JP4200611B2 - Winding formation method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a winding forming method for a rotating electrical machine such as an AC generator for a vehicle.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a stator having a winding formed by joining a plurality of conductor segments is known as a stator used in a vehicle AC generator. For example, in WO98 / 54823, a stator in which a winding is formed by inserting a plurality of U-shaped conductor segments from one end face side of a stator core and then joining ends on the opposite side to each other. Is disclosed. This stator has a feature that it is easy to form regularly arranged windings as compared to a case where windings are formed by winding continuous conductor windings.
[0003]
In the above-mentioned WO 98/54823, the end portions of the conductors inserted in the slots of the stator core are joined to each other, and the respective joints surround the shape of the stator core. They are arranged at equal intervals in the direction. For example, the above-mentioned publication discloses a stator in which four conductors are inserted in each slot as shown in FIG. The stator winding is formed by twisting a first conductor segment formed in a substantially U shape and a U-shaped second conductor segment having a bending radius larger than that of the first conductor segment. It is formed by inserting into the slots of the stator core and joining the tips of the anti-turn portions of the conductor segments together.
[0004]
[Problems to be solved by the invention]
By the way, in the conventional winding forming method in which the first and second conductor segments are overlapped and twisted and then inserted into the slots of the stator core, the first conductor segment included in the two overlapped conductor segments is included. If the distance between the tip portions of one conductor segment varies, the tip portions of the first conductor segment may come into contact with each other. Such contact between the tip portions also occurs after the first conductor segment is inserted into each slot of the stator core. For example, in FIG. 5, the second tip portion 232d and the third tip portion 232e viewed from the inside in the radial direction correspond to the first conductor segment, and when these tip portions 232d and 232e come into contact with each other, Since it becomes easy to produce a short circuit between, it is not preferable. In particular, even if the tip portions 232d and 232e are separated from each other, they cannot be deformed as expected by the springback, so that the correction work for these portions is not easy. For this reason, in order to reliably separate the tip portions 232d and 232e that are in contact with each other, a method of inserting an insulating material between them can be considered, but this is not preferable because the number of parts increases.
[0005]
The present invention has been created in view of such a point, and an object of the present invention is to provide a winding forming method capable of ensuring the distance between the tip portions of the conductor segments.
[0006]
[Means for Solving the Problems]
In order to solve the above-described problem, according to the winding forming method of the present invention, the second conductor segment formed in a substantially U shape is disposed outside the first conductor segment formed in a substantially V shape. The first step, the second step of setting the distance between the tips of the first conductor segment to a predetermined value in a state where the first conductor segment and the second conductor segment are combined, and the first conductor A third step of simultaneously twisting the segment and the second conductor segment in a combined state; a fourth step of simultaneously inserting the first conductor segment and the second conductor segment into a slot formed in the laminated iron core; It has. In this way, by disposing the second conductor segment molded in a substantially U shape outside the first conductor segment molded in a substantially V shape, the tip of the first conductor segment disposed on the inner side In the portion, since the elastic force for maintaining the V-shaped shape and the force pushed by the second conductor segment arranged on the outside work, the tip of the first conductor segment and the second conductor segment The tip will come into contact. Therefore, the distance between the front-end | tip parts of a 1st conductor segment is securable.
[0007]
In addition, the first conductor segment described above is formed such that the interval increases from the turn part to the tip part, and the second conductor segment is formed substantially parallel from the turn part to the tip part. In a state before the second conductor segments are combined, it is desirable that the distance between the tip portions of the first conductor segments is set wider than the distance between the tip portions of the second conductor segments. In this way, by disposing the second conductor segment having a narrow tip portion interval from the outside of the first conductor segment having a wide tip portion interval, the distance between the tip portions of the first conductor segment to be included can be reduced. It can be ensured, and contact between these tip portions can be prevented before and after assembly.
[0008]
Further, by the fourth step described above, the portions from the respective turn portions to the tip portions of the first and second conductor segments are divided and arranged on the inner diameter side and the outer diameter side of the annular core formed in an annular shape. Then, the inner peripheral side ends of the first and second conductor segments protruding from different slots and the outer peripheral side ends of the first and second conductor segments protruding from different slots are joined together. It is desirable to include a process. Thus, when joining the inner peripheral side edge parts of the 1st and 2nd conductor segments, and joining outer peripheral side edge parts, the inner peripheral side edge part of the 1st conductor segment which protruded from a certain slot It is necessary to secure an insulation state between the outer peripheral side end portion of the first conductor segment protruding from the other slot and the inner peripheral side of the first conductor segment according to the present invention. Since the distance between the end and the outer peripheral end can be secured, partial short-circuiting of windings in which four or more conductors are accommodated in the same slot can be performed without using other insulating members or the like. It can be effectively prevented.
[0009]
In addition, a plurality of combinations of conductor segments in which the first conductor segments described above are arranged inside the second conductor segments described above are simultaneously formed, and twisting is simultaneously performed on the combinations of the plurality of conductor segments. It is desirable to simultaneously insert a combination of a plurality of conductor segments into the slots of the laminated core. As a result, it is possible to reduce the number of man-hours for manufacturing the winding, and to reduce the cost, while preventing a short circuit in the winding.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an AC generator for a vehicle according to an embodiment to which the present invention is applied will be described in detail with reference to the drawings.
[0011]
FIG. 1 is a diagram showing an overall configuration of an automotive alternator. A vehicle alternator 1 shown in FIG. 1 includes a stator 2, a rotor 3, a frame 4, a rectifier 5, and the like.
[0012]
The stator 2 includes a stator core 22, conductor segments 23 that constitute the stator winding 21, and an insulator 24 that electrically insulates between the stator core 22 and each conductor segment 23. The detailed structure of the stator 2 will be described later.
[0013]
The rotor 3 has a structure in which a field winding 8 in which an insulated copper wire is wound in a cylindrical and concentric manner is sandwiched from both sides through a shaft 6 by a pole core 7 having six claws. Have. An axial flow type cooling fan 11 is attached to the end face of the front pole core 7 by welding or the like in order to discharge the cooling air sucked from the front side in the axial direction and the radial direction. Similarly, a centrifugal cooling fan 12 is attached to the end face of the pole core 7 on the rear side by welding or the like in order to discharge the cooling air sucked from the rear side in the radial direction.
[0014]
The frame 4 accommodates the stator 2 and the rotor 3, is supported in a state where the rotor 3 is rotatable about the shaft 6, and a predetermined gap is provided on the outer peripheral side of the pole core 7 of the rotor 3. The stator 2 arranged via is fixed. Further, the frame 4 has a cooling air discharge window 42 at a portion facing the stator winding 21 protruding from the axial end face of the stator core 22, and a suction window 41 at the axial end face. .
[0015]
In the vehicle alternator 1 having the above-described structure, the rotor 3 rotates in a predetermined direction when a rotational force from an engine (not shown) is transmitted to the pulley 20 via a belt or the like. By applying an excitation voltage from the outside to the field winding 8 of the rotor 3 in this state, each claw portion of the pole core 7 is excited, and a three-phase AC voltage can be generated in the stator winding. A predetermined direct current is taken out from the output terminal of the rectifier 5.
[0016]
Next, details of the stator 2 will be described. FIG. 2 is a partial cross-sectional view of the stator 2. FIG. 3 is a perspective view of a conductor segment constituting the stator winding.
[0017]
The stator winding 21 provided in the slot 25 of the stator core 22 is composed of a plurality of electric conductors, and each slot 25 accommodates an even number (four in this embodiment) of electric conductors. Further, the four electric conductors in one slot 25 are arranged in the order of the inner end layer, the inner middle layer, the outer middle layer, and the outer end layer from the inside along the radial direction of the stator core 22 as shown in FIG. Is arranged.
[0018]
The electric conductor 231a in the inner end layer in one slot 25 is paired with the electric conductor 231b in the outer end layer in another slot 25 which is one magnetic pole pitch away in the clockwise direction of the stator core 22. . Similarly, the inner and middle layer electric conductors 232a in one slot 25 are paired with the outer and middle layer electric conductors 232b in the other slots 25 separated by one magnetic pole pitch in the clockwise direction of the stator core 22. Yes. The paired electric conductors are connected via the turn portions 231c and 232c by using a continuous line on one end face side of the stator core 22 in the axial direction.
[0019]
Therefore, on one end face side of the stator core 22, a continuous line connecting the outer middle layer electric conductor 232b and the inner middle layer electric conductor 232a is connected to the outer end layer electric conductor 231b and the inner end layer electric conductor 231a. A continuous line connecting and is surrounded. As described above, on one end face side of the stator core 22, the turn portion 232 c as a connecting portion of the paired electric conductors serves as a connecting portion of the other pair of electric conductors accommodated in the same slot 25. Is surrounded by the turn part 231c. The middle layer coil end is formed by the connection between the outer middle layer electrical conductor 232b and the inner middle layer electrical conductor 232a, and the end layer coil end is formed by the connection between the outer end layer electrical conductor 231b and the inner end layer electrical conductor 231a. The
[0020]
On the other hand, the inner and middle layer electric conductors 232a in one slot 25 are also paired with the inner end layer electric conductors 231a 'in the other slots 25 which are separated by one magnetic pole pitch in the clockwise direction of the stator core 22. ing. Similarly, the outer end layer electric conductor 231b ′ in one slot 25 is also paired with the outer end layer electric conductor 232b in another slot 25 which is one magnetic pole pitch away from the stator core 22 in the clockwise direction. There is no. These electrical conductors are connected on the other end face side in the axial direction of the stator core 22.
[0021]
Therefore, on the other end face side of the stator core 22, the outer joint portion connecting the outer end layer electric conductor 231b 'and the outer middle layer electric conductor 232b, the inner end layer electric conductor 231a' and the inner middle layer. Inner joints that connect the electrical conductors 232a are arranged in a state of being displaced from each other in the radial direction and the circumferential direction. Two adjacently arranged concentric circles by connecting the outer end layer electric conductor 231b 'and the outer middle layer electric conductor 232a, and the inner end layer electric conductor 231a' and the inner middle layer electric conductor 232a. A layer coil end is formed.
[0022]
Furthermore, as shown in FIG. 3, the inner end layer electric conductor 231a and the outer end layer electric conductor 231b are provided by a large segment 231 formed by forming a series of electric conductors in a substantially U shape. The inner and middle layer electric conductors 232a and the outer and middle layer electric conductors 232b are provided by a small segment 232 formed by forming a series of electric conductors in a substantially U shape. The basic U-shaped conductor segment 23 is formed by a large segment 231 and a small segment 232. Each of the segments 231 and 232 includes a portion that is accommodated in the slot 25 and extends along the axial direction, and includes oblique portions 231f, 231g, 232f, and 232g that extend at an angle with respect to the axial direction. These skewed portions form coil ends that protrude from the stator core 22 to both end faces in the axial direction, and the cooling fans 11 and 12 attached to both end faces in the axial direction of the rotor 3 are rotated. The cooling air ventilation path that is sometimes generated is formed mainly between the inclined portions.
[0023]
The above configuration is repeated for each conductor segment 23 in all slots 25. At the coil end opposite to the turn portions 231c and 232c, the leading end portion 231e 'of the outer end layer conductor segment 23, the leading end portion 232e of the outer middle layer conductor segment 23, and the leading end portion 232d of the inner middle layer conductor segment 23 are provided. And the tip end portion 231d 'of the conductor segment 23 of the inner end layer are joined and electrically connected by means of welding, ultrasonic welding, arc welding, brazing or the like.
[0024]
For the stator 2 manufactured in this way, each conductor segment 23 for one phase viewed from the inner peripheral side of the stator core 22 is shown in FIG. 4 and the coil on the opposite side to the turn portions 231c and 232c. A perspective view of the end group is shown in FIG.
[0025]
In the first coil end group 21a corresponding to the turn portions 231c and 232c, the middle layer coil end and the end layer coil end are the basic coil ends. In the second coil end group 21b opposite to the turn portions 231c and 232c, the adjacent layer coil end serves as the basic coil end. A plurality of basic coil ends are arranged regularly and repeatedly. A gap is secured between all coil ends. Moreover, the basic coil ends are distributed at a substantially constant density in the circumferential direction within the annular coil end group.
[0026]
The inner peripheral surfaces of both coil end groups 21 a and 21 b are formed to have an inner diameter that is slightly larger than the inner peripheral surface of the stator core 22. Furthermore, both the coil end groups 21a and 21b have a substantially constant height over the entire circumference.
[0027]
Next, the manufacturing process of the conductor segment 23 constituting the stator winding 21 will be described. 6 to 10 are perspective views showing the manufacturing process of the conductor segment 23. First, the linear conductor segment 23 having a predetermined length corresponding to the large segment 231 and the linear conductor segment 23 having a predetermined length corresponding to the small segment 232 are respectively inserted into the slots of the stator core 22. Prepare as many as 25.
[0028]
Next, the linear conductor segment 23 having a predetermined length corresponding to the small segment 232 is bent substantially at the center and processed into a V shape (FIG. 6). In this step of processing the small segment 232, the angle at which the conductor segment 23 is bent so as to be V-shaped is adjusted. By this step, a turn part 232c having a predetermined radius of curvature is formed, and the interval becomes wider from the turn part 232c to the tip part. In addition, the outer space | interval of the front-end | tip part of the small segment 232 formed in this V shape is set to a.
[0029]
Next, the linear conductor segment 23 having a predetermined length corresponding to the large segment 231 is bent substantially at the center and processed into a U-shape (FIG. 7). In this process of processing the large segment 231, the angle at which the conductor segment 23 is bent so as to be U-shaped is adjusted. By this step, a turn portion 231c having a radius of curvature larger than the radius of the bent portion of the V-shaped small segment 232 described above is formed, and the two straight portions bent by the turn portion 231 become substantially parallel. In addition, let the inner space | interval of the front-end | tip part of the large segment 231 formed in this U shape be b. There is a relationship of a> b between the outer space a at the tip of the small segment 232 and the inner space b at the tip of the large segment 231.
[0030]
Next, the large segment 231 is arranged outside the small segment 232 (FIG. 8). As described above, the outer space “a” of the tip of the small segment 232 is wider than the inner space “b” of the tip of the large segment 231, and the V-shaped shape is formed at the tip of the small segment 232. Since the elastic force to be maintained and the force pushed by the U-shaped large segment 231 disposed on the outside work, the distal end of the small segment 232 is securely attached to the distal end of the large segment 231 as shown in FIG. And the tips of the small segments 232 are separated from each other. The process shown in FIG. 8 described above corresponds to the “first process” in the present invention.
[0031]
Thereafter, while maintaining the state in which the small segment 232 and the large segment 231 are overlapped (the state shown in FIG. 8), the distance between the respective distal ends of the small segment 232 and the large segment 231 is adjusted to a predetermined value. Both ends of the two segments 231 and 232 are fixed by the twisting jigs 300 and 310, respectively (FIG. 9), and the twisting jig 300 is moved in the direction perpendicular to the bending direction of the two segments 231 and 232 by the half magnetic pole pitch. At the same time, the twisting jig 310 is moved in the opposite direction to the twisting jig 300 by the opposite magnetic pole pitch (FIG. 10). As a result, the large segment 231 and the small segment 232 are simultaneously twisted. The steps shown in FIGS. 9 and 10 correspond to the “second step” and the “third step” in the present invention.
[0032]
The segments 231 and 232 twisted in this way are inserted into the slots 25 of the stator core 22 in the state of being combined (FIG. 11). The process shown in FIG. 11 corresponds to the “fourth process” in the present invention. In FIG. 11, in order to make it easy to understand how the segments 231 and 232 are inserted into the slot 25, the shape of the opening side of the slot 25 is simplified and the insulator 24 is omitted. However, the slot 25 is actually shaped as shown in FIG. 2 described above, and the insulator 24 is interposed between the segments 231 and 232 and the wall surface of the slot 25.
[0033]
The segments 231 and 232 are inserted into the slot 25 so that the turn portions 231 c and 232 c are aligned on the same side of the axial side surface of the stator core 22. At this time, the two straight portions included in each of the segments 231 and 232 are accommodated in different slots 25 separated by one magnetic pole pitch.
[0034]
Next, as shown in FIG. 5 described above, after the tip portions 231d ′, 232d, 232e, and 231e ′ located on the counter-turn portion side are twisted in the opposite circumferential directions, the tips corresponding to the conductors of the inner end layer The portion 231d ′ and the tip 232d corresponding to the inner middle layer conductor are joined by welding or the like, and the tip 232e corresponding to the outer middle layer conductor and the tip 231e ′ corresponding to the outer end conductor are welded or the like. Join by. The joint portions of the segments 231 and 232 formed in this way are formed so that the height from the stator core 22 is substantially the same. The process described above corresponds to the “fifth process” in the present invention.
[0035]
As described above, in the vehicle alternator 1 of the present embodiment, when the stator 2 is manufactured, after the large segment 231 formed in the U shape is disposed outside the small segment 232 formed in the V shape, The conductor segments 23 are formed by simultaneously twisting these segments 231 and 232 in a combined state. Since the outer space a of the tip of the small segment 232 formed into a V shape is wider than the inner space b of the tip of the large segment 231 formed into a U shape, the tip of the small segment 232 is Since the elastic force for maintaining the V-shaped shape and the force pushed by the U-shaped large segment 231 disposed on the outside work, the tip of the small segment 232 and the large segment 231 are reliably in contact with each other. In addition, the effect that the tips of the small segments 232 are separated from each other can be obtained. Further, after the twist molding, the small segment 232 and the large segment 231 are kept in a combined state, and these segments are simultaneously inserted into a predetermined slot provided in the stator core, thereby the stator winding 21. Is forming. Therefore, the small segments 232 are adjacent to each other in a state in which the segments 231 and 232 are inserted into the slots of the stator core 22 or after the tips of the small segments 232 are twisted in opposite circumferential directions. The tip portions do not come into contact with each other, and the distance between the tip portions of the small segment 232 as the encapsulated conductor segment 23 and the insulation state can be ensured. Moreover, since it is not necessary to secure an insulating state by inserting an insulating material or the like, the number of parts does not increase.
[0036]
In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. For example, in the above-described embodiment, as shown in FIGS. 9 and 10, the twisting jigs 300 and 310 are used to twist a pair of conductor segments formed by disposing the small segment 232 inside the large segment 231. Although twisting has been performed, a plurality of sets of conductor segments may be arranged in parallel and arranged, and the plurality of sets of conductor segments may be twisted simultaneously. FIG. 11 illustrates the case where one set of conductor segments 23 subjected to twisting is inserted into the slots 25 of the stator core 22, but a plurality of sets of conductor segments 23 are simultaneously inserted into a predetermined number of slots 25. You may do it. Thus, the number of man-hours for manufacturing the stator 2 can be reduced by simultaneously twisting and forming a plurality of sets of conductor segments 23 and simultaneously inserting them into a predetermined number of slots 25 provided in the stator core 22. Therefore, the cost reduction of the vehicle alternator 1 as a whole can be achieved.
[0037]
In the embodiment described above, the winding forming method of the present invention has been described by taking the stator of the vehicle alternator as an example. However, the stator or rotor winding of various rotating electric machines other than the vehicle alternator is described. The present invention can be applied to the case where a line is formed using a conductor segment.
[Brief description of the drawings]
FIG. 1 is a diagram showing an overall configuration of an automotive alternator.
FIG. 2 is a partial cross-sectional view of a stator.
FIG. 3 is a perspective view of segments constituting a stator winding.
FIG. 4 is a partial side view of the stator winding as seen from the inner peripheral side.
FIG. 5 is a partial perspective view of a stator.
FIG. 6 is a perspective view showing a manufacturing process of a conductor segment before being assembled to a stator.
FIG. 7 is a perspective view showing a manufacturing process of a conductor segment before being assembled to a stator.
FIG. 8 is a perspective view showing a manufacturing process of a conductor segment before being assembled to a stator.
FIG. 9 is a perspective view showing a manufacturing process of a conductor segment before being assembled to a stator.
FIG. 10 is a perspective view showing a manufacturing process of a conductor segment before being assembled to a stator.
FIG. 11 is a perspective view showing a manufacturing process when the conductor segment is assembled to the stator.
[Explanation of symbols]
1 AC generator 2 for vehicle 2 Stator 3 Rotor 22 Stator core 23 Conductor segment 231 Large segment 232 Small segment 25 Slot

Claims (4)

A first step of disposing a second U-shaped second conductor segment outside the first V-shaped first conductor segment; and
A second step of setting the distance between the tip portions of the first conductor segments to a predetermined value in a state where the first and second conductor segments are combined;
A third step of simultaneously twisting the first and second conductor segments;
A fourth step of simultaneously inserting the first and second conductor segments into slots formed in the laminated core;
A winding forming method comprising: In claim 1,
The distance between the first conductor segment increases from the turn part to the tip part, and the second conductor segment is formed substantially in parallel from the turn part to the tip part,
In a state before the first and second conductor segments are combined, the winding distance between the tip portions of the first conductor segments is set wider than the tip portion spacing of the second conductor segments. Line forming method. In claim 1 or 2,
According to the third step, the portions from the turn portions to the tip portions of the first and second conductor segments are arranged separately on the inner diameter side and the outer diameter side of the laminated core formed in an annular shape. Later, the inner peripheral side ends of the first and second conductor segments protruding from different slots and the outer peripheral side ends of the first and second conductor segments protruding from different slots are joined together. A winding forming method comprising a fifth step. In any one of Claims 1-3,
Forming a plurality of combinations of the first and second conductor segments in the first step;
In the third step, simultaneously twisting the first and second conductor segments,
The winding forming method, wherein the first and second conductor segments are simultaneously inserted into the slots of the laminated core in the fourth step.

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