JP4006637B2 - Armature of rotating electric machine and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an armature for a rotating electrical machine and a method for manufacturing the same, and more particularly to a method for manufacturing an armature having a segment conductor bonded armature coil.
[0002]
[Prior art and problems to be solved by the invention]
2. Description of the Related Art Conventionally, there has been proposed a segment conductor junction type armature coil formed by sequentially joining a number of segment conductors inserted into slots of a stator core. For example, the following Patent Documents 1 and 2 owned by the present applicant disclose the manufacture of a segment conductor junction type armature coil formed by sequentially joining segment conductors which are conductor pieces having a substantially U shape. .
[0003]
More specifically, these segment conductor-bonded armature coils have a pair of leg portions of the segment conductor inserted into a pair of slots separated from each other by a substantially magnetic pole pitch of the rotor, and protruded from the pair of end portions. It is formed by bending the ends of the leg portions of each segment conductor in order to bend each other in the opposite direction.
[0004]
As the above-described segment conductor junction type armature coil, a two-conductor radial arrangement in which a pair of leg portions are individually constituted by two types of segment conductors that are individually accommodated in two radial slots in the slot in the radial direction. A four-conductor radially arranged coil composed of two types of segment conductors individually housed in four conductor housing positions where two pairs of leg portions are sequentially adjacent in the slot in the radial direction in the slot, three pairs A six-conductor radial arrangement type coil is known which is composed of three types of segment conductors that are individually housed in six conductor housing positions that are sequentially adjacent in the slot in the radial direction. In order to increase the number of turns of the phase winding, a plurality of the various coils described above can be arranged in the radial direction and serially arranged for each phase.
[0005]
It is also known to increase the number of slots per pole per phase in order to increase the number of turns of the phase winding. For example, the following patent documents 4 and 5 filed by the present applicant disclose a segment conductor-joined armature coil of a rotating electric machine having a plurality of slots (per pole and phase).
[0006]
These publications disclose that a plurality of segment conductors constituting a phase winding of the same phase are accommodated in a group of adjacent in-phase slots composed of a plurality of slots adjacent to each other, so that the phase winding turns without increasing the number of poles. It is disclosed to increase the number. When such an adjacent in-phase slot group is used, a partial coil is formed by connecting only the segment conductors of slots of the same rank in the circumferential direction in the adjacent in-phase slot group, and each partial coil is connected in series to form a coil. .
[0007]
In the case where only one of the above-described two-conductor radial arrangement coil or four-conductor radial arrangement coil is used as the coil, this coil constitutes a phase winding. When a plurality of the above-mentioned two-conductor radial arrangement type coils and four-conductor radial direction arrangement type coils are arranged in the radial direction as the coils, the coil composed of these two-conductor radial arrangement type coils or four-conductor radial arrangement type coils Are connected in series or in parallel to form a phase winding.
[0008]
However, if the number of adjacent in-phase slots is increased to increase the number of turns of the phase winding, the heads or ends of adjacent segment conductors of different phases are brought closer due to the reduction in the circumferential width of the teeth between the slots. There is a problem that corona discharge is likely to occur.
[0009]
In order to improve this problem, Patent Document 6 below sequentially increases the radius of curvature in the vicinity of the bending point of each coil end conductor that protrudes from the adjacent in-phase slot group and then bends in the circumferential direction from one side in the circumferential direction. Propose that. In this way, the coil end conductors that protrude from the adjacent in-phase slot group and bend in the circumferential direction are hardened together in the circumferential direction, and as a result, the circumferential gap between the coil end conductors of different phases adjacent to each other is increased. And the electrical insulation between both can be improved and corona discharge can also be suppressed.
[0010]
However, the above-mentioned solution proposed by Patent Document 6 in which the radius of curvature near the bending point of the coil end conductor is variously changed is that each coil end conductor protruding from the adjacent in-phase slot group (hereinafter referred to as an adjacent in-phase coil for simplicity). Since the traveling directions after bending of the end conductor groups (also called end conductor groups) are different from each other precisely, the circumferential gap between them is not constant, and there is a possibility that rubbing or the like may occur between them.
[0011]
Further, the circumferential pitch of the tip end portions of the coil end conductors varies, and it becomes difficult to join the tip end portions of the coil end conductors with the tip ends of other coil end conductors adjacent in the radial direction.
[0012]
Furthermore, in order to make the curvature radii of the coil end conductors belonging to adjacent in-phase coil end conductor groups different in the vicinity of the bending point, many bending jigs having various curvature radii must be manufactured and used. Tool manufacturing and angle adjustment work become extremely complicated.
[0013]
Furthermore, when performing the process of expanding the head or end of each coil end conductor in the circumferential direction automatically, it is difficult to develop an automatic device having such a bending jig, and It is not easy to adjust the radius of curvature with such a bending jig except for the coil end conductors that are arranged radially in the outermost or innermost radial direction.
[0014]
The present invention has been made in view of the above problems, and an object of the present invention is to provide an armature for a rotating electrical machine that can improve voltage resistance at a coil end while suppressing the complexity and difficulty of work.
[0015]
[Patent Document 1]
Japanese Patent No. 3118837
[Patent Document 2]
Japanese Patent No. 319638
[Patent Document 3]
Japanese Patent Application No. 2001-379259
[Patent Document 4]
Japanese Patent Application No. 2002-171230
[Patent Document 5]
Japanese Patent Application No. 2002-171242
[Patent Document 6]
JP-A-5-137285
[0016]
[Means for Solving the Problems]
this The armature of the rotating electric machine according to the present invention has an U-shaped armature winding in which a number of segment conductors inserted through the slots of the armature core are sequentially connected on one axial side of the armature core. The segment conductors are formed in a substantially U shape to form a head-side coil end, and extend from both ends of the head and individually extend into two slots. Each of the slot conductor portions, and a pair of end portions that protrude from the pair of slot conductor portions to the outside of the slot and then bend in the circumferential direction to form an end-side coil end. Is an armature of a rotating electrical machine that is sequentially segmented for each phase into adjacent in-phase slot groups composed of a plurality of the slots adjacent to each other containing the segment conductors of the same phase,
The head portion or the end portion is bent at a predetermined angle in the circumferential direction with a predetermined radius of curvature from a bending start point that is separated from the end face of the armature core in the axial direction by a predetermined angle, and is the most circumferential direction among the adjacent in-phase slot groups The bending start point of the head or end protruding from the slot located on one side is more than the bending start point of the head or end protruding from the remaining slot of the adjacent in-phase slot group. Also, the bending start point of the head or end protruding from the slot located closest to the other circumferential side of the adjacent in-phase slot group is close to the end face of the armature core, It is characterized in that it is farther from the end face of the armature core than the bending start point of the head or end protruding from the remaining slot.
[0017]
According to the present invention, it is possible to realize an armature for a rotating electrical machine that can improve voltage resistance at a coil end while suppressing complication and difficulty of work. More specifically, in the present invention, as in Patent Document 6 described above, in the vicinity of the bending point of each coil end conductor (head or end in the present invention) protruding from each slot of the adjacent in-phase slot group. Rather than changing the radius of curvature in various ways, by changing the axial distance from the end face of the armature core to the bending start point, the circumference between each coil end conductor (head or end) coming out of the adjacent in-phase slot group is changed. The directional gap is reduced, and the circumferential gap between a pair of coil end conductors (heads or ends) individually accommodated in different adjacent in-phase slot groups and adjacent to each other is widened. For this reason, the advancing direction itself after each coil end conductor becomes equal, the circumferential gap between them becomes equal, and a necessary gap can be secured between them. Further, the circumferential pitch at the tip of each coil end conductor is constant, and the operation of joining the tip of the coil end conductor to the tip of another coil end conductor that is adjacent in the radial direction is reliable and easy. Further, as will be described later, since the change in the axial distance from the end face of the armature core to the bending start point is very simple, the operation becomes easy and simple, and the simultaneous processing and automation of the operation become easy. . Furthermore, among the coil end conductors that are arranged in a large number in the radial direction, the axial distance adjustment can be easily performed for the coil end conductors other than the radially outermost or innermost coil end conductor.
[0021]
2. The method of manufacturing an armature for a rotating electrical machine according to claim 1, wherein a head expanding step of expanding a head of the segment conductor in a circumferential direction, and the segment conductors of the slots belonging to the same adjacent in-phase slot group are different from each other. A pre-axial displacement step for axial displacement by a predetermined distance, an end unfolding step for unfolding the end portion of the segment conductor in the circumferential direction, and a predetermined difference between the segment conductors of the slots belonging to the same adjacent in-phase slot group. The post-axial displacement process for displacing in the axial direction by the distance is performed in the above order.
[0022]
If it does in this way, adjustment of the above-mentioned axial direction distance of each coil end conductor (head or end) can be performed easily, and automation and simultaneous processing will become easy.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
A stator coil of an automotive alternator that is an embodiment of the present invention and its manufacture will be described with reference to the drawings.
[0024]
However, before explaining the features of the armature of this embodiment that adjusts the circumferential gap of the coil end conductor (head or end) and the manufacturing method thereof, a reference to the stator coil that does not perform this and the manufacturing method thereof Examples 1 and 2 will be described in detail in advance, and then the armature of this embodiment for adjusting the circumferential gap of the coil end conductor (head or end) and the manufacturing method thereof will be described as an embodiment. .
(Reference Example 1)
Reference Example 1 will be described below. FIG. 1 is a longitudinal sectional view of an automotive alternator, FIG. 2 is a perspective view of a segment forming a part of a stator coil, and FIG. 3 is a sectional view showing a state in which the segment is accommodated in a slot.
(overall structure)
In FIG. 1, the vehicle alternator 1 includes a rotor 2, a stator 3, a housing 4, a rectifier 5, an output terminal 6, a rotating shaft 7, a brush 8, and a slip ring 9. The stator 3 includes a stator coil 31 and a stator core 32 fixed to the inner peripheral surface of the peripheral wall of the housing 4, and the stator coil 31 is wound around each slot of the stator core 32. The rotor 3 includes a Landel-type rotor core 71 fixed to a rotating shaft 7 rotatably supported by the housing 4, and a field coil 72 wound around the rotor core 71. Has been. The stator coil 31 is a three-phase armature winding, and the three-phase AC voltage output from the three AC output terminals is rectified by the rectifier 5 constituting the three-phase full-wave rectifier circuit and output from the output terminal 6. Is output. The field coil 72 is magnetized by a field current supplied through the brush 8 and the slip ring 9 to generate a field magnetic field. The field current is adjusted by a regulator (not shown), and the generated voltage is controlled to a predetermined level. Since the structure and operation of this type of vehicle alternator are no longer known as an alternator, further explanation is omitted.
(Description of stator coil 31)
The stator coil 31 is inserted into each slot of the stator core 32 from one side of the stator core 32 through a predetermined number of segment conductors (hereinafter also simply referred to as segments) 33 shown in FIG. The protruding end portion of the segment 33 is protruded to the other side of the stator core 32 by a necessary length, and the protruding end portion of each segment 33 is twisted by an electrical angle π / 2 in the circumferential direction, and the tip of the protruding end portion of each segment 33 A part (joint part) is welded in a predetermined combination. The segment 33 has a long plate U shape that is covered with a resin film except for the welded portion, that is, the tip end portion (joint portion) of the protruding end portion. This type of segmented stator coil itself is no longer known as described above.
[0025]
The details of the segment 33 will be described in more detail.
[0026]
The segment 33 includes a substantially U-shaped head, a pair of slot conductors linearly extending from both ends of the head and housed in the slot, and a pair of ends extending from the ends of both slot conductors. It consists of. As a result, the stator coil 31 has a first coil end portion (head side coil end) that exists in a ring shape as a whole on one side of the stator core 32, and a first ring that exists in a ring shape as a whole on the other side of the stator core 32. It is divided into two coil end portions (end side coil ends) and a slot conductor portion existing in the slot. Therefore, the head-side coil end is constituted by the head portion of each segment 33, and the end-side coil end is constituted by the end portion of each segment 33.
[0027]
As shown in FIG. 2, the segment 33 has a large (large-circular) large segment 331 and a small (small-circular) small segment 332.
[0028]
In the large segment 331, 331a and 331b are slot conductor portions, 331c is a head portion, 331f and 331g are end portions. Since the end portions 331d and 331e of the end portions 331f and 331g are joint portions, they are also referred to as end tip portions or joint portions. The slot conductor portion 331a is referred to as an innermost slot conductor portion, and the slot conductor portion 331b is referred to as an outermost slot conductor portion.
[0029]
In the small segment 332, 332a and 332b are slot conductor portions, 332c is a head portion, 332f and 332g are end portions. Since the end portions 332d and 332e of the end portions 332f and 332g are joint portions, they are also referred to as end tip portions or joint portions. The slot conductor portion 332a is referred to as a middle inner layer slot conductor portion, and the slot conductor portion 332b is referred to as a middle outer layer slot conductor portion.
[0030]
The symbol 'indicates the same portion as the portion without the large segment or small segment symbol' (not shown). Accordingly, in FIG. 2, the joint portion 331 d and the joint portion 332 d ′ that are adjacent to each other in the radial direction are welded, the joint portion 332 d and the joint portion 331 d ′ that are adjacent to each other in the radial direction are welded, and are adjacent to each other in the radial direction. The joint portion 332e and the joint portion 331e ′ are welded.
[0031]
In FIG. 2, when the innermost slot conductor portion 331 a and the inner inner slot conductor portion 332 a of the pair of segments 331 and 332 are accommodated in the predetermined slots of the rotor core 71, The slot conductor portion 331b and the slot conductor portion 332b in the middle and outer layers are accommodated in a slot that is separated from the predetermined slot by a predetermined odd-numbered magnetic pole pitch T (in this embodiment, one magnetic pole pitch (electrical angle π)). The head 332c of the small segment 332 is disposed so as to be surrounded by the head 331c of the large segment 331.
[0032]
The segment arrangement state of the slot is shown in FIG.
[0033]
The innermost slot conductor portion 331a is disposed on the radially innermost side of the slot 35 of the stator core 32. Hereinafter, the innermost slot conductor portion 332a, the outermost slot conductor portion 332b ′, The slot conductor portions 331b ′ are arranged in this order. Eventually, each slot 35 accommodates four slot conductor portions in one row of four layers. In FIG. 3, the slot conductor portions 332b ′ and 332b ′ belong to a large segment 331 and a small segment 332 that are different from the large segment 331 and the small segment 332 having the slot conductor portions 332a and 331a.
[0034]
An example of a state in which the large segment 331 and the small segment 332 are inserted into the slot 35 is shown in FIG. However, this example shows a case where one magnetic pole pitch is composed of three slot pitches.
[0035]
FIG. 5 shows a case where three composite phase coils constituting a three-phase stator coil are configured by connecting two phase coils in series with interphase connection lines.
[0036]
The U-phase coil and the X-phase coil are connected in series to form a UX-phase composite phase coil. Similarly, a VY-phase composite phase coil and a WZ-phase composite phase coil are configured. . More specifically, in this case, one magnetic pole pitch (electrical angle π) is composed of 6 slots adjacent to each other, and the slot arrangement is U, X, −V, −Z, W, Y, −U, −X, V, Z, -W, -Y. In this slot arrangement method, the U-phase coil and the X-phase coil adjacent to each other are connected in series by the interphase connection line 1000, both ends are set as the neutral point C and the U-X output terminal, and the adjacent W-phase coil and Y-phase are connected to each other. A phase coil is connected in series with an interphase connection line 1000 and both ends are neutral points C and W-Y output terminals, and a V phase coil and a Z phase coil adjacent to each other are connected in series with an interphase connection line 1000 and both ends. Are the neutral point C and the VZ output terminal.
[0037]
A segment having a pair of slot conductors connected to the interphase connection line 1000 (also referred to as an interphase connection line segment) is different from the same-angle position segment where the slot conductor portion pair is separated from the magnetic pole pitch by one pitch from the magnetic pole pitch. Has a shifted circumferential pitch.
[0038]
Similarly, a segment (also referred to as a terminal segment) composed of, for example, the first slot conductor portion of the U phase connected to the phase output terminal and the last slot conductor portion of the X phase connected to the neutral point C, for example, is separated later. Thus, an output terminal (also referred to as a lead terminal) 2000 and a neutral crossover wire 3000 are configured. This terminal segment has a circumferential pitch that is one pitch less than the magnetic pole pitch, unlike the above-mentioned equiangular position segment in which the slot conductor portion pair is separated from the magnetic pole pitch.
(Description of manufacturing method)
1. Head twisting process (head expanding process)
The head twisting process will be described below with reference to FIGS. However, the different angle position segment composed of the terminal segment and the interphase connecting line segment is already twisted by one slot pitch by the pre-twisting process described later.
[0039]
The state before the segment insertion in this head twisting process is shown in FIG. In FIG. 6, 10 is a head twisting device, 11 is a small ring, 12 is a large ring, and both are coaxially arranged so as to be relatively rotatable. The large ring 11 is provided with a pair of holes 121 and 122 arranged in the radial direction at a predetermined pitch in the circumferential direction, and the small ring 12 is paired with a pair of holes 111 arranged in the radial direction at an equal pitch in the circumferential direction. , 112 are provided. The holes 111 to 114 are arranged in a line in the radial direction. Both slot conductor portions of the large-turn segment (large segment) 331 are inserted into the innermost hole 111 and the outermost hole 122, and both slot conductor portions of the small-turn segment (small segment) 332 are located outside the innermost hole 111. And the inner hole 121 of the outermost hole 122.
[0040]
FIG. 7 shows a state in which all the large segments 331 and all the small segments 332 are inserted into the holes 111, 112, 121, 122 of the small ring 11 and the large ring 12. In FIG. 7, reference numeral 16 denotes a head pressing plate disposed in the axial direction above the small ring 11 and the large ring 12. The lower end surface of the head pressing plate 16 has a claw portion 160 that sandwiches a pair of the top of the head of the large segment 331 and the top of the head of the small segment 332 at the same circumferential position. . That is, after each segment 33 is inserted into the holes 111, 112, 121, 122, the holding plate 16 is lowered, and each pair of claw portions 160 is smaller than the top of the head of the large segment 331 at the same circumferential position. The top of the head of the segment 332 is sandwiched from both sides in the circumferential direction.
[0041]
Thereafter, the large ring 12 and the small ring 11 are rotated in opposite directions by a half magnetic pole pitch (3-slot pitch) relative to the stationary head pressing plate 16. As a result, the two legs of all the segments 33 are twisted (deployed in the circumferential direction) by one magnetic pole pitch in the circumferential direction. In addition, since the top of the head of the segment 33 is displaced axially toward the rings 11 and 12 as the rings 11 and 12 are rotated during the rotation with the rings 11 and 12, the head pressing plate 16 is Together, they are displaced in the axial direction.
[0042]
Next, the small ring 11 and the large ring 12 are separated from the segments 33 while the segments 33 are held by the head pressing plate 16.
[0043]
2. Segment insertion process
Next, the segments 33 separated from the rings 11 and 12 are moved to the middle and middle layer positions of the slots 35 of the stator core 32 as shown in FIG. 4 without disturbing the relative spatial position and posture of each other. Insert through. Thereafter, the head pressing plate 16 is removed, but the head pressing plate 16 may be used in the next end twisting step.
[0044]
3. End twisting process (end unfolding process)
The twist forming process of the end portion of the segment 33 inserted through the slot as described above will be described below with reference to FIGS. This process is essentially the same as before. 8 is a schematic longitudinal sectional view of the stator coil twisting device 500, and FIG. 9 is a sectional view taken along the line AA in FIG.
[0045]
An end portion 331g (also referred to as an outer layer side end portion) connected to the outermost layer slot conductor portion 331b of the large segment 331 is twisted to one side in the circumferential direction, and an end portion 331f (inner layer side) connected to the innermost layer slot conductor portion 331a of the large segment 331 Is also twisted to the other circumferential side. An end portion 332f (also referred to as an inner layer side end portion) connected to the slot conductor portion 332a in the middle and inner layers of the small segment 332 is twisted to one side in the circumferential direction, and an end portion 332g (connected to the slot conductor portion 332b in the middle and outer layers of the small segment 332) Is also twisted to the other side in the circumferential direction. The total circumferential twist amount of the conductor portions 331f and 332f is one magnetic pole pitch, and the total circumferential twist amount of the conductor portions 331g and 332g is one magnetic pole pitch.
[0046]
First, the configuration of the stator coil twisting device 500 shown in FIG. 8 will be described.
[0047]
The stator coil twisting device 500 includes a workpiece receiver 51 that receives the outer periphery of the stator core 32, a clamper 52 that restricts and holds the radial movement of the stator core 32, a workpiece presser 53 that prevents the stator core 32 from being lifted, and one end of the stator core 32. A twist shaping portion 54 for twisting the protruding leg portion of the segment 33 that has come out, an elevating shaft 54a for driving the twist shaping portion 54 in the axial direction, and a rotational drive mechanism 541a for rotating the twist shaping portion 54 in the circumferential direction. 544a, an elevating drive mechanism 54b for moving the elevating shaft 54a in the axial direction, and a controller 55 for controlling the rotational drive mechanisms 541a to 544a and the elevating drive mechanism 54b.
[0048]
In the twist shaping section 54, four cylindrical twist jigs 541 to 544 arranged concentrically are arranged with their front end surfaces aligned. Each of the twisting jigs 541 to 544 can be independently rotated by the rotation drive mechanisms 541a to 544a, and can be lifted and lowered simultaneously by raising and lowering the lifting shaft 54a by the lifting drive mechanism 54b.
[0049]
As shown in FIG. 9, segment insertion portions for holding the respective distal ends (joining portions) of the end portions 331 f, 331 g, 332 f, and 332 g of the inserted segment 33 are provided on the distal end surfaces of the twisting jigs 541 to 544. 541b to 544b are formed. The segment insertion portions 541b to 544b are formed in the circumferential direction of the twisting jigs 541 to 544 by the same number as the slots 35 of the stator core 32. In FIG. 3, reference numeral 34 denotes an insulating resin sheet.
[0050]
As shown in FIG. 9, the segment insertion portions 541b to 544b are provided with partition walls 541c to 544c, 542d, and 543d for preventing communication between the segment insertion portions 541b to 544b that are adjacent to each other in the radial direction. The thicknesses of the partition walls 541c to 544c, 542d, and 543d are the distance d1 formed by the partition walls 541c and 542c between the first layer and the second layer, counted from the outside in the radial direction, and between the third layer and the fourth layer. The distance d2 formed by the partition walls 542d and 543d between the second layer and the third layer is set to be larger than the distance d3 formed by the partition walls 543c and 544c.
[0051]
Next, the operation of the stator coil twisting device 500 will be described.
[0052]
The stator core 32 in which the segment 33 is disposed in the slot 35 is set on the work receiver 51. Next, the outer peripheral portion of the stator core 32 is fixed to the clamper 52. After that, the upper part of the stator core 32 and the head 331c of the large segment 331 are pressed by the work presser 53, thereby restricting the vertical movement of the stator core 32 and the segment 33.
[0053]
After the stator core 32 on which the segment 33 is disposed is fixed by the clamper 52 and the work receiver 53, the twist shaping portion 54 is raised by the lifting shaft 54a, and the segment insertion portions 541b to 544b formed on the twist jigs 541 to 544 are raised. The end portions 331f, 331g, 332f, and 332g of the segment 33 are inserted into the segments.
[0054]
Only the tip portions of the end portions 331f, 331g, 332f, 332g, and 332g of the segment 33, that is, the portions to be joined later, can be inserted into the segment insertion portions 541b to 544b. Since the end portions 331f, 331g, 332f, and 332g of the segment 33 are formed in a tapered shape, they can be smoothly inserted into the segment insertion portions 541b to 544b.
[0055]
After the end portions 331f, 331g, 332f, and 332g of the segment 33 are inserted into the segment insertion portions 541b to 544b of the twist shaping portion 54, the twist shaping portion 54 is rotated by the rotation drive mechanisms 541a to 544a and the elevation drive mechanism 54b. Lifted and lowered. The twist shaping unit 54 performs all of the twist shaping units 541 to 544 at the same time.
[0056]
Next, the rotation of the twist shaping unit 554 will be described.
[0057]
The twisting jig 541 and the jig 543 are rotated clockwise by a half magnetic pole pitch, and the twisting jig 542 and the twisting jig 544 are rotated counterclockwise by a half magnetic pole pitch. After that, of the end portions 331f, 331g, 332f, and 332g of the segment 33, the elevating drive mechanism 54b and the rotary drive mechanism are maintained so that the lengths from the outlet of the slot 35 to the inlets of the segment insertion portions 541b to 544b are kept constant. The twist shaping section 54 is raised while rotating while controlling 541a to 544a. At this time, the end portions 331f, 331g, 332f, and 332g of the segment 33 rise while rotating so as to draw an arcuate locus. The twist drawing the arc-shaped locus is performed up to an angle exceeding a predetermined amount beyond the angle corresponding to the half magnetic pole pitch (T / 2) in order to prevent the deformation of the segment 33 due to the spring back.
[0058]
In this process, the torsion shaping parts 541 to 544 are driven not only in the circumferential direction but also in the axial direction by exceeding a predetermined processing amount, but the exit portion of the slot 35 of the segment 33 has already been bent. Therefore, the segment 33 does not rise and come out of the slot 35.
[0059]
Thereafter, the elevation drive mechanism 54b and the rotation drive mechanisms 541a to 544a are rotated and lowered in the opposite direction to the previous step. In this way, the twisting process of the segment 33 is completed, the twist shaping portion 54 is lowered, and the end portions 331f, 331g, 332f, 332g of the segment 33 are removed from the segment insertion portions 541b-544b of the twisting jigs 541-544. . The twist shaping section 54 from which the segment 33 is removed is rotated by the rotation drive mechanisms 541a to 544a and returned to the original position. Finally, the clamper 52 and the work holder 53 are removed, and the stator with the segments 33 twisted is taken out.
[0060]
After all, in this twisting process, first, the end portion of the segment 33 is rotationally displaced only in the circumferential direction, the segment 3 is tilted in the circumferential direction, and then the end portion of the segment 33 is displaced in the circumferential direction and the axial direction. Inclined deeply, then, the end of the segment 3 is displaced in the circumferential direction and the axial direction beyond a predetermined processing amount, the segment 33 is excessively inclined, and then the end of the segment 33 is returned to the predetermined processing amount. Is done.
[0061]
The torsion shaping portion 54 moves relative to the stator core 32 not only in the circumferential direction but also in the axial direction. Therefore, of the end portions 331f, 331g, 332f, and 332g of the segment 33, the portion from the exit of the slot 35 to the entrance of the segment insertion portions 541b to 544b, that is, the end portion from the end portions 331f, 331g, 332f, and 332g (Junction part) Twist so that the edge part 331f, 331g, 332f, 332g of the segment 33 may draw an arc-shaped locus | trajectory so that the length which deducted the length of 331d, 331e, 332d, 332e may be kept constant. Accordingly, the segment 33 can be prevented from coming out of the segment insertion portions 541b to 544b.
[0062]
In addition, the thickness of the partition walls 541c to 544c, 542d, and 543d is larger than the partition walls 541c and 542c between the first layer and the second layer and the partition walls 543c and 544c between the third layer and the fourth layer. 2 Layer and 3 The partition walls 541d and 542d between the layers are set to be large. When the first layer, the second layer, the third layer, and the fourth layer are rotated by a half magnetic pole pitch in the opposite directions, the potential conductors 3 of the first layer, the second layer, the third layer, and the fourth layer approach each other. . On the other hand, the segment 3 insertion portions 542b and 543b in the second layer and the third layer have the partition 542d and 543d having a large thickness, so that the interval between the second layer and the third layer segment 33 is increased. Accordingly, the segments 3 to be joined, that is, the first and second layers, and the third and fourth segments 3 can be brought close to each other. The gap can be increased to facilitate the joining process.
[0063]
4). Joining process
Next, the joining process to be performed will be described below. This process is essentially the same as before.
[0064]
After the twisting of the end portion, as shown in FIG. 2, the tip ends (joined portions) of the first and second layers are welded from the radially inner side, and the third and fourth layers are welded from the radially inner side. The end tip (joint portion) is welded to complete the stator coil 31. TIG welding, brazing, resistance welding, electron beam welding, laser welding, etc. are used for welding.
[0065]
(Reference Example 2)
Hereinafter, Reference Example 2 will be described. However, the symbols used in Reference Example 2 below are irrelevant to the symbols used in Reference Example 1 above. FIG. 11 is a longitudinal sectional view of an AC generator for a vehicle, FIG. 12 is a perspective view of a segment forming a part of a stator coil, and FIG. 13 is a sectional view showing a state in which the segment is accommodated in a slot.
(Overall structure)
FIG. 11 is a vertical cross-sectional view of this vehicle alternator. In FIG. 11, 1 is a stator (stator), 2 is a stator core, 3 is a stator coil, 4 is a rotor (rotor), 5 is a housing, and 6 is a rotating shaft.
[0066]
The stator 1 is fixed to the inner peripheral surface of the peripheral wall of the housing 5, and the rotary shaft 6 on which the rotor 4 is fitted is rotatably supported on both end walls of the housing 5 by a pair of bearings. Pulley connected by belt.
[0067]
In the vicinity of the outer peripheral surface of the rotor 4, permanent magnets (not shown) are alternately buried in polarity at a predetermined pitch in the circumferential direction to constitute a permanent magnet type three-phase brushless DC motor (IPM type synchronous motor) as a whole. The rotor structure may have various types other than the Landel pole core structure. However, since the various types of synchronous machines themselves are well known, description thereof will be omitted.
[0068]
The stator 1 includes a stator winding (see FIG. 12) 2 having a slot S and a tooth portion T, and a plurality of segment conductors that pass through the slots S in the axial direction. A three-phase star-connected stator coil) 3 and an insulator 7 that electrically insulates between the stator core 2 and each segment conductor.
[0069]
The stator coil 3 includes three phase coils formed by inserting U-shaped segment conductors 30 into the slots S from the right side to the left side in the axial direction in FIG. It consists of a three-phase star-shaped winding to which a U-phase coil, a V-phase coil, and a W-phase coil are connected, but may be a three-phase delta winding.
[0070]
As shown in FIG. 13, each segment conductor 30 includes a substantially V-shaped head portion 31 and a pair of leg portions 32 respectively extending from both ends of the head portion 31. The leg portion 32 protrudes from the front end portion of the stator core 2 with the slot conductor portion 33 accommodated in the slot S, and then bends substantially in the circumferential direction, and other segment conductors 30 adjacent in the radial direction. The end portion 34 is welded to the end portion 34 to constitute the end portion side coil end 8. The head portion 31 of the segment conductor 30 also protrudes from the rear end portion of the stator core 2 and constitutes the head-side coil end 9.
[0071]
In one slot S, as shown in FIG. 12, six slot conductor portions 33 are arranged in a row in the radial direction. The radial position of the slot conductor portion 33 is referred to as a first layer, a second layer, a third layer, a fourth layer, a fifth layer, and a sixth layer in order from the radially inner side. That is, the slot conductor portion 331 has one layer, the slot conductor portion 332 has two layers, the slot conductor portion 333 has three layers, the slot conductor portion 334 has four layers, the slot conductor portion 335 has five layers, and the slot conductor portion has three layers. 336 is accommodated in six layers. The pair of slot conductor portions 33, 33 of the same segment conductor 30 are inserted into a pair of slots S separated from each other by approximately one magnetic pole pitch (electrical angle π), and are accommodated at different positions in the radial direction.
[0072]
In this embodiment, as shown in FIGS. 11 and 14, the segment conductor 30 has three types of segment conductors 300, 301, and 302 formed in a substantially U shape.
[0073]
The segment conductor 300 has a one-layer slot conductor portion 331 and a four-layer slot conductor portion 334, and is also called a large segment. The segment conductor 301 has a two-layer slot conductor portion 332 and a three-layer slot conductor portion 333, and is also called a small segment. The segment conductors 300 and 301 together constitute the first coil (the four-conductor radial direction arrangement coil described above). The segment conductor 302 has a five-layer slot conductor portion 335 and a six-layer slot conductor portion 336, and is also called a small segment. The segment conductor 302 alone constitutes the second coil (the already described two-conductor radial direction arrangement type coil).
[0074]
Therefore, in FIG. 14, the one-layer slot conductor portion 331 and the four-layer slot conductor portion 334 belonging to the same segment conductor 300 individually belong to two slots separated by a substantially magnetic pole pitch. Similarly, the two-layer slot conductor portions 332 and the three-layer slot conductor portions 333 belonging to the same segment conductor 301 individually belong to two slots separated by a substantially magnetic pole pitch. Similarly, the five-layer slot conductor portions 335 and the six-layer slot conductor portions 336 belonging to the same segment conductor 302 individually belong to two slots separated by a substantially magnetic pole pitch.
[0075]
As shown in the equivalent circuit diagram of FIG. 15, the four-conductor radial arrangement type coil 400 formed by alternately connecting the segment conductors 300 and 301 and the two-conductor radial arrangement type coil formed by sequentially connecting the segment conductors 302. 200 is connected in series for each phase to constitute a phase winding of each phase. Reference numeral 500 denotes a substantially U-shaped segment conductor forming a coil connection line, one slot conductor portion forming the final slot conductor portion of the four-conductor radial arrangement type coil, and the other slot conductor portion including two conductors. It forms the first slot conductor of the radially arranged coil. The final slot conductor portion of the two-conductor radial arrangement coil belongs to a substantially L-shaped segment conductor 600, and this segment conductor 600 also serves as a neutral point jumper. The first slot conductor portion of the four-conductor radially arranged coil belongs to a substantially L-shaped segment conductor 700, and this segment conductor 700 also serves as an external lead terminal for each phase. A two-conductor radial direction arrangement type coil 200 and a four-conductor radial direction arrangement type coil 400 are shown enlarged in FIG.
[0076]
The specific winding pattern into the slots of the two-conductor radial arrangement coil 200 and the four-conductor radial arrangement coil 400 for each phase is as follows. Depending on the application, a suitable winding pattern may be adopted depending on the application, and since it is already well known to those skilled in the art, a detailed description is omitted.
(Coil manufacturing process)
Next, a manufacturing method of the above-described two-conductor radial arrangement coil 200 and four-conductor radial arrangement coil 400 will be described below.
[0077]
1. Head twisting process (head expanding process)
The head twisting process will be described below with reference to FIGS. 17 and 18 show a state before the head 31 of the three types of segment conductors 300 to 302 is twisted in the circumferential direction, that is, a state before the head is unfolded, and the first leg 321 and the first leg 321 of the segment conductors 300 to 302 are shown. The two leg portions 322 extend from both ends of the head portion 31 in a straight line.
[0078]
Reference numerals 1000 to 1002 denote rings arranged so as to be rotatable relative to each other, and are arranged coaxially. The diameter of the ring 1000 is the minimum, and the diameter of the ring 1002 is the maximum. Each of the rings 1000 to 1002 has grooves or holes h equal to the number of slots at equal pitches to the slots.
[0079]
The legs 34 of the segment conductors 300 to 302 are accommodated in the grooves or holes of the rings 1000 to 1002, and the heads 31 of the segment conductors 300 to 302 protrude above the rings 1000 to 1002.
[0080]
The slot conductor portion 331 of the segment conductor 300 and the slot conductor portion 332 of the segment conductor 301 are inserted into the groove or hole of the ring 1000, and the slot conductor portion 333 of the segment conductor 301, the slot conductor portion 334 of the segment conductor 301, and the segment conductor 302. The slot conductor portion 335 is inserted into the groove or hole of the ring 1001, and the slot conductor portion 336 of the segment conductor 302 is inserted into the groove or hole of the ring 1002. Since the head is not deployed, the pair of slot conductors 33 of the same segment conductor are disposed at the same position in the circumferential direction (see FIG. 18).
[0081]
The distal ends of the head portions 31 of the segment conductors 300 and 301 are sandwiched in the circumferential direction by a pair of sandwiching claws (only one in the circumferential direction shown in the drawing) 1004 that hangs down from the pressing ring 1003. The tip of the head 31 of the segment conductor 302 is sandwiched in the circumferential direction by a pair of sandwiching claws (only one in the circumferential direction shown in the figure) 1005 that hangs down from the pressing ring 1003.
[0082]
In this state, in a state where the holding ring 1003 is not rotated, the rings 1000 and 1002 are rotated clockwise, for example, and the ring 1001 is rotated counterclockwise. In this embodiment, the rotation angle of each of the rings 1000 to 1002 is set to a semi-magnetic pole pitch, but the sum of the rotation angles of the rings 1000 and 1002 and the rotation angle of the ring 1001 is the magnetic pole pitch (electrical angle π). If it becomes.
[0083]
By the rotation of the rings 1000 to 1002, the head portions 31 of the segment conductors 300 to 302 are developed in the circumferential direction, and the first leg portion 321 and the second leg portion 322 of the same segment conductor are separated by one magnetic pole pitch.
[0084]
When this head unfolding process is performed, the height in the axial direction of the head 31 of each segment conductor 300 to 302 is reduced, so that the holding ring 1003 is lowered toward the rings 1000 to 1002 accordingly. After the deployment is completed, the segment conductors 300 to 302 are detached from the rings 1000 to 1002 while the segment conductors 300 to 302 are held by the pressing ring 1003.
[0085]
In this head expanding step, if the sum of the rotation angle of the ring 1000 and the rotation angle of the ring 1001 is one magnetic pole pitch, the rotation angle of the ring 1000 and the rotation angle of the ring 1001 can be freely set. can do. As a modified form of the head expanding step, the rings 1000 and 1002 may not be rotated, but the ring 1001 may be rotated in the same direction by one magnetic pole pitch and the holding ring 1003 may be rotated in the same direction by, for example, a half magnetic pole pitch. The rings 1000 and 1002 may be rotated in the same direction by one magnetic pole pitch and the holding ring 1003 by, for example, a half magnetic pole pitch.
[0086]
According to the head expanding step described above, the first leg 321 of the segment conductor 302 belonging to the two-conductor radial direction arrangement type coil 200 and the first leg of the segment conductor 302 belonging to the four-conductor radial direction arrangement type coil 400. The first leg 321 of the segment conductor 300 adjacent to the part 321 in the radial direction is held by the same ring 1001, and the second leg 322 of the segment conductor 302 is held by the ring 1002 radially outside the ring 1001, The second leg portion 322 of the segment conductor 300 is held in the ring 1000 radially inward from the ring 1001 and these rings 1000 to 1002 are relatively rotated. Therefore, in summary, they belong to different coils and are adjacent in the radial direction. Since the heads are expanded while holding the legs of the two segment conductors 300 and 302 in the same ring, Together reduce the grayed number, a rubbing of the head 31 of the head 31 and the conductor segment 302 of the conductor segments 300 can be prevented.
[0087]
2. Segment conductor insertion process
Next, these segment conductors 300 to 302 are inserted into the slots S of the stator core 2 without disturbing the relative spatial position and posture of each other, and then the pressing ring 1003 is removed.
[0088]
3. End twisting process (end unfolding process)
An end unfolding process for twisting the end portions 34 of the segment conductors 300 to 302 inserted into the slots as described above will be described below with reference to FIG. For the specific configuration of the actual twisting device, refer to the above-mentioned patent document filed by the present applicant.
[0089]
Reference numerals 2000 to 2004 denote rings arranged so as to be rotatable relative to each other, and are arranged coaxially. Each of the rings 2000 to 2004 has a groove or hole h ′ equal to the number of slots at an equal pitch to the slots.
[0090]
A front end portion 35 of the end portion 34 is accommodated in each groove or hole h ′ recessed in the upper end surface of the rings 2000 to 2004. The end portion 34 is a portion obtained by removing the slot conductor portion 33 from each leg portion 32 of the segment conductors 300 to 302 protruding from the stator core 2.
[0091]
341 is an end portion of the segment conductor 300 belonging to the second leg portion 322, 342 is an end portion of the segment conductor 301 belonging to the second leg portion 322, 343 is an end portion of the segment conductor 301 belonging to the first leg portion 321 and 344 is An end portion of the segment conductor 300 belonging to the first leg portion 321, 345 is an end portion of the segment conductor 302 belonging to the first leg portion 321, and 346 is an end portion of the segment conductor 302 belonging to the second leg portion 322.
[0092]
The tip 35 of the end 341 is in the ring 2000, the tip 35 of the end 342 is in the ring 2001, the tip 35 of the end 343 is in the ring 2002, and the tip 35 of the end 344 and the tip of the end 345. 35 is held by the ring 2003, and the tip 35 of the end 346 is held by the ring 2004.
[0093]
In this state, if the odd-numbered rings 2000, 2002, 2004 are rotated in the clockwise direction by the semi-magnetic pole pitch and the even-numbered rings 2001, 2003 are rotated in the counterclockwise direction by the semi-magnetic pole pitch from the inside in the radial direction. ˜346 are developed in the circumferential direction. Further, the distal end portion 35 of the leg portion 341 and the distal end portion 35 of the leg portion 342 are separated from each other by the magnetic pole pitch, and the distal end portion 35 of the leg portion 343 and the distal end portion 35 of the leg portion 344 are separated from each other by the magnetic pole pitch. 35 and the tip 35 of the leg 346 are separated from each other by the magnetic pole pitch. After the end deployment is completed, the rings 2000 to 2004 are detached from the end portions 341 to 346. In addition, since the axial direction height of the edge parts 341-346 reduces with edge part expansion | deployment, it is suitable to lower the stator core 2 or raise the rings 2000-2004.
[0094]
If the sum of the rotation angle of the even-numbered rings 2000, 2002, 2004, 2006 and the rotation angle of the odd-numbered rings 2001, 2003 in this end unfolding step is one magnetic pole pitch, The rotation angle and the rotation angle of the odd-numbered ring can be set freely. Further, as a modified form of the end unfolding step, one of the odd-numbered ring and the even-numbered ring may not be rotated, and the other may be rotated by one magnetic pole pitch and the stator core 2 may be rotated by a predetermined angle.
[0095]
According to the above-described end unfolding step, the first leg portion 321 (end portion 345) of the segment conductor 302 belonging to the two-conductor radial arrangement coil 200, the segment conductor belonging to the four-conductor radial arrangement coil 400 and the segment conductor. Since the first leg portion 321 (end portion 344) of the segment conductor 300 radially adjacent to the first leg portion 321 (end portion 345) of 302 is held by the same ring 2003, these end portions 344, Thus, rubbing with 345 can be prevented and the number of rings can be reduced.
[0096]
4). Joining process
Next, the joining process to be performed will be described below. This process is essentially the same as before.
[0097]
After developing the end portions 341 to 346 described above, the distal end portion 35 of the end portion 341 and the distal end portion 35 of the end portion 342 that are adjacent to each other in the radial direction are welded, and the distal end portion of the end portion 343 that is adjacent to each other in the radial direction. 35 and the distal end portion 35 of the end portion 344 are welded, and the distal end portion 35 of the end portion 345 and the distal end portion 35 of the end portion 346 which are adjacent to each other in the radial direction are welded. TIG welding, brazing, resistance welding, electron beam welding, laser welding, etc. are used for welding.
[0098]
The deformed segment conductors 500, 600, and 700 described with reference to FIG. 15 may be developed in the above-described head unfolding step and end portion unfolding step, but those previously unfolded may be inserted into the slots. Also, in the two-conductor radial direction arrangement type coil 200 and the four-conductor radial direction arrangement type coil 400, when two or more common-phase slots per phase per pole are arranged adjacent to each other, the segment conductors of these adjacent common-mode slots are adjacent to each other. A U-shaped segment for crossing slots for connecting the two is adopted. For details of these, see, for example, Patent Documents 3 and 4 described above.
Example 1
Hereinafter, the armature of the present invention for adjusting the circumferential gap of the coil end conductor (head or end) will be described with reference to Example 1 (corresponding to the second invention referred to in this specification). Since the entire configuration of the rotating electric machine, the structure of the stator coil, and the manufacturing method itself have already been described with reference examples 1 and 2, only the characteristic points of the armature of this embodiment will be described. Note that the reference numerals used in the description of the first embodiment are irrelevant to the reference numerals used in the first and second reference examples.
(Structure of coil end)
Hereinafter, the structure of the coil end in this embodiment will be described with reference to FIG. FIG. 21 shows the head-side coil end of the stator coil, but the same applies to the end-side coil end.
[0099]
In FIG. 21, S1 to S3 are three slots constituting one adjacent in-phase slot group G1 of the U phase, S4 to S6 are three slots constituting one adjacent in-phase slot group G2 of the V phase, and S7 to S9 are Three slots constituting one adjacent in-phase slot group G3 of the W phase, and S10 to S12 are three slots constituting one adjacent in-phase slot group G4 of the U phase. That is, the stator core (armature core) 2 has three slots per phase per pole.
[0100]
C1 is a segment conductor that penetrates through the first slots S1 and S10 counted from one circumferential side of the adjacent in-phase slot groups G1 and G4. C2 is a segment conductor penetrating through the second slots S2 and S11 counted from one side in the circumferential direction of the adjacent in-phase slot groups G1 and G4. C3 is a segment conductor penetrating through the third slots S3 and S12 counted from one side in the circumferential direction of the adjacent in-phase slot groups G1 and G4. The segment conductors C1, C2, and C3 constitute one U-phase adjacent in-phase coil end conductor group G1 ′.
[0101]
C4 is a segment conductor penetrating through the first slots S4 and S13 counted from one circumferential side of the adjacent in-phase slot groups G2 and G5. C5 is a segment conductor penetrating through the second slots S5 and S14 counted from one circumferential side of the adjacent in-phase slot groups G2 and G5. C6 is a segment conductor penetrating through the third slots S6 and S15 counted from one side in the circumferential direction of the adjacent in-phase slot groups G1 and G4. The segment conductors C4, C5, and C6 constitute one V-phase adjacent in-phase coil end conductor group G2 ′.
[0102]
C7 is a segment conductor that penetrates through the first slots S7 and S16 counted from one circumferential side of the adjacent in-phase slot groups G3 and G6. C8 is a segment conductor penetrating through the second slots S8 and S17 counted from one side in the circumferential direction of the adjacent in-phase slot groups G3 and G6. C9 is a segment conductor that penetrates through the third slots S9 and S18 counted from one side in the circumferential direction of the adjacent in-phase slot groups G3 and G6. The segment conductors C7, C8, and C9 constitute one W-phase adjacent in-phase coil end conductor group G3 ′.
[0103]
In this embodiment, a slot pitch d between a pair of adjacent slots belonging to each adjacent in-phase slot group is set narrower than a slot pitch e between a pair of adjacent slots belonging to different adjacent in-phase slot groups. Has been.
[0104]
As a result, the gap X between a pair of segment conductors belonging to each adjacent in-phase coil end conductor group and adjacent to each other, although the shapes of the radius of curvature, bending position, etc. of the segment conductors C1 to C9 are set equal. Compared to the case, the gap Y between a pair of adjacent segment conductors belonging to different adjacent in-phase coil end conductor groups and adjacent to each other can be set wider, and the gap between all the segment conductors can be made equal. Can be set widely.
[0105]
Thus, compared to the voltage between a pair of adjacent segment conductors belonging to each adjacent in-phase coil end conductor group, a large voltage is applied between a pair of segment conductors belonging to different adjacent in-phase coil end conductor groups and adjacent to each other. Even when (interphase voltage) is applied, the occurrence of corona discharge can be satisfactorily prevented, and the voltage endurance of the coil end can be improved.
[0106]
In addition, the improvement in the voltage endurance of the coil end according to this embodiment is excellent in workability because the bending operation (deployment operation) of the coil end is not complicated. However, when the tip portion of the head of the segment conductor is held with a nail in the above-described head unfolding step, it is necessary to adjust the position of the nail. In addition, it is necessary to adjust the position of the hole or groove of the ring that holds the tip portion of the end portion of the segment conductor in the above-described end portion developing step.
(Example 2)
Hereinafter, the armature of the present invention for adjusting the circumferential gap of the coil end conductor (head or end) will be described with reference to the following Example 2 (corresponding to the first invention in this specification). Since the entire configuration of the rotating electric machine, the structure of the stator coil, and the manufacturing method itself have already been described with reference examples 1 and 2, only the characteristic points of the armature of this embodiment will be described. This example 2 It is assumed that the reference numerals used in the description of the above are unrelated to the reference numerals used in Reference Examples 1 and 2 above.
(Structure of coil end)
Hereinafter, the structure of the coil end in the second embodiment is shown in FIG. 2 Will be described with reference to FIG. FIG. 2 Shows the head side coil end of the stator coil, and the same applies to the end side coil end. Except for the fact that all slot pitches are constant, the arrangement of the slots S1 to S12 and the adjacent in-phase coil end conductor groups G1 to G4 is the same as that of the first embodiment (see FIG. 21). Further, the arrangement of the adjacent in-phase coil end conductor groups G1 ′, G2 ′, G3 ′ and the segment conductors C1 to C9 constituting them is also the same as that in Example 1 except that the positions of the bending start points described later are different (see FIG. 21). ).
[0107]
The heads (or end portions) of the three segment conductors belonging to the same adjacent common-phase coil end conductor group first protrude in a straight line from the slots in the axial direction to reach the bending start points P1, P2, and P3. As shown in the figure, they are bent by the same angle in the circumferential direction with the same radius of curvature, and then extend again in a straight line to reach the tip of the head (or end).
[0108]
The feature of the second embodiment is that the heads (for example, C4, C5, C6) of the three segment conductors belonging to the same adjacent in-phase coil end conductor group have different bending start points. More specifically, the head (for example, C4) that is most shifted to one side in the circumferential direction among the adjacent in-phase coil end conductor groups indicates the bending start point P1, and the head at the center in the circumferential direction (for example, C5) among the adjacent in-phase coil end conductor groups. ) Has a bending start point P2, and the head (for example, C6) that is most shifted to the other circumferential side of the adjacent in-phase coil end conductor group has a bending start point P3.
[0109]
The axial distance a between the bending start point P1 and the end surface of the stator core 2 is set to be smaller than the axial distances b and c of the other bending start points P2 and P3. The axial distance c between them is set larger than the axial distances a and b of the other bending start points P2 and P3.
[0110]
In this way, as in the case of the first embodiment, the segment conductors C1 to C9 belong to each adjacent in-phase coil end conductor group and are adjacent to each other even though the curvature radii, slot pitches, and the like are set to be equal. Compared to a gap X between a pair of segment conductors, a gap Y between a pair of segment conductors belonging to different adjacent in-phase coil end conductor groups and adjacent to each other can be set wide, and all the segment conductors The gap can be set wider than when the gaps are equal.
[0111]
Thus, compared to the voltage between a pair of adjacent segment conductors belonging to each adjacent in-phase coil end conductor group, a large voltage is applied between a pair of segment conductors belonging to different adjacent in-phase coil end conductor groups and adjacent to each other. Even when (interphase voltage) is applied, the occurrence of corona discharge can be satisfactorily prevented, and the voltage endurance of the coil end can be improved.
[0112]
In addition, the improvement in the voltage endurance of the coil end according to this embodiment is excellent in workability because the bending operation (deployment operation) of the coil end is not complicated. However, when the tip portion of the head of the segment conductor is held with a nail in the above-described head unfolding step, it is necessary to adjust the position of the nail. In addition, it is necessary to adjust the position of the hole or groove of the ring that holds the tip portion of the end portion of the segment conductor in the above-described end portion developing step.
(How to set the bending start point of the head (or end))
Hereinafter, a preferred method for setting the bending start point of the head (or the end) will be described.
[0113]
First, the segment conductor in which the head is expanded (twisted) by performing the head expansion process described above is used as the stator core. 3 2 is inserted from one end side in the axial direction, and the end development step is performed. In the insertion of the segment conductor before the end development step, the portion that finally enters the slot and becomes the slot conductor portion is inserted. The above-mentioned end unfolding step is carried out by extracting all of the head side coil end side by a predetermined distance. Thereafter, as shown in FIG. 22, the segment conductors on one side in the circumferential direction of the adjacent in-phase coil end conductor groups (for example, segment conductors C1, C4, C 7) Is pushed in deeply, and the segment conductors in the circumferential center of adjacent in-phase coil end conductor groups (for example, segment conductors C2, C5, C 8) Push shallower than that. Further, the segment conductor on the other side in the circumferential direction of the adjacent in-phase coil end conductor group (for example, segment conductor C 3 , C 6 , C 9) Does not push in.
[0114]
Thereby, the adjustment of the bending start point shown in FIG. 22 can be realized. At the same time, also in the end side coil end, the segment conductor (for example, segment conductor C) on one side in the circumferential direction in the adjacent in-phase coil end conductor group. 3 , C 6 , C 9 The starting point of bending is the stator core 3 2 segment conductors far from the end face of 2 and in the circumferential center of adjacent in-phase coil end conductor groups (for example, segment conductors C2, C5, C 8) Is the stator core 3 2 segment conductors (for example, segment conductor C) that are separated from the end face of the middle, and are located on the other circumferential side of the adjacent common-phase coil end conductor group. 1 , C 4 , C 7 ) Stator core 3 Almost no distance from the end face of 2.
[0115]
Thereby, the bending start point can be easily adjusted. In this case, the tip of the end of the segment conductor may vary for each segment conductor, but by adjusting the axial length of the end conductor of the segment conductor in advance, the end of each segment conductor It is also possible to make the lengths in the axial direction of the tip portions of the same. This simplifies subsequent welding operations.
[0116]
Instead of adjusting the bending start point at the head side coil end and the end side coil end by pushing in the axial direction after the end deployment process of the segment conductor, a jig is used in the head deployment process and the end deployment process. It is also possible to change the bending start point of each segment conductor using.
[0117]
If it does in this way, adjustment of the above-mentioned axial direction distance of each coil end conductor (head or end) can be performed easily, and automation and simultaneous processing will become easy.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view of an automotive alternator of Reference Example 1. FIG.
FIG. 2 is a schematic perspective view of the segment of FIG.
FIG. 3 is a partial cross-sectional view of the stator core of FIG.
FIG. 4 is a schematic perspective view showing a state immediately before the slot insertion of a segment.
5 is a winding diagram of a three-phase star connection type three-phase stator coil using six phase coils. FIG.
FIG. 6 is a perspective view showing a ring for twisting the head.
FIG. 7 is a cross-sectional view of a head twisting device.
FIG. 8 is a schematic longitudinal sectional view of the end twist shaping apparatus.
9 is a plan view of the twisting jig of FIG. 8. FIG.
FIG. 10 is a development view showing before and after the head full twisting process.
11 is a schematic axial sectional view of an automotive alternator of Reference Example 2. FIG.
12 is a partial cross-sectional view of the stator core of FIG.
13 is a schematic axial cross-sectional view of the segment conductor of FIG.
14 is a schematic perspective view of the segment conductor of FIG. 11. FIG.
FIG. 15 is a winding diagram of a three-phase star-connected three-phase armature coil using six coils.
16 is a schematic side view of the stator coil of FIG. 11 viewed in the axial direction.
FIG. 17 is a schematic explanatory view showing a head twisting process.
FIG. 18 is a schematic perspective view showing a head twisting process (before twisting).
FIG. 19 is a schematic perspective view showing a head twisting process (after twisting).
FIG. 20 is a schematic explanatory view showing an end twisting process.
FIG. 21 is a partial plan view showing a head-side coil end according to the first embodiment.
22 is a partial plan view showing a head-side coil end according to Embodiment 2. FIG.
[Explanation of symbols]
2 Stator core (armature core)
G1 to G4 adjacent in-phase slots
S1 to S3 Three slots constituting one adjacent in-phase slot group of U phase
S4 to S6 Three slots constituting one adjacent in-phase slot group of V phase
S7 to S9 Three slots constituting one adjacent in-phase slot group of W phase
S10 to S12 Three slots constituting one adjacent in-phase slot group of U phase
C1-C9 segment conductor
G1 'to G3' Adjacent in-phase coil end conductor group
d Slot pitch between a pair of slots belonging to each adjacent in-phase slot group and adjacent to each other
P1 Bending start point of the head most shifted to one side in the circumferential direction among adjacent in-phase coil end conductor groups
P2 Bending start point of the head at the center in the circumferential direction of adjacent in-phase coil end conductor groups
P3 Bending start point of the head most shifted to the other side in the circumferential direction of the adjacent in-phase coil end conductor group

Claims (2)

An armature winding formed by sequentially connecting a number of segment conductors inserted into each slot of the armature core having a U shape on one side in the axial direction of the armature core;
The segment conductor is formed in a substantially U shape to form a head-side coil end, and a pair of slot conductors extending from both ends of the head and individually extending into two slots. And a pair of end portions that are bent in the circumferential direction and constitute an end-side coil end after jumping out of the slot from the pair of slot conductor portions,
Each slot is an armature of a rotating electrical machine that is sequentially divided for each phase into adjacent in-phase slot groups composed of a plurality of the slots adjacent to each other, accommodating the segment conductors in phase.
The head or end is bent at a predetermined angle in the circumferential direction with a predetermined radius of curvature from a bending start point that is a predetermined distance away from the end face of the armature core in the axial direction;
The bending start point of the head or end protruding from the slot located on the most circumferential side of the adjacent in-phase slot group is the head protruding from the remaining slot of the adjacent in-phase slot group. Closer to the end face of the armature core than the bending start point of the part or end,
The head starting from the slot located on the other circumferential side of the adjacent in-phase slot group or the bending start point of the end is the head protruding from the remaining slot in the adjacent in-phase slot group Or the armature of a rotary electric machine characterized by being separated from the end surface of the armature core more than the bending start point of the end portion . In the manufacturing method of the armature of the rotary electric machine according to claim 1,
A head expanding step of expanding the head of the segment conductor in the circumferential direction;
An axial displacement pre-step of axially displacing the segment conductors of each slot belonging to the same adjacent in-phase slot group by a predetermined distance different from each other;
An end development step of developing the end of the segment conductor in the circumferential direction;
An axial displacement post-process for displacing the segment conductors of the slots belonging to the same adjacent in-phase slot group in the axial direction by a predetermined distance different from each other;
Are performed in the above-mentioned order.

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