric machine described in Japanese Patent Application Laid-Open No. 2012-085393 is arranged in a case, and a first cooling passage and a second cooling passage are formed between the case and the rotary electric machine.

The first coil end is arranged in the first cooling passage, and the second coil end is arranged in the second cooling passage. Then, the refrigerant flows through the first cooling passage and the second cooling passage, so that the first coil end and the second coil end are cooled.

Japanese Unexamined Patent Publication No. 2012-085393

In the rotary electric machine as described above, an O-ring is provided between the case and the stator core in order to ensure the sealing performance of the cooling passage. Further, a varnish for fixing the coil to the stator core is provided, and further, a mold resin covering the coil end is included.

As described above, the conventional rotary electric machine has a problem that the number of parts is large and the manufacturing cost is high.

The present disclosure has been made in view of the above problems, and an object of the present disclosure is to provide a method for manufacturing a rotary electric machine in which the number of parts is reduced.

In the method for manufacturing a rotary electric machine according to the present disclosure, a plurality of slots are formed, an annular stator core formed so as to surround the center line, a coil mounted in the slot, and a seal member formed on the stator core. A method of manufacturing a rotary electric machine, which is fixed to a stator core by a sealing member and includes a cooling jacket that forms a cooling passage in which a part of the coil is located, and is a process of mounting the stator core on the coil. It includes a step of forming a thermosetting resin on the stator core, a step of covering a part of the coil and bringing the cooling jacket into contact with the thermosetting resin, and a step of thermosetting the thermosetting resin.

According to the above-mentioned manufacturing method of the rotary electric machine, by curing the thermosetting resin, the cooling jacket can be fixed to the stator core and the coil can be fixed to the stator core, and the number of parts can be reduced.

According to the method for manufacturing a rotary electric machine according to the present disclosure, the number of parts can be reduced.

It is a schematic diagram which shows the vehicle 2 which mounted the rotary electric machine 1. It is sectional drawing which shows typically the stator 7. It is a perspective view which shows the stator 7 when viewed from the end face 25 side. It is a perspective view which shows the stator 7 when viewed from the end face 26 side. It is a perspective view which shows a part of the stator 7 schematically. It is an exploded perspective view which shows a part of a stator 7. It is sectional drawing which shows the insulator 33. It is an exploded perspective view which shows a part of a U-phase coil 21U. It is sectional drawing which shows the state in which the U-phase coil 21U is inserted into insulators 33, 34. It is a flow chart which shows the manufacturing flow of a rotary electric machine 1. The segment formation step S1 is schematically a schematic diagram. It is a development view which shows typically the core preparation process S2. It is a developed view which shows the sealing process S3. It is a developed view which shows typically the insertion process S4. It is a developed view which shows the connection process S5. It is a developed view which shows typically the coating process S6. It is sectional drawing which shows the mounting process S7. It is sectional drawing which shows the heat treatment step S8.

The rotary electric machine according to the present embodiment will be described with reference to FIGS. 1 to 18. Of the configurations shown in FIGS. 1 to 18, the same or substantially the same configuration is designated by the same reference numerals and duplicated description will be omitted. In addition, in the configuration shown in the embodiment, the configuration of the claim may be described together in parentheses for the configuration corresponding to the configuration described in the claim.

FIG. 1 is a schematic view showing a vehicle 2 on which a rotary electric machine 1 is mounted. The vehicle 2 includes a rotary electric machine 1, a transaxle case 3, a cooling device 4, and drive wheels 5.

The rotary electric machine 1 is housed in the transaxle case 3. The rotary electric machine 1 includes a rotor 6, a stator 7, and cooling jackets 8 and 9.

The stator 7 is formed in an annular shape, and the rotor 6 is inserted into the stator 7. The rotor 6 is rotatably provided about the rotation center line O1. The rotor 6 is fixed to the shaft 15, which is mechanically connected to the drive wheels 5. The cooling jackets 8 and 9 are provided on the stator 7.

The cooling device 4 includes a radiator 10, a fan 11, refrigerant pipes 12 and 13, and a pump 14, and the refrigerant C circulates in the cooling device 4. The refrigerant pipes 12 and 13 are connected to the radiator 10 and the cooling jackets 8 and 9.

The fan 11 blows outside air onto the radiator 10 to cool the refrigerant C flowing in the radiator 10. The refrigerant C cooled in the radiator 10 passes through the refrigerant pipe 12 and is supplied to the cooling jackets 8 and 9 to cool the rotary electric machine 1. The refrigerant C that has cooled the rotary electric machine 1 returns to the radiator 10 through the refrigerant pipe 13.

FIG. 2 is a cross-sectional view schematically showing the stator 7. The stator 7 includes a stator core 20, a coil 21, a plurality of insulators 33, 34, and adhesives 35, 36.

The stator core 20 is formed by laminating a plurality of electromagnetic steel plates in a direction in which the rotation center line O1 extends. The stator core 20 includes a yoke portion 22 extending in an annular shape and a plurality of teeth 23. The teeth 23 are formed so as to project from the inner peripheral surface of the yoke portion 22, and the plurality of teeth 23 are formed at intervals in the circumferential direction. Slots 24 are formed between the teeth 23.

The stator core 20 includes an end face 25 and an end face 26 arranged in a direction in which the rotation center line O1 extends.

The plurality of insulators 33 are provided at intervals on the end face 25, and the adhesive 35 is formed on the surface and the end face 25 of the insulator 33. The plurality of insulators 34 are provided at intervals on the end faces 26, and the adhesive 36 is formed on the surface and the end faces 26 of the insulator 34.

The cooling jacket 8 is provided on the end face 25 side, and the cooling jacket 9 is provided on the end face 26 side. The cooling jacket 8 and the cooling jacket 9 are formed in an annular shape.

The cooling jacket 8 includes an outer peripheral wall 30, an inner peripheral wall 31, and an end plate 32, and the cooling jacket 8 is formed so as to open toward the end surface 25. An opening of the cooling jacket 8 is formed by the side portion of the outer peripheral wall 30 and the side portion of the inner peripheral wall 31. The side portions of the inner peripheral wall 31 and the end plate 32 are in contact with the adhesive 35, and the cooling jacket 8 is fixed to the stator core 20.

Since the cooling jacket 8 is fixed in this way, a cooling passage 40 through which the refrigerant C flows is formed between the cooling jacket 8 and the end face 25.

A refrigerant pipe 12 and a refrigerant pipe 13 are connected to the outer peripheral wall 30. Then, the refrigerant C is supplied from the refrigerant pipe 12 into the cooling passage 40, and the refrigerant C passing through the cooling passage 40 is discharged from the refrigerant pipe 13.

The cooling jacket 9 includes an inner peripheral wall 37, an outer peripheral wall 38, and an end plate 39, and the cooling jacket 9 is formed so as to open toward the end surface 26.

The opening of the cooling jacket 9 is formed by the side portions of the inner peripheral wall 37 and the outer peripheral wall 38, and the side portions of the inner peripheral wall 37 and the outer peripheral wall 38 are in contact with the adhesive 36. The cooling jacket 9 is fixed to the stator core 20 by the adhesive 36.

A cooling passage 41 through which the refrigerant C flows is formed between the cooling jacket 9 and the end surface 26. A refrigerant pipe 12 and a refrigerant pipe 13 are connected to the outer peripheral wall 38. Then, the refrigerant C is supplied from the refrigerant pipe 12 to the cooling passage 41, and the refrigerant C that has passed through the cooling passage 41 is discharged from the refrigerant pipe 13.

FIG. 3 is a perspective view showing the stator 7 when viewed from the end face 25 side, and FIG. 4 is a perspective view showing the stator 7 when viewed from the end face 26 side. The coil 21 includes a U-phase coil 21U, a V-phase coil 21V, and a W-phase coil 21W.

FIG. 5 is a perspective view schematically showing a part of the stator 7, and FIG. 6 is an exploded perspective view showing a part of the stator 7. Note that the coil 21 is not shown in FIG. The slots 24 are formed between the teeth 23. The insulator 33 is arranged so as to straddle the insulators 33 adjacent to each other in the circumferential direction, and the insulator 34 is also arranged to straddle the insulators 34 adjacent to each other in the circumferential direction.

The insulator 34 is formed so as to be substantially the same as the insulator 33. The insulator 33 includes a plate portion 45 and legs 46 and 47. The plate portion 45 is formed so as to extend in the radial direction of the stator 7, and the plate portion 45 includes main surfaces 50 and 51. The main surface 51 is arranged on the end surface 25, and the main surface 50 is located on the opposite side of the main surface 51.

A plurality of through holes 49 are formed in the plate portion 45 at intervals in the radial direction of the stator 7, and each through hole 49 is formed so as to reach the main surface 51 from the main surface 50.

The legs 46 and 47 are formed on the main surface 51. The legs 46 and 47 are formed so as to extend in the radial direction of the stator 7, and the legs 46 and 47 are formed so as to project from the main surface 51 toward the end surface 26. The legs 46 and 47 are in the slot 24, and the legs 46 and 47 are in contact with the teeth 23. The plurality of through holes 49 are located between the legs 46 and the legs 47.

The insulator 34 is formed in the same manner as the insulator 33. The insulator 34 includes a plate portion 52 and legs 53 and 54, and a plurality of through holes 55 are formed in the plate portion 52. Then, the legs 53 and 54 are inserted into the slot 24.

FIG. 7 is a cross-sectional view showing the insulator 33. As shown in FIG. 7, the inner surface of the through hole 49 is formed so as to bulge inward toward the center in the thickness direction of the insulator 33. Specifically, the inner surface of the through hole 49 includes an inner side surface 56 and an inner side surface 57, and the inner side surface 56 and the inner side surface 57 are formed so as to face each other.

The inner side surface 56 and the inner side surface 57 are curved so as to approach each other toward the center of the insulator 33 in the thickness direction. Although the shape of the through hole 49 formed in the insulator 33 has been described, the through hole formed in the insulator 34 is also formed in the same manner as the through hole 49.

Returning to FIG. 5, the U-phase coil 21U, the V-phase coil 21V, and the W-phase coil 21W extend, for example, in the circumferential direction on the end face 25, and then are inserted into the through hole 49 formed in the insulator 33. Will be done. Then, each coil passes through the slot 24 and through the through hole formed in the insulator 34.

Each coil is formed so as to extend in the circumferential direction through the through hole formed in the insulator 34.

FIG. 8 is an exploded perspective view showing a part of the U-phase coil 21U. Here, the U-phase coil 21U is formed by connecting a plurality of segment coils 59. Specifically, the U-phase coil 21U is formed by welding the ends of the segment coils 59 to each other. The segment coil 59 includes a lead wire 60 formed of copper or the like, and an insulating member 61 formed so as to cover a part of the lead wire 60.

The lead wire 60 of the segment coil 59 includes a crossover wire 62 and an insertion portion 63. The crossover line 62 is arranged on the end face 25 or the end face 26, and the insertion portion 63 is inserted into the slot 24. The insulating member 61 is formed so as to cover the insertion portion 63. The insulating member 61 ensures electrical insulation between the lead wire 60 and the stator core 20 in the slot 24.

The crossover lines 62 are arranged at intervals from the end faces 25 and 26. A welded end 65 is formed at the end of the crossover line 62, and a welded end 66 is also formed at the end of the insertion portion 63. The U-phase coil 21U is formed by connecting a plurality of segment coils 59. For example, the welded end 65 of the segment coil 59A and the welded end 66 of the segment coil 59B are welded. Further, the welded end 65 of the segment coil 59B and the welded end 66 of the segment coil 59C are welded. Although the U-phase coil 21U has been described, the V-phase coil 21V and the W-phase coil 21W are also configured in the same manner as the U-phase coil 21U.

FIG. 9 is a cross-sectional view showing a state in which the U-phase coil 21U is inserted into the insulators 33 and 34. As shown in FIG. 9, the insertion portion 63 of the U-phase coil 21U is inserted into the through hole 49 of the insulator 33.

Here, a gap is formed between the inner surface of the teeth 23 and the insulating member 61, and a gap is also formed between the insertion portion 63 and the teeth 23. Therefore, the insertion portion 63 and the teeth 23 are electrically insulated.

Further, the insulator 33 and the insulator 34 are fixed to the stator core 20, and the insertion portion 63 is fixed by the insulator 33 and the insulator 34 at intervals in the extending direction of the rotation center line O1.

As described above, the U-phase coil 21U is fixed to the stator core 20 by the insulator 33 and the insulator 34, and the insulation property with the stator core 20 is ensured.

The adhesive 35 is formed over the surface of the insulator 33, the end surface 25, and the surface of the U-phase coil 21U, and the insulator 33 and the U-phase coil 21U are fixed to the stator core 20. Similarly, the adhesive 36 is formed over the surface of the insulator 34, the end surface 26, and the surface of the U-phase coil 21U, and the insulator 34 and the U-phase coil 21U are fixed to the stator core 20. The cooling jackets 8 and 9 are also fixed to the end faces 25 and 26 of the stator core 20 by the adhesives 35 and 36.

The insulating member 61 protrudes from the insulators 33 and 34. The inner peripheral surface of the through hole 49 of the insulator 33 is in close contact with the insulating member 61. Then, the adhesive 35 is applied to the surface of the insulating member 61, and the gap between the through hole 49 of the insulator 33 and the insulating member 61 is closed.

The inner peripheral surface of the through hole of the insulator 34 is also in close contact with the insulating member 61, and the adhesive 36 is formed on the surface of the insulator 34. The gap between the inner peripheral surface of the through hole of the insulator 34 and the insulating member 61 is closed by the adhesive 36.

Returning to FIG. 2, the opening of the slot 24 located on the end face 25 side is closed by the insulator 33, and the opening of the slot 24 located on the end face 26 side is closed by the insulator 34.

Therefore, even if the refrigerant C flows through the cooling passage 40 and the cooling passage 41, the leakage of the refrigerant C from the slot 24 is suppressed.

The crossover 62 of the U-phase coil 21U and the crossover of the V-phase coil 21V and the W-phase coil 21W are located on the end face 25 side, and each crossover is located in the cooling passage 40. As the refrigerant C flows through the cooling passage 40, each crossover is cooled. The crossover 64 of the U-phase coil 21U and the crossover of the V-phase coil 21V and the W-phase coil 21W are located on the end face 26 side, and each crossover is located in the cooling passage 41. As the refrigerant C flows through the cooling passage 41, each crossover is cooled.

The manufacturing method of the rotary electric machine 1 configured as described above will be described. FIG. 10 is a flow chart showing a manufacturing flow of the rotary electric machine 1. The manufacturing method of the rotary electric machine 1 includes a segment forming step S1, a core preparation step S2, a sealing step S3, an inserting step S4, a connecting step S5, a coating step S6, a mounting step S7, and a heat treatment step S8. including.

FIG. 11 is a schematic diagram of the segment forming step S1. The segment forming step S1 includes a preparation step S10, a forging step S11, a forming step S12, and a forming step S13.

The preparation step S10 is a step of preparing the columnar wire 70. The wire 70 is made of copper, and no insulating coating or the like is formed on the surface of the wire 70. In the forging step S11, the wire 70 is forged to form a square forged wire 71.

The molding step S12 is a step of forging the forged wire 71 to form an L-shaped segment coil 59. The forming step S13 is a step of forming the insulating member 61 in the insertion portion 63 of the segment coil 59.

FIG. 12 is a development view schematically showing the core preparation step S2. FIG. 12 shows a developed view of the inner peripheral surface of the stator core.

FIG. 13 is a developed view showing the sealing step S3. The sealing step S3 includes a step of arranging a plurality of insulators 33 on the end face 25 and a step of arranging a plurality of insulators 34 on the end face 26.

Here, the insulator 33 is provided so as to close the opening of the slot 24 on the end face 25 side, and further, the insulator 34 is provided so as to close the opening of the slot 24 on the end face 26 side.

FIG. 14 is a developed view schematically showing the insertion step S4. The insertion step S4 is a step of inserting the insertion portion 63 of the segment coil 59 into the slot 24. Note that FIG. 14 illustrates a state in which two segment coils 59 are inserted by way of example. In this way, the segment coil 59 can be temporarily fixed by inserting the segment coil 59 into the through hole 49 of the insulator 33 and the through hole of the insulator 34.

FIG. 15 is a developed view showing the connection step S5. The connection step S5 is a step of welding the welded ends 66 and the welded ends 65 of the plurality of segment coils 59 to each other. As a result, the plurality of segment coils 59 are electrically connected to form, for example, the U-phase coil 21U. Similarly, a V-phase coil 21V and a W-phase coil 21W are also formed.

As described above, since the insulators 33 and 34 can hold the plurality of segment coils 59 also in the connection step S5, each segment coil 59 is not fixed with an adhesive or the like. 59 can be connected by welding.

FIG. 16 is a development view schematically showing the coating process S6. The coating step S6 includes a step of forming the thermosetting resin 72 on the end face 25 and a step of forming the thermosetting resin 73 on the end face 26.

The thermosetting resins 72 and 73 are formed of, for example, a resin such as FIPG (Formed In Place Gasket). The thermosetting resin 72 is formed so as to cover the end face 25 of the stator core 20, the surface of the insulator 33, and a part of a coil such as the U-phase coil 21U. Similarly, the thermosetting resin 73 is formed so as to cover the end surface 26 of the stator core 20, the surface of the insulator 34, and a part of the coil such as the U-phase coil 21U.

FIG. 17 is a cross-sectional perspective view showing the mounting step S7. The mounting step S7 includes a step of arranging the cooling jacket 8 on the end surface 25 of the stator core 20 and a step of arranging the cooling jacket 9 on the end surface 26. At this time, the opening edge of the cooling jacket 8 is in close contact with the thermosetting resin 72, and the opening edge of the cooling jacket 9 is in close contact with the thermosetting resin 73.

FIG. 18 is a cross-sectional perspective view showing the heat treatment step S8. In this heat treatment step S8, the thermosetting resin 72 and the thermosetting resin 73 are heat-treated. The thermosetting resin 72 is thermosetting to become the adhesive 35, and the thermosetting resin 73 is thermosetting to become the adhesive 36. As a result, the cooling jacket 8 is fixed to the end face 25, and the coil such as the U-phase coil 21U and the insulator 33 are integrally fixed to the end face 25 of the stator core 20. Similarly, the cooling jacket 9 is fixed to the end face 26, and the coil such as the U-phase coil 21U and the insulator 34 are integrally fixed to the end face 26 of the stator core 20.

As described above, according to the manufacturing method of the rotary electric machine 1 according to the present embodiment, the cooling jackets 9 and 8 are fixed, the coil such as the U-phase coil 21U, and the insulators 33 and 34 are collectively heat-treated. In step S8, it can be fixed to the stator core 20.

For example, in the conventional manufacturing method for a rotary electric machine, the step of fixing the coil and the step of fixing the cooling jacket are different steps. Specifically, when fixing the coil, the varnish was filled in the slot, and the varnish was heat-treated to be thermoset. Further, when fixing the cooling jacket, it is necessary to form an adhesive and perform heat treatment in a state where the cooling jacket is in contact with the adhesive.

As described above, according to the manufacturing method according to the present embodiment, the number of steps can be reduced, the manufacturing cost can be reduced, and the manufacturing time can be shortened as compared with the conventional manufacturing method. Further, as compared with the case where the insulators 33 and 34 and the coil such as the U-phase coil 21U are integrally fixed to the stator core 20 by the adhesives 35 and 36, and each member is separately fixed to the stator core 20. The number of parts can be reduced.

It should be considered that the embodiments disclosed this time are exemplary in all respects and not restrictive. The scope of the present invention is indicated by the claims and is intended to include all modifications within the meaning and scope equivalent to the claims.

1 rotary electric machine, 2 vehicle, 3 transformer axle case, 4 cooling device, 5 drive wheel, 6 rotor, 7 stator, 8, 9 cooling jacket, 10 radiator, 11 fan, 12, 13 refrigerant pipe, 14 pump, 15 shaft, 20 stator core, 21,21U, 21V, 21W coil, 22 yoke part, 23 teeth, 24 slots, 25,26 end face, 30,38 outer wall, 31,37 inner wall, 32,39 end plate, 33,34 insulator, 35,36 adhesive, 40,41 cooling passage, 45,52 plate part, 46,47,53,54 legs, 49,55 through hole, 50,51 main surface, 56,57 inner surface, 59,59A, 59B , 59C segment coil, 60 lead wire, 61 insulation member, 62,64 cross wire, 63 insertion part, 65,66 welded end, 70 wire, 71 forged wire, 72,73 sealant, C refrigerant, O1 rotation center line , S1 segment formation process, S2 core preparation process, S3 sealing process, S4 insertion process, S5 connection process, S6 coating process, S7 mounting process, S8 heat treatment process, S10 preparation process, S11 forging process, S12 molding process, S13 formation. Process.

Claims (1)

An annular stator core formed so as to surround the center line as well as a plurality of slots.
With the coil installed in the slot
The seal member formed on the stator core and
A cooling jacket that is fixed to the stator core by the seal member and forms a cooling passage in which a part of the coil is located inside.
It is a manufacturing method of a rotary electric machine equipped with
The process of mounting the stator core on the coil and
The process of forming a thermosetting resin on the stator core and
A step of covering a part of the coil and bringing the cooling jacket into contact with the thermosetting resin.
The step of thermosetting the thermosetting resin and
A method of manufacturing a rotary electric machine.