JP3226170B2 - Method for manufacturing windings of rotating electric machine - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a winding of a rotating electric machine.

[0002]

2. Description of the Related Art WO92 / 06527 (PCT / DE9)
No. 1/00738) discloses that a large number of generally U-shaped or substantially I-shaped (linear) conductor segments are inserted into each slot of the stator core from one end surface side of the core, and these conductor segments protrude toward the other end surface side of the core. Are welded to form a stator coil.

More specifically, a pair of straight portions of a U-shaped conductor segment are individually inserted into, for example, two slots separated by an electrical angle of π, and a large number of I-shaped conductor segments are connected in cascade. It is used to pull the straight portion of the first or last conductor segment of the conductor segment back to one end of the core again through another slot.

[0004]

However, the above U
Since the pair of straight portions individually inserted into different slots in the U-shaped conductor segment can strongly grip the slot by elastic deformation of the curved portion of the U-shaped conductor segment,
It is stably held in the slot of the core, and as a result, it is easy to stably hold the U-shaped conductor segment required in the subsequent shaping and joining process, whereas the I-shaped conductor segment is It is not possible to obtain a slot gripping force like a U-shaped conductor segment, and therefore, there is some special device to stably maintain the position and posture of the I-shaped conductor segment in the subsequent shaping and welding process. It was found that it had a disadvantage that it was necessary.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described problems, and when a large number of conductor segments are sequentially joined to form a winding of a rotary electric machine, the conductor segments can be stably held without complicating the manufacturing process. It is an object of the present invention to provide a method for manufacturing a winding of a rotating electric machine that is possible.

[0006]

According to a first aspect of the present invention, there is provided a method of manufacturing a winding of a rotating electrical machine, comprising: a pair of intermediate U-shaped conductors corresponding to the above-described U-shaped conductor segments; The linear portions are separately inserted from the one end surface of the core into different slots, and the ends of the linear portions projecting toward the other end surface of the core are joined in pairs to form a phase coil of a predetermined phase.

Further, in order to locate the starting end and the end of the phase coil on one end side of the core, in this configuration, an end made of a special U-shaped conductor segment is used instead of the above-mentioned I-shaped conductor segment. A part U-shaped conductor is used.

[0008] One linear portion of the end U-shaped conductor (the first outgoing conductor of this phase coil) has a tip portion which is formed by the above-mentioned I-shaped conductor.
Similarly to the U-shaped conductor segment, it is joined to the leading end of the first linear portion (first return conductor of this phase coil) of the intermediate U-shaped conductor at the very beginning of the phase coil of this predetermined phase. Similarly, the front end of the other straight portion (the last return conductor of the phase coil) of the U-shaped conductor for the end is connected to the end of the U-shaped conductor for the middle end on the farthest end of the phase coil of the predetermined phase. (The last outgoing conductor of this phase coil).

The curved portion of the predetermined end-shaped U-shaped conductor is:
After at least part, preferably all, of the necessary processing (for example, shaping or joining) for the end U-shaped conductor is completed, the end U-shaped conductor is cut off. Is converted into an I-shaped conductor segment.

In this way, the first outgoing conductor and the last return conductor of the phase coil can be temporarily constituted by one end-shaped U-shaped conductor. In this case, the pair of straight portions of the end U-shaped conductor can be strongly held in the slots by the elastic deformation of the curved portions, and as a result, workability and reliability are improved.

The term "phase coil" as used herein means a part or all of one phase winding of a multi-phase winding wound around a stator core or a rotor core in a rotating electric machine. Therefore, it is also possible to produce one phase winding by connecting a plurality of phase coils in series or in parallel.

By the way, the reason why "the starting end and the end of this phase coil are located on one end face side of the core" is, for example, to arrange a connector or an electric component on one end face side of the core.
In addition, when joining the tip portions of the U-shaped conductors for the intermediate portions and the U-shaped conductors for the end portion on the other end surface side of the core (for example, collective welding), a portion serving as a starting end or an end of the phase coil becomes an obstacle. This is because the start and end portions of these phase coils are arranged on one end face side of the core.

In particular, it is preferable that the conductor part which becomes the starting end or the end of the phase coil is extended as it is to form a lead wire. However, if the part which becomes the starting end or the end of the phase coil is arranged on one end side of the core, These lead-out portions do not hinder the end joining operation.

According to a second aspect of the present invention, in the method for manufacturing a winding of a rotating electric machine according to the first aspect, the linear portions of the U-shaped conductor are further arranged in order from one radial end to the other radial end in the slot. One is accommodated in each of the first to fourth positions.

The two straight portions of the large-circle intermediate U-shaped conductor are inserted into the first and fourth positions on both ends of the slot. Side second and third positions.

In this way, a large round U-shaped conductor for the intermediate portion and a small round U-shaped conductor for the intermediate portion may be prepared as the U-shaped conductor for the intermediate portion. Since the U-shaped conductor for the intermediate part of the large round shape can be arranged outside the U-shaped conductor for the part, they do not intersect,
The coil end, that is, the crossover conductor, can be made compact.

Furthermore, in this configuration, both straight portions of the U-shaped conductor for extraction are inserted into the first and third positions on both ends of the slot, and both straight portions of the U-shaped conductor for interlayer connection are connected to the center of the slot. Side second and fourth positions.

According to a third aspect of the present invention, in the method for manufacturing a winding of a rotary electric machine according to the second aspect, the first and second cores may further include:
A first ring having a number of through holes extending in the axial direction at a position substantially equal to the second position in the radial direction, and a number of through holes extending in the axial direction at positions substantially equal to the third and fourth positions of the core in the radial direction. A jig for forming a transition conductor portion having a hole and comprising a second ring rotatable relative to the first ring is prepared.

Next, a U-shaped conductor for an intermediate portion and a U-shaped conductor for an end portion are inserted into each through-hole in the arrangement order described in claim 2, and the two rings are turned in opposite directions at a predetermined angle (usually an electrical angle). π /
(2 by 2) relative rotation to form a transition conductor portion on one end side (curved portion side). That is, the U-shaped conductor for the middle part and the U-shaped conductor for the end part
The two straight portions of the U-shaped conductor are separately inserted into the two rings, and the two rings are rotated in opposite directions to enlarge their curved portions by a required angle in the circumferential direction.

Here, the first and third positions where both straight portions of the U-shaped conductor for insertion are inserted, and the second and fourth positions where both straight portions of the U-shaped conductor for interlayer connection are inserted. Before the two rings reversely rotate, they are arranged at the same position in the circumferential direction.

[0021] This is because both straight portions of the U-shaped conductor for extraction occupy the first and third positions of the predetermined insertion hole, so that the second and fourth positions of the insertion hole necessarily have an empty space. This is because it occurs.

However, since the curved portion of the interlayer connection U-shaped conductor inserted earlier occupies almost immediately above either the second or third position, the straight portion of the drawn-out U-shaped conductor is later inserted into this portion. It is difficult to insert into either the second or third position.

Therefore, in this configuration, the curved portion of the interlayer connection U-shaped conductor inserted first is bent in advance in the circumferential direction, so that the straight portion of the lead-out U-shaped conductor inserted later is connected to the second portion. Or, it can be easily inserted into either the third position.

This facilitates insertion of the U-shaped conductor for extraction.

According to a fourth aspect of the present invention, in the method for manufacturing a winding of a rotating electrical machine according to any one of the first to third aspects, furthermore, the two remaining projecting portions (curved portions) of the U-shaped conductor for extraction after the cutting are further provided. The protruding part of the straight part protruding from the core after resection)
Are protruded by different lengths, so that these protruding portions can be bent in the circumferential direction to have a lead wire of a suitable length (lead wire for external lead or lead wire for neutral point connection). it can.

According to a fifth aspect of the present invention, in the method for manufacturing a winding of a rotating electrical machine according to any one of the first to fourth aspects, the lead-shaped U-shaped conductor is formed longer than the intermediate-portion U-shaped conductor. Therefore, after cutting off the bent portion of the U-shaped conductor for drawing, the remaining protruding portion of the U-shaped conductor for drawing can be formed as a drawing line which is routed to a necessary portion, and there is no need to separately prepare a drawing line. . U for drawer
Despite the fact that the straight portion of the U-shaped conductor has such a portion as a lead line in this way, the conductor portion can be formed all at once from the U-shaped conductor for extraction and the U-shaped conductor for the intermediate portion. Does not increase.

According to the configuration of the sixth aspect, after arranging a large number of U-shaped conductors for the intermediate portion as described above, the portion including the curved portion is shaped in the circumferential span expanding direction, and the crossover at one end is formed. When forming a conductor portion, or when shaping the tip protruding from the core to the inflection portion side in the circumferential span expansion or contraction direction and forming a transition conductor portion on the other end side, these intermediate portions are used. A predetermined position of the curved portion of the U-shaped conductor, preferably a central portion thereof, is pressed.

As a result, when the portion including the curved portion of the intermediate portion U-shaped conductor is shaped in the circumferential direction of the span expansion to form a transition conductor portion on one end side, the intermediate portion U-shaped conductor at the time of the shaping is used. The deformation of the curved portion and the straight portion adjacent thereto spreads to both sides of the curved portion from the predetermined position as a base point, and the variation in the shape of the crossover conductor portion after shaping between the U-shaped conductors for the intermediate portions is reduced. Can be reduced. This is due to the fact that the deformation of each U-shaped conductor for the intermediate portion starts from the same pressed position.

Furthermore, if the bent portion of the intermediate portion U-shaped conductor is pressed at a predetermined position using a dedicated jig, and not only the pressing but also the holding is performed, each intermediate portion can be maintained after the shaping. The arrangement state of the U-shaped conductors can be maintained, and the leading end of each U-shaped conductor can be inserted into each slot of the core as it is, facilitating the slot insertion process of the U-shaped conductors. Can be achieved.

Further, when the tip of the U-shaped conductor for the intermediate portion, which protrudes from the core toward the bent side, is shaped in the direction of expanding or reducing the span in the circumferential direction to form the transition conductor at the other end. In a case where a predetermined position of the curved portion of the part U-shaped conductor, preferably a central portion thereof, is pressed, an effect of preventing the U-shaped conductor for the intermediate portion from being displaced toward the curved portion in the axial direction during this shaping can be realized.

[0031] In further accordance to the construction of claim 6, also used for leading out the U-shaped conductor as described in claim 1.

In this case, as described above, the lead-shaped U-shaped conductor includes the lead-out portion, and therefore is longer in the axial direction than the intermediate-portion U-shaped conductor. It is not easy to hold the U-shaped conductor for drawing out by a jig for holding the U-shaped conductor (a jig for holding the U-shaped conductor for the middle part).

Therefore, in the present configuration, the jig for holding the U-shaped conductor for the intermediate portion is provided with a groove or a hole through which the U-shaped conductor for drawing out penetrates.

In this way, despite the fact that the U-shaped conductor for the intermediate portion and the U-shaped conductor for drawing out have different axial protruding lengths, both U-shaped conductor holding jigs for the intermediate portion are used. It is possible to satisfactorily regulate the circumferential displacement of the U-shaped conductors during their shaping.

Further, since the groove or the hole allows the U-shaped conductor for drawing to be maintained in an aligned state even after the shaping, the tip of the U-shaped conductor for drawing is thereafter inserted into the slot of the core. To make things easier.

According to a seventh aspect of the present invention, in the method for manufacturing a winding of a rotating electric machine according to the sixth aspect , the crossover conductor portion on one end side is formed by connecting the pair of straight portions of each of the U-shaped conductors in a radially coaxial manner. The first jig and the second jig, each of which is arranged and relatively rotatable, are individually held on a first jig and a second jig, and these jigs are moved in opposite directions with respect to the jig for holding the U-shaped conductor for the intermediate portion. The rotation is performed by turning.

In this way, both the U-shaped conductor for the intermediate portion and the U-shaped conductor for extraction, which protrudes in the axial direction from the intermediate portion, can be favorably shaped into the crossover conductor portion.

According to the configuration of claim 8, claims 1 to
7. In the method for manufacturing a winding of a rotating electric machine according to any one of 7 , the formation of the crossover conductor on the other end side is performed by shaping each linear portion protruding from the core in the circumferential direction, and thereafter, the tip of each linear portion is formed. The pairing is performed by, for example, welding in a predetermined selection pattern. Further, in this configuration, the U-shaped conductor for the end portion or
The resection of the curved portion of the lead-out U-shaped conductor, performed after the welding.

Further, in the present configuration, the cutting of the curved portion of the U-shaped conductor for drawing is performed after this welding.

This makes it easy to hold the straight portion of the lead-out U-shaped conductor during welding, and improves welding reliability.

[0041]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described with reference to the following examples.

[0042]

(Preparation of U-shaped conductors A to D and rear-side twisting jig 1) First, as shown in FIG. 1, a rear-side twisting jig 1 is prepared.

In the rear twisting jig 1, an outer ring-shaped jig (first jig) 11 is rotatably housed in a ring-shaped fixed frame 10, and an inner ring jig is provided radially inside the outer ring-shaped jig. The jig (second jig) 12 is rotatably accommodated.

On the end surfaces of the outer ring jig 11 and the inner ring jig 12, through holes 13 and 14 are provided at the same positions as slots of a stator core of an alternator to be described later. The through-hole 13 of the outer ring-shaped jig 11 is set at the same position on the outer peripheral half of the slot, and the through-hole 14 of the inner ring-shaped jig 12 is set at the same position on the inner peripheral half of the slot.

Next, the U-shaped conductor A for the intermediate part having a large round shape,
The required number of small-turn U-shaped conductors B for the middle portion, U-shaped conductors C for drawing, and U-shaped conductors D for interlayer connection are prepared.

Here, the number of slots is 96, each of A and B is 90, and each of C and D is 6. Each of the U-shaped conductors A to D has a pair of straight portions S extending linearly at a predetermined interval from each other, and a curved portion UU connecting the base ends of these straight portions S, S.

As shown in FIG. 2, each slot 201 of the stator core 200 has a first position S
1, a second position S2, a third position S3, and a fourth position S4 are set, and between the straight portions S of the U-shaped conductors A to D, such that the straight portions S are accommodated in these four positions. The interval is set.

More specifically, the distance between the U-shaped conductors A is set so that both straight portions S thereof can be individually inserted into the first position S1 and the fourth position S4. The straight portions S are set so as to be individually insertable into the second position S2 and the third position S3, and the distance between the U-shaped conductors C is such that both straight portions S are individually inserted into the first position S1 and the third position S3. The space between the U-shaped conductors D is set so that both straight portions S can be individually inserted into the second position S2 and the fourth position S4.

(Step of Inserting Each U-shaped Conductor A to D into Rear Twisting Jig 1) Next, as shown in FIG.
D is sequentially inserted into the through holes 13 and 14 of the rear-side twisting jig 1. Note that the two straight portions S of one U-shaped conductor are individually inserted into one predetermined through-hole 13 and one predetermined through-hole 14 which are radially adjacent to each other (located at equal positions in the circumferential direction). .

Therefore, the through-hole 13 of the outer ring-shaped jig (first ring) 11 is in the first position S of the slot 201.
1, formed at the same position at the second position S2, and the through hole 14 of the inner ring-shaped jig (second ring) 12 is formed at the same position at the third position S3 and the fourth position S4 of the slot 201. Hereinafter, for the sake of simplicity, a position corresponding to the first position S1 of the through hole 13 is similarly referred to as a first position S1,
A position corresponding to the second position S2 of the through hole 13 is also referred to as a second position S2, a position corresponding to the third position S3 of the through hole 14 is also referred to as a third position S3, and a fourth position S4 of the through hole 14 Is also referred to as a fourth position S4.

Therefore, the U-shaped conductors A and B, that is, the intermediate portion U
A pair of U-shaped conductors or a pair of U-shaped conductors C and D, that is, a pair of U-shaped conductors for end portions are inserted.

As will be described later, the straight portions S of the U-shaped conductors A and B are connected in pairs at the front side of the stator core 200, respectively, and a total of six phase coils (U, V, W,
(X, Y, Z).

The U-shaped conductor D is a U-shaped conductor U
This is a U-shaped conductor for interlayer connection of the phase coil, wherein the U-shaped conductors A and the U-shaped conductors B for small intermediate portions are alternately connected.

The U-shaped conductor C has a curved portion U as described later.
It is a U-shaped lead-out conductor that constitutes both ends of a coil corresponding to one phase of a three-phase winding by removing U. Therefore, the U-shaped conductor C is used as a lead wire later,
It is formed longer in the axial direction than the other U-shaped conductors A, B, and D.

As shown in FIG. 3, a total of four straight portions S of a pair of U-shaped conductors C and D are inserted into a pair of through holes 13 and 14 which are radially adjacent to each other at equal circumferential positions. The bent portion UU of the U-shaped conductor D for interlayer connection is bent in the circumferential direction. Thereby, one of the straight portions S of the U-shaped conductor C for drawing is connected to the third position S3 of the through-hole 14 of the inner ring-shaped jig 12 of the rear side twisting jig 1 at the third position S3. It can be inserted without being disturbed by the conductor D.

(Preparation of jig 2 for holding U-shaped conductor for intermediate portion) Next, the intermediate portion having a hole through which U-shaped conductor C penetrates while holding curved portions UU of U-shaped conductors A, B, and D A jig for holding U-shaped conductor 2 is prepared.

FIG. 4 is a partially cutaway perspective view of the jig 2 for holding the U-shaped conductor for the intermediate portion, and FIG.

The jig 2 is a shallow trough-shaped member, and a bottom portion 21 has a hole 22 through which a U-shaped conductor C for drawing out passes.
Are formed, and a hole 23 having a circumferential width twice as large as that of the hole 22 is formed. One drawer U-shaped conductor C can be inserted into each of the holes 22, and two drawer U-shaped conductors C can be inserted into the hole 23 (see FIG. 6).

Each U-shaped conductor A,
A predetermined number of pairs of gripping projections 24 for individually gripping the central portions of the curved portions UU of B and D are provided over one circumference.

(Holding of U-shaped conductors A to D by jig 2)
Through holes 13 and 14 of rear twisting jig 1 by the above-described steps.
Curved portions UU of the respective U-shaped conductors A to D inserted in a predetermined arrangement
Then, as shown in FIG. 6, the jig 2 is put on, and the jig 2 is supported so as not to rotate. At this time, the draw-out U-shaped conductor C that is long in the axial direction projects from the holes 22 and 23 in the axial direction. FIG. 7 shows the holding state of each of the U-shaped conductors A to D.

(Shaping of rear-side transition conductor by reverse rotation of rear-side twisting jig 1) Next, as schematically shown in FIG. The inner ring-shaped jig 12 is rotated in a direction opposite to each other by a predetermined angle (the electrical angle π as a whole). Note that the jig 2 is not shown in FIG.

As a result, a rear-side transition conductor portion is formed, and the U-shaped conductors A to D become U-shaped conductors A 'to D' each having a transition conductor portion. In FIG. 8, the U-shaped conductors A and B
Only changes to U-shaped conductors A ′ and B ′ are shown.

Note that, despite the reverse rotation of the jigs 11 and 12, the curved portion UU of the U-shaped conductor C for drawing and the pair of straight portions S adjacent thereto are formed by the holes 22 and 23 of the jig 2. It does not deform because it is inserted into

(Preparation of Stator Core 200 and Front Twisting Jig 4) Next, the stator core 200 and the front twisting jig 4 are prepared. The stator core 200 is as described above.

As shown in FIG. 11, the front-side twisting jig 4 includes an outer ring-shaped jig 11 and an inner ring-shaped jig 12.
Is divided into two.

More specifically, the front-side twisting jig 4
As shown in FIG. 10, a ring-shaped fixed frame 40
Are provided with four ring-shaped jigs 41 to 44 which are rotatable from the outside to the inside in the radial direction.

A through hole (first position through hole) is provided on the end surface of the ring jig 41 in the axial direction at the same position in the circumferential direction and the radial direction at the first position S1. A through hole (a second position through hole) is provided in the end face in the axial direction at a position equal to the second position S2 in the circumferential direction and the radial direction, and the end face of the ring-shaped jig 43 is provided in the third position S3. A through hole (third position through hole) is provided in the axial direction at the same position in the circumferential direction and the radial direction, and the end face of the ring-shaped jig 44 is positioned at the same position in the circumferential direction and the radial direction as the fourth position S4. A through hole (fourth position through hole) is provided in the axial direction.

The front end face of the stator core 200 is brought into close contact with the end face of the front twisting jig 4 so that each slot is aligned with each through hole of the ring jigs 41 to 44.

(Transfer process of U-shaped conductor) Next, each of the U-shaped conductors A 'to D' on each of which the crossover conductor portion is formed is fixed to the jig 2 while the arrangement state thereof is maintained. 1 and inserted into each slot from the rear end face of the stator core 200 (see FIG. 10). Therefore, the exfoliated tip of the straight portion S of each of the U-shaped conductors A ′ to D ′ is
The jigs 4 are individually inserted into the respective through holes through the slots.

(Step of Forming Front Crossover Conductor) Next, as shown in FIG. 11, the ring-shaped jigs 41 and 43 are rotated by π / 2 in one direction, and the ring-shaped jigs 42 and 44 are moved. Rotate in the opposite direction by π / 2. Since each of the U-shaped conductors A 'to D' is held by the stator core 200, only their leading ends are deformed substantially in the circumferential direction to become front-side transition conductors.

Thereafter, the leading ends of the linear portions S of the U-shaped conductors A 'to D' are extracted from the through holes of the ring-shaped jigs 41 to 44, and the jig 2 for holding the U-shaped conductor holding member for the intermediate portion is removed. Remove from each U-shaped conductor A'-D '. The jig 2 for holding the U-shaped conductor for the intermediate portion is not removed until this stage.
This is to prevent the curved portion UU of each of the U-shaped conductors A 'to D' from protruding toward the rear side in the axial direction during the rotation of the 1 to 44.

Next, a large U-shaped conductor A 'for the intermediate portion having a round shape is used.
And the distal end of the second position S2 of the U-shaped conductor B 'for the intermediate portion, which is a small turn and is π apart from the U-shaped conductor A' by an electrical angle, is brought into close contact with the distal end E of the first position S1.

Similarly, the tip E at the fourth position S4 of the large-sized intermediate U-shaped conductor A ', and the small-sized intermediate U-shaped conductor separated by π in electrical angle from the U-shaped conductor A' The tip of the third position S3 of B 'is brought into close contact.

The leading end E of the first position S1 of the lead-out U-shaped conductor C 'and the first U-shaped conductor B' for the intermediate part having a small turning shape separated from the U-shaped conductor C 'by an electrical angle of π. Two position S2
In close contact with the tip.

Similarly, the leading end E of the third position S3 of the drawing U-shaped conductor C 'and the electric angle between the leading end E and the U-shaped conductor C' are π.
The fourth position S of the intermediate U-shaped conductor A 'for the intermediate part having a large distant shape
4. Make the tip of 4 close.

Further, the tip E of the second position S2 of the U-shaped conductor D 'for interlayer connection and the U-shaped conductor A' for the intermediate portion having a large roundabout which is π apart from the U-shaped conductor D 'by an electrical angle. The tip of one position S1 is brought into close contact.

Similarly, the tip E of the fourth position S4 of the U-shaped conductor D 'for interlayer connection, and the U-shaped conductor B' for the intermediate portion having a small turning angle π apart from the U-shaped conductor D 'by an electrical angle. Third position S1
In close contact with the tip.

(Welding Step) Next, as shown in FIG.
The tip E of each pair of adjacent U-shaped conductors A 'to D',
E is welded and joined one by one to complete the front-side transition conductor portion. As a result, six-phase coils of U, V, W, X, Y, and Z are formed, and these six-phase coils are connected to almost complete two three-phase stator coils (windings in the present invention) ( See FIG. 13).

(Step of Cutting UU Curved Part of U-shaped Conductor C 'for Extraction) Next, the straight portion S of each U-shaped conductor C' for extraction is extracted.
Are cut at suitable cutting positions 300 and 301, respectively, and the resin is peeled off from the tip portion 400, and each is bent by a predetermined distance in the circumferential direction to form a lead wire 500.

Six phase coils each having a pair of lead wires are formed. FIG. 17 shows the lead-out position of the lead wire 500 of each phase coil.

In this embodiment, a total of six phase coils are manufactured. Therefore, at least six lead-shaped U-shaped conductors C are provided for leading both ends of each phase coil, and six interlayer connection U-shaped conductors D are provided inside each phase coil for interlayer connection. Is done.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one step of a method for manufacturing a winding of a rotating electric machine according to the present invention.

FIG. 2 is a partial front view showing the vicinity of a slot of a stator core.

FIG. 3 is a perspective view of a U-shaped conductor for extraction and a U-shaped conductor for interlayer connection.

FIG. 4 is a perspective view of a jig for holding a U-shaped conductor for an intermediate portion.

FIG. 5 is a front view of a jig for holding a U-shaped conductor for an intermediate portion.

FIG. 6 is a perspective view showing one step of a method for manufacturing a winding of a rotary electric machine according to the present invention.

FIGS. 7A and 7B show a state in which each U-shaped conductor is held or pressed by a jig for holding a U-shaped conductor for an intermediate portion, wherein FIG. 7A is a side view and FIG.

FIG. 8 is a perspective view showing one step of a method for manufacturing a winding of a rotary electric machine according to the present invention.

FIG. 9 is a perspective view showing one step of the method for manufacturing a winding of a rotary electric machine according to the present invention.

FIG. 10 is a perspective view showing one step of a method for manufacturing a winding of a rotary electric machine according to the present invention.

FIG. 11 is a schematic side view showing one step of the method for manufacturing a winding of a rotating electric machine according to the present invention.

FIG. 12 is a schematic side view showing one step of the method for manufacturing a winding of a rotary electric machine according to the present invention.

FIG. 13 is a perspective view showing a state before a stator cutting step using the method for manufacturing a winding of a rotating electric machine according to the present invention.

FIG. 14 is a perspective view showing a cutting step of a U-shaped conductor for extraction.

FIG. 15 is a perspective view showing a lead wire forming step by bending a lead U-shaped conductor.

FIG. 16 is a perspective view showing a completed stator.

FIG. 17 is a perspective view showing a lead-out position of a lead wire in the stator of FIG. 16;

[Explanation of symbols]

1 is a rear-side twisting jig, 2 is a jig for holding a U-shaped conductor for an intermediate portion, 4 is a front-side twisting jig, 11 is a first ring (outer ring-shaped jig), and 12 is a second ring (inner ring). Jig A), A is a U-shaped conductor for the middle part having a large round shape, B is a U-shaped conductor for the middle part having a small round shape, C is a U-shaped conductor for drawing,
D is a U-shaped conductor for interlayer connection, UU is a curved portion, and S is a straight portion.

Continuation of the front page (56) References JP-A-2000-228852 (JP, A) JP-A-2000-236650 (JP, A) Patent 3118837 (JP, B2) (58) Fields investigated (Int. Cl. ⁷ , DB) (Name) H02K 15/085 H02K 3/04

Claims (8)

(57) [Claims] 1. A plurality of U-shaped conductors for an intermediate portion having a pair of straight portions parallel to each other and a curved portion connecting the base ends of the two straight portions, wherein the curved portion of the U-shaped conductor for an intermediate portion is produced. The core is formed by shaping a portion including a crossover conductor portion into two of a number of slots extending substantially axially along the peripheral surface of the core while being spaced apart from each other by a predetermined distance in the circumferential direction. The individual straight portions of the U-shaped conductors for the intermediate portions are individually inserted from the core portion, and the tip portions of the straight portions protruding from the other end surface of the core are shaped to form a transition conductor portion on one end side, A predetermined number of phase coils are formed by connecting the ends of the straight portions in a predetermined order to form a crossover conductor portion on the other end side, and the ends of the phase coils are connected to complete the winding. A method for manufacturing a winding of a rotating electrical machine, comprising: a pair of straight portions parallel to each other; and the pair of straight portions. A required number of end U-shaped conductors having a curved portion connecting between the base ends are produced in a required number, and the pair of straight portions of the end U-shaped conductor are individually inserted into two different slots of the core, The end portion of the pair of straight portions is connected to the tip portion of the straight portion of the intermediate portion U-shaped conductor on the other end surface side of the core, and a portion of the predetermined U-shaped conductor for the end portion including at least the curved portion Wherein the remaining protruding portions of the pair of straight portions of the end U-shaped conductor remaining in a posture protruding toward the one end surface side of the core after the cutting are formed as both end portions of the phase coil. Method for manufacturing windings of rotating electric machines. 2. The method for manufacturing a winding of a rotating electric machine according to claim 1, wherein the slots are respectively located at first to fourth positions arranged in order from one radial end to the other radial end of the core. Each of the straight portions is accommodated one by one, and one-half of each of the intermediate portion U-shaped conductors has a pair of linear portions individually inserted into the pair of the first position and the fourth position, and a large round shape connecting them. The intermediate portion is formed of a U-shaped conductor having a round shape having the curved portion, and the other half of the U-shaped conductor for each intermediate portion is inserted into the pair of the second position and the third position. It is composed of a U-shaped conductor for a middle portion having a small-turn shape having a straight portion and the curved portion having a small-turn shape connecting them, wherein each of the first U-shaped conductors for the end portion is a pair of the first position and the third position. Having the pair of straight portions individually inserted and a curved portion connecting them; A lead-shaped U-shaped conductor formed to be long in the axial direction, wherein each of the second U-shaped conductors for the end portion is a pair of the linear portions individually inserted into the pair of the second position and the fourth position. And a curved portion connecting them and comprising a U-shaped conductor for interlayer connection formed short in the axial direction. 3. The method for manufacturing a winding of a rotating electric machine according to claim 2, wherein the first ring has a large number of through holes extending in the axial direction at radially equal positions to the first and second positions of the core. And a crossover comprising a second ring rotatable with respect to the first ring, having a number of through holes extending in the axial direction at radially equal positions to the third and fourth positions of the core. Prepare a jig for forming a conductor portion, individually insert the straight portions of the U-shaped conductor for the intermediate portion of each of the large round shape at a position corresponding to the first position, the fourth position of the through hole, The two straight portions of each of the small-turn intermediate U-shaped conductors are individually inserted into the positions corresponding to the second position and the third position of the through hole, respectively. Individually inserting the two straight portions of the interlayer connection U-shaped conductor into positions corresponding to the positions, The two linear portions of the lead-out U-shaped conductor are individually inserted into positions corresponding to the first position and the third position of the through hole, and then, the two rings are relatively rotated in opposite directions by a predetermined angle. And forming a transitional conductor portion on the curved portion side by shaping a portion including the curved portion of each of the U-shaped conductors to form the transitional conductor portion. A method for manufacturing a winding of a rotating electrical machine, characterized in that the curved portion of the U-shaped conductor for interlayer connection is bent in a circumferential direction at a dimension not less than a dimension capable of being inserted into a hole. 4. The method for manufacturing a winding of a rotating electrical machine according to claim 1, wherein the cutting is performed such that the two remaining projecting portions of the lead-out U-shaped conductor have different lengths. A method for manufacturing a winding of a rotating electric machine. 5. The method for manufacturing a winding of a rotary electric machine according to claim 1, wherein the lead-shaped U-shaped conductor is formed longer than the intermediate-portion U-shaped conductor. Method for manufacturing windings of rotating electric machines. 6. A plurality of U-shaped conductors for an intermediate portion having a pair of straight portions parallel to each other and a curved portion connecting the base ends of the two straight portions, wherein the straight portions of the U-shaped conductor for an intermediate portion are manufactured. A required number of end conductors having at least a linear portion connected to the tip of the end portion are manufactured, at least the intermediate portion U-shaped conductor is shaped to form a transition conductor portion on one end side, and a predetermined interval in the circumferential direction with respect to each other The two straight portions of each of the intermediate portion U-shaped conductors are individually inserted into two of a large number of slots extending substantially in the axial direction along the peripheral surface of the core while separating them from the one end surface side of the core, Inserting the end conductor into the remaining slot, shaping the tip of each of the straight portions and the tip of each of the straight portions protruding from the other end surface of the core, and shaping the tip of each of the straight portions and the straight portion Connecting the parts in a predetermined order to form a transition conductor on the other end A method for manufacturing a winding of a rotating electrical machine, wherein a predetermined number of phase coils are formed, and ends of the phase coils are connected to complete a winding, wherein the crossover conductor is formed at least in each of the intermediate portions The U-shaped conductors for intermediate portions are arranged in a circumferential direction in a predetermined order in a state where the linear portions of the U-shaped conductors extend in the axial direction, and the curved portions of the U-shaped conductors for intermediate portions are A step of displacing a pair of linear portions of each of the intermediate portion U-shaped conductors in the circumferential direction to each other while being locked by a jig for holding the U-shaped conductor , wherein the end portion conductors are different from each other. Insert into slot
And a pair of straight portions parallel to each other and the pair of straight portions
The straight portions of the end-shaped U-shaped conductor having a curved portion connecting the base ends.
The U-shaped conductor for the end portion is drawn long in the axial direction using a wire portion.
U-shaped conductor for extraction and U-shaped conductor for interlayer connection short in the axial direction
Composed of a body, the jig for the U-conductor presser said intermediate portion, the drawer
Holes or grooves through which the curved portion of the U-shaped conductor
The straight sections and the straight sections are extended in the axial direction.
Are arranged in a predetermined order in the circumferential direction, and the curved portion of the lead-out U-shaped conductor is
Each of the intermediate portions is protruded in the axial direction from the curved portion of the U-shaped conductor, and the jig for holding the U-shaped conductor for the intermediate portion is used.
While locking the curved portion of the U-shaped conductor,
A distance between a pair of straight portions is changed, and at least the bent portion of the U-shaped conductor for drawing is included.
A method for manufacturing a winding of a rotating electric machine, comprising cutting off a part . 7. The method for manufacturing a winding of a rotating electric machine according to claim 6 , wherein the crossover conductor portion is formed by forming the pair of linear portions of each of the intermediate portion U-shaped conductor and each of the end portion U-shaped conductors. One is held by a first jig, and the other of the pair of linear portions of each of the intermediate portion U-shaped conductors and each of the end portion U-shaped conductors is held by a second jig, and The U-shaped conductor and the curved portion of the U-shaped conductor for interlayer connection are locked by the jig for holding down the U-shaped conductor for the middle portion, and the U-shaped conductor for drawing is used for holding down the U-shaped conductor for the middle portion. The first jig and the second jig are rotated by a predetermined angle in directions opposite to each other, and after the crossover conductor portion is formed, the cut-out of the U-shaped conductor for extraction is performed. A method for manufacturing a winding of a rotating electrical machine, comprising a step of performing. 8. The winding method for manufacturing a rotary electric machine according to any one of claims 1 to 7, the formation of the bridging conductor portion of the other end, joined to the distal end portion of each of the linear portions to each pair The method of manufacturing a winding for a rotating electrical machine, wherein after the joining, the cutting of the end-shaped U-shaped conductor or the drawn-out U-shaped conductor is performed.