JP4453489B2 - Manufacturing method of stator winding of rotating electric machine and stator winding of rotating electric machine - Google Patents

Description

  The present invention relates to a method of manufacturing a stator winding of a rotating electrical machine for manufacturing a stator winding of a rotating electrical machine such as an electric motor or a generator mounted on an automobile or a truck, and a stator winding of the rotating electrical machine.

2. Description of the Related Art Conventionally, a rotating electrical machine having a stator winding formed by sequentially joining a number of segment conductors inserted through slots of a stator core is known (see, for example, Patent Document 1). In this rotating electrical machine, each U-shaped segment constituting the stator winding was set on a twisting jig in a state in which each linear portion was radially arranged before being inserted into the stator core. Thereafter, the straight portions are twisted in opposite directions in the circumferential direction. After each segment twisted in this way is inserted into the slot of the stator core, the end portion on the side opposite to the turn portion protruding from the end surface of the starter core is shaped in the circumferential direction and then joined to a predetermined winding specification. A stator winding having is completed. As a method for manufacturing a U-shaped segment before being inserted into the above-described twisting jig, a method is known in which a single wire is cut into a predetermined length and then bent into a U-shape (for example, Patent Document 2). reference.). In this method, when the wire is bent into a U-shape, an excessive bending prevention member is interposed in the bent portion to prevent excessive bending in the bent portion, and damage to the insulating film formed around the wire is prevented. It is preventing.
Japanese Patent No. 3118837 (page 4-7, FIG. 1-15) JP 2001-45721 A (page 3-8, FIG. 1-12)

  By the way, when manufacturing a U-shaped segment using the method disclosed in Patent Document 2 described above, since the width in the vicinity of the turn portion of the segment is increased by an amount corresponding to the excessive bending prevention member, When the number of segments inserted into one slot increases, there is a problem that the coil end portion of the stator winding constituted by the turn portion spreads in the radial direction. For example, when considering a case where a stator winding is formed by arranging four sets of U-shaped large and small segments in the radial direction, each U-shaped segment has a turn portion rather than a radial dimension of the straight portion. When the space factor of the straight portion inserted into the slot is increased (when the straight portions are arranged in the radial direction so that there is almost no gap in the slot), the turn portion becomes larger. Projecting radially outward (or inward), it is difficult to reduce the size of the rotating electrical machine if it does not interfere with the frame (or the rotor disposed on the inner peripheral side) disposed on the outer peripheral side thereof. Moreover, when the respective turn portions are inclined toward the outer diameter side, it is necessary to add a process for the inclination, which is not preferable because the process becomes complicated. Further, it is conceivable to reduce the amount of protrusion in the radial direction by shifting the turn parts of the four sets of U-shaped segments in the axial direction. In this case, however, it is difficult to reduce the axial size. Since the segment length changes for each group and the resistance value varies, it is difficult to employ the segment.

  The present invention was created in view of the above points, and an object of the present invention is to provide a method for manufacturing a stator winding of a rotating electrical machine and a rotating electrical machine that can prevent the coil end portion from spreading in the radial direction. It is to provide a stator winding.

In order to solve the above-described problem, a method for manufacturing a stator winding of a rotating electrical machine according to the present invention is a method of manufacturing a U-shaped segment having two straight portions whose positions along a radial direction are shifted. Twist process by twisting each by moving to the opposite side in the circumferential direction, Inserting process to insert each straight part of segment twisted by twisting process into slot formed in stator core, Inserting into slot A bending step of bending the anti-turn portion side of the formed segment in the circumferential direction, and a joining step of joining the ends of adjacent segments bent by the folding step, and before the twisting step, the circumferential direction by relatively moving the linear portion of the segments arranged radially opposite one another, comprising a preliminary step of shifting the radial position and circumferential position of each straight line portion, preliminary It is made different and the direction of moving the linear portion, and a direction of moving the linear portion in the twisting process in extent. As described above, the U-shaped segment used in the twisting process is projected along the circumferential direction because the radial position and the circumferential position of the two linear portions are shifted in the preliminary process performed before that. In addition, even when the positions of these two straight portions are approximated along the radial direction, there is no need to bend the segment with an extremely small radius in the turn portion, and a stator formed using such a segment. The spread of the coil end portion of the winding in the radial direction can be prevented.

  Moreover, the U-shaped segment mentioned above is manufactured by the bending shaping process which bends and shapes a linear wire material in a U shape, and a preliminary process may be performed for each of the segments manufactured by the bending shaping process. desirable. Thereby, since a preliminary | backup process can be implemented according to a bending shaping process, the delay time by adding a process can be suppressed to the minimum.

  In addition, it is desirable that the amount by which each linear portion of the segment is displaced along the radial direction in the preliminary process described above is substantially equal to the width along the radial direction of the segment. Thereby, the spread of the coil end part in the radial direction can be minimized.

  Further, it is desirable that the amount of shifting each linear portion of the segment along the circumferential direction in the preliminary step described above is equal to or less than the adjacent pitch of the slots formed along the circumferential direction of the stator core. Thereby, the interference between the adjacent segments at the time of implementing a twist process can be prevented.

  Moreover, it is desirable that the above-described insertion process be performed in parallel for a plurality of segments corresponding to a plurality of slots. Thus, by performing the operation of inserting a plurality of segments into each slot in parallel, it is possible to simultaneously twist the plurality of segments in the subsequent twisting process, thereby improving the efficiency of the manufacturing process. it can.

  In the stator winding of the rotating electrical machine of the present invention, the segment inserted into each slot of the stator core in the above-described insertion step includes a small segment and a large segment surrounding the small segment, and at least a small segment is included. As the segment, a segment manufactured using the above-described preliminary process or the first twisting process is used. In particular, since the radius of the turn portion of the small segment becomes small and the insulating film of this portion is easily damaged, the diameter of the turn portion can be reduced by manufacturing this small segment by the manufacturing method of the present invention, and the coil end portion It is possible to effectively prevent the whole from spreading in the radial direction. In addition, by using a large segment manufactured by another method, for example, a method disclosed in Patent Documents 1 and 2, the straight portion protruding from the stator core performs a twisting process (or a second twisting process). The degree of twisting can be reduced.

  Hereinafter, a rotating electrical machine according to an embodiment to which the present invention is applied will be described in detail with reference to the drawings.

  FIG. 1 is an axial sectional view of a traveling motor as a rotating electrical machine according to an embodiment used for generating traveling power of a vehicle. FIG. 2 is a perspective view of a segment forming a part of the stator coil. FIG. 3 is a partial cross-sectional view showing a state in which segments are accommodated in slots provided in the stator core.

  As shown in FIG. 1, the travel motor 100 of this embodiment includes a stator core (stator core) 1, a rotor 2, a stator coil (stator winding) 3, a housing 4, and a rotating shaft 7. . The stator core 1 is fixed to the inner peripheral surface of the peripheral wall of the housing 4. The stator coil 3 is wound around each slot of the stator core 1. The rotor 2 is an IPM type rotor that is fixed to a rotating shaft 7 that is rotatably supported by the housing 4, and is disposed on the inner side of the stator core 1. The stator coil 3 is a three-phase armature winding, and is fed by a three-phase inverter connected to an external battery of about 300V.

  The traveling motor 100 is a permanent magnet type three-phase brushless DC motor (synchronous motor) that generates traveling power of a secondary battery vehicle, a fuel cell vehicle, or a hybrid vehicle. However, as a rotor structure, there are various known types. It can be replaced. Since such various types of synchronous machines are well known, a detailed description of the operation principle is omitted.

  The stator coil 3 is inserted into a slot 33 of the stator core 1 from one end face side of the stator core 1 through a segment 33 having a predetermined shape shown in FIG. 2, and the protruding end of each segment 33 from the slot is placed on the other end face side of the stator core 1. Project the required length, twist the protruding end of each segment 33 in the circumferential direction by an electrical angle of approximately π / 2, and weld the protruding end of each segment 33 (joint) in a predetermined combination. Configured. The segment 33 has a long plate U shape that is covered with a resin film (insulating film) except for a welded portion, that is, a tip end portion of the protruding end portion (also referred to as an end tip portion).

  As shown in FIG. 1, in the stator coil 3 of the present embodiment, the segment set S1 arranged on the innermost circumference side and the segment set S4 arranged on the outermost circumference side have the large and small segments 33 shown in FIG. The segment sets S <b> 2 and S <b> 3 arranged in the middle have a structure composed of one segment 33.

  Next, the details of the segment set S1 including the two segments 33 (the same applies to the segment set S4) will be described in more detail. The segment set S1 includes a head portion as a substantially V-shaped turn portion, a pair of slot conductor portions that extend linearly from both ends of the head portion and are accommodated in slots, and from the tip ends of both slot conductor portions. It consists of two segments 33 each having a pair of extending end portions that extend. Of these two segments 33, the smaller one is called a small segment 332, and the larger one surrounding the small segment 332 is called a large segment 331. In addition, in the state before inserting in each slot 35 of the stator core 1, the protrusion end part is not formed, but the part corresponding to a slot conductor part and a protrusion end part forms the linear part.

  The stator coil 3 includes a first coil end portion (head-side coil end portion) 31 that exists in a ring shape as a whole on one end face side of the stator core 1 and a ring shape as a whole on the other end face side of the stator core 1. It is divided into a second coil end portion (end side coil end portion) 32 that exists and a slot conductor portion that exists in the slot. That is, in FIG. 1, the head-side coil end 31 is constituted by the head portion of each segment 33, and the end-side coil end 32 is constituted by the protruding end portion of each segment 33.

  The large segment 331 has slot conductor portions 331a and 331b, a head portion 331c, and protruding end portions 331f and 331g. Since the tip end portions 331d and 331e of the protruding end portions 331f and 331g are joint portions, they are also referred to as end tip portions or joint portions.

  The small segment 332 includes slot conductor portions 332a and 332b, a head portion 332c, and protruding end portions 332f and 332g. Since the leading end portions 332d and 332e of the protruding end portions 332f and 332g are joint portions, they are also referred to as end tip portions or joint portions.

  The symbol “′” indicates the same portion as the portion without the symbol “′” of the large segment 331 or the small segment 332 (not shown). Accordingly, in FIG. 2, the joint portion 332 d and the joint portion 331 d ′ that are adjacent to each other in the radial direction are welded, and the joint portion 332 e and the joint portion 331 e ′ that are adjacent to each other in the radial direction are welded.

  In FIG. 2, when the slot conductor portion 331a of the innermost layer and the slot conductor portion 332a of the innermost layer are accommodated in one slot of the stator core 1, the slot conductor portions 331b of the outermost layer of the same large segment 331 and small segment 332 The middle and outer layer slot conductor portions 332b are accommodated in other slots separated from the one slot by a predetermined odd-numbered magnetic pole pitch T (for example, 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.

  The arrangement state of the segments in each slot 35 of the stator core 1 will be described with reference to FIG. In each slot 35, twelve conductor housing positions P1 to P12 are set along the radial direction, and one slot conductor portion is housed in each of the conductor housing positions P1 to P12. In each slot 35, four segment sets S1 to S4 are sequentially accommodated in the radial direction, the conductor accommodation positions P1 to P4 are the segment set S1, the conductor accommodation positions P5 and P6 are the segment set S2, the conductor accommodation position P7, P8 accommodates the segment set S3, and the conductor accommodation positions P9 to P12 accommodate the segment set S4.

  The innermost segment set S1 will be described in detail as an example. The innermost slot conductor portion 331a is disposed on the radially innermost side of the slot 35 of the stator core 1, and hereinafter, in the radially outer side, the innermost slot conductor portion 331a. The slot conductors 332b ′ in the middle and outer layers are arranged in this order in the order of the slot conductors 331b ′ in the outermost layer. As a result, each slot 35 accommodates four slot conductors in one row of four layers. In FIG. 3, the slot conductor portions 332 b ′ and 332 b ′ 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 332 a and 331 a. The segment set S4 has the same arrangement as described above, and the other segment sets S2 and S3 have an arrangement in which only one segment 33 (for example, the small segment 332) is extracted from the above arrangement. FIG. 4 is a diagram illustrating a state in which the segment set S1 including the large segment 331 and the small segment 332 is inserted into the slot 35.

  Next, the manufacturing process of the stator coil 3 will be described.

(Bending and shaping process)
First, after cutting a continuous wire having a rectangular shape (rectangular shape) into a predetermined length, the U-shaped segment 33 before shaping constituting each of the segment sets S1 to S4 is bent by the vicinity of the center. To manufacture. FIG. 5 is a front view of the U-shaped segment 33 manufactured by the bending and shaping process. FIG. 6 is a side view of the segment 33 shown in FIG. 5 and shows a state viewed from the head side. FIG. 7 is a perspective view of the segment 33 shown in FIG. As shown in these drawings, the segment 33 shaped in a U shape has two straight portions 33a and 33b with a head portion 33c interposed therebetween.

(First twisting process)
Next, a first twisting process for twisting the head 33c is performed on each of the segments 33 after being shaped into a U shape by the bending shaping process. Assuming that the direction in which the two straight portions 33a and 33b are arranged as a first direction, in the first twisting step, each of the two straight portions 33a and 33b is along a second direction different from the first direction. By moving them relative to each other, the segment 33 in the vicinity of the head 33c is twisted.

  FIG. 8 and FIG. 9 are diagrams showing details of the first twisting process, and show the states before and after the twist shaping using the twisting jig. As shown in FIGS. 8 and 9, the first twisting process is performed by a twisting jig in which the fixed clamper 200 and the movable clamper 210 are combined. The fixed clamper 200 includes a storage unit 202, a moving unit 204, and an adjusting unit 206. The storage part 202 has a concave part for storing one linear part 33a of the segment 33 in part. Two adjacent side surfaces of the linear portion 33a abut against the recess. The moving unit 204 rotatably accommodates a cylindrical adjustment unit 206 having a flat portion on a part of the side surface. By pressing the flat portion against the side surface of the linear portion 33a, the storage unit 202 and the moving unit 204 are moved. The one linear portion 33a is restrained by the above. By providing the rotatable adjustment portion 206, it is possible to adjust the flat portion formed in the adjustment portion 206 so as to be parallel to the side surface of the straight portion 33a, and the straight portion 33a is reliably restrained. be able to.

  Similarly, the movable clamper 210 includes a storage unit 212, a moving unit 214, and an adjusting unit 216. The storage part 212 has a concave part for storing the other straight part 33b of the segment 33 in part. Two adjacent side surfaces of the linear portion 33b abut against the recess. The moving part 214 rotatably accommodates a cylindrical adjustment part 216 having a flat part on a part of the side surface, and the storage part 212 and the moving part 214 are pressed by pressing the flat part against the side surface of the linear part 33b. The other straight portion 33b is constrained by this. By providing the rotatable adjustment portion 216, it becomes possible to adjust the flat portion formed in the adjustment portion 216 so as to be parallel to the side surface of the straight portion 33b, and the straight portion 33b is reliably restrained. be able to.

  The movable clamper 210 is configured to be movable as a whole by a drive mechanism (not shown). As shown in FIG. 8, when the direction in which the two straight portions 33a and 33b of the segment 33 before twist shaping are aligned is the first direction A, as shown in FIG. The movable clamper 210 moves along a second direction B substantially perpendicular to the direction B. As a result, each of the two straight portions 33a and 33b restrained by the fixed clamper 200 and the movable clamper 210 moves relatively perpendicular to the first direction A, and the head 33c is twisted. In the present embodiment, the two straight portions 33a and 33b are arranged along the first direction A at positions separated from each other by the adjacent pitch of the slot 35 in the first twisting step. In addition, the amount by which the straight portions 33a and 33b of the segment 33 are displaced along the radial direction in the first twisting step is set to be approximately equal to the width along the radial direction of the segment 33.

  FIG. 10 is a perspective view showing the segment 33 after the twist shaping is performed by the first twisting process. In the segment 33 shown in FIG. 10, one straight portion 33 b moves in a direction different from the first direction A with respect to the segment 33 before twist shaping shown in FIG. 7, and the head 33 c is twisted. Recognize.

  The bending shaping process and the first twisting process described above are performed for all the segments 33 constituting the segment sets S1 to S4.

(Second twisting process)
Next, a second twisting step of twisting the head 33c by aligning the first direction A described above with the circumferential direction and relatively moving each of the straight portions 33a and 33c of the segment 33 to the opposite side in the circumferential direction. Is done. For example, a case will be described in which twist shaping is simultaneously performed on two segments 33 (large segment 331 and small segment 332) included in the segment set S1.

  FIG. 11 is a cross-sectional view of a twisting jig used in the second twisting step. FIG. 12 is a perspective view showing the main part of the twisting jig shown in FIG. As shown in FIG. 11, the twisting jig 300 includes an inner twisted portion 311 and an outer twisted portion 312, rotational drive mechanisms 313 and 314 that rotationally drive the inner twisted portion 311 and the outer twisted portion 312, respectively, a controller 315, A segment presser 316, a segment push-up jig 317, a lift drive mechanism 318, and the like are provided.

  The inner twisted portion 311 is provided with segment insertion holes 321 and 322 adjacent to each other in the radial direction in which the slot conductor portions 331a and 332a (linear portions 33a) of the large segment 331 and the small segment 332 are inserted and held. Yes. The segment insertion holes 321 and 322 are formed in the circumferential direction at equal intervals corresponding to the number of slots 35 of the stator core 1. That is, in this embodiment, a large number of segment insertion holes 321 and 322 arranged in the circumferential direction at equal intervals are formed on concentric circles. The same applies to the outer twisted portion 312, and a large number of segment insertion holes 323 and 324 arranged in the circumferential direction at equal intervals are formed concentrically. As a result, four segment insertion holes 321, 322, 323, and 324 are formed side by side in the inner twisted portion 311 and the outer twisted portion 312.

  As shown in FIG. 12, the slot conductor portions 331b and 332b as one straight portion 33b of one set of the large segment 331 and the small segment 332 are inserted into the segment insertion holes 324 and 323 of the outer twisted portion 312, and the other The slot conductor portions 331a and 332a as the straight portions 33a are inserted into the segment insertion holes 321 and 322 which are shifted by one slot pitch of the inner twisted portion 311.

  After the large segment 331 and the small segment 332 are inserted into all the segment insertion holes 321, 322, 323, and 324, the annular segment presser 316 is lowered from above the inner twisted portion 311 and the outer twisted portion 312 to It contacts the head 331c of 331. Thereby, it is possible to prevent the large segment 331 and the small segment 332 from floating from the segment insertion holes 321, 322, 323, and 324 in the twisting process.

  Each of the inner twisted portion 311 and the outer twisted portion 312 is rotationally driven by rotational drive mechanisms 313 and 314 controlled by the controller 315. In the present embodiment, as viewed from above the twisting jig 300, the inner twisted portion 311 is rotated counterclockwise and the outer twisted portion 312 is rotated by a predetermined amount, respectively, but the second twisting step is performed. In the previous state, the straight portions 33a and 33b of each segment 33 are already arranged with a one-slot pitch shift in the circumferential direction, so the outer twisted portion 312 and the inner twisted portion are taken into account in consideration of this one-slot pitch shift. A rotational drive amount 311 is set.

  The second twisting process is performed in the same manner for the two segments 33 included in the segment set S4. However, for the segment sets S2 and S3, one segment 33 included in each segment set is used. The second twisting process is performed in the same manner. For example, the second twisting process may be performed only on the small segment 332 except for the large segment 331 in FIGS.

  The first twisting process described above corresponds to the “preliminary process” in claim 1, and the second twisting process corresponds to the “twisting process” in claim 1.

(Insertion process)
Next, each segment 33 after being twisted by the second twisting process is inserted into each slot 35 of the stator core 1 from one end face side along the axial direction. At this time, as shown in FIG. 4, the segment sets S1 and S4 are inserted in a state where the small segments 332 are aligned so that the large segments 331 surround them.

(Bending process)
After inserting each segment 33, the straight portions 33 a and 33 b that are opposite to the head portion 33 c and project from the end face of the stator core 1 are bent in the circumferential direction according to the winding specifications of the stator coil 3.

(Joining process)
The ends of the straight portions 33a and 33b of the adjacent segments 33 bent by the bending process are joined so as to obtain electrical continuity by means of welding, ultrasonic welding, arc welding, brazing, etc. A stator coil 3 having a cross section shown in FIG.

  FIG. 13 is a partial perspective view of the stator coil 3 manufactured by using the manufacturing process of the present embodiment, and shows the detailed shape of the head-side coil end portion 31. In addition, in FIG. 13, the detailed shape of the head side coil end part 31 is shown about segment set S4 arrange | positioned at the outermost periphery side. Since each segment 33 manufactured by the manufacturing method of the present embodiment has the extending direction of the wire material substantially parallel to the end surface of the stator core 1 in the head 33c, the height of the head-side coil end portion 31 (the amount of the extension direction) (Height along the rotary shaft 7) can be reduced, which is advantageous for downsizing the traveling motor 100 in the axial direction.

  As described above, in the stator coil 3 used in the travel motor 100 of the present embodiment, the U-shaped segment 3 used in the second twisting process includes two pieces in the first twisting process performed before that. Since the radial position and the circumferential position of the straight portions 33a and 33b are shifted, the positions of the two straight portions 33a and 33b projected along the circumferential direction are close to each other along the radial direction. However, it is not necessary to bend the segment 33 with an extremely small radius in the head 33c, and the radial expansion of the head-side coil end portion 31 of the stator coil 3 formed using such a segment 33 is prevented. be able to.

  In particular, the U-shaped segment 33 is formed by bending a linear wire into a U-shape in the bending and shaping process, and the next first twisting process is performed for each of the segments 33 manufactured by the bending and shaping process. Therefore, the first twisting process can be performed in accordance with the bending shaping process, and the delay time due to the addition of the process can be minimized.

  Further, in the first twisting step, the amount by which the straight portions 33a and 33b of the segment 33 (particularly the small segment 332) are displaced along the radial direction is set to be substantially equal to the width of the segment 33 along the radial direction. Therefore, the spread of the head-side coil end portion 31 in the radial direction can be minimized.

  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. In the embodiment described above, both the large segment 331 and the small segment 332 constituting the segment sets S1 and S4 are manufactured by the same method. However, the conventional method may be used for the large segment 331. That is, for the small segment 332, when the methods disclosed in Patent Documents 1 and 2 are used, the radial extension of the coil end portion increases, but there is no such inconvenience when only the large segment 331 is considered. . Therefore, even when the small segment 332 manufactured using the method of the present embodiment and the large segment 331 manufactured using the conventional method are combined, the radial expansion of the head-side coil end portion 331 is prevented. be able to.

  FIG. 14 is a partial perspective view showing the detailed shape of the head-side coil end portion 31 in which the small segment 332 manufactured by the method of the present embodiment and the large segment 331 manufactured by the conventional method are combined. In the conventional method, after the segments 33 are set on the twisting jig 300 shown in FIGS. 11 and 12 in a state where the two straight portions 33a and 33b are arranged along the radial direction, the straight portions 33a and 33b are set. Are twisted to the opposite sides in the circumferential direction, but the radial side surfaces of the straight portions 33a and 33b after the twist shaping tend to maintain the direction along the circumferential direction. Therefore, as shown in FIG. 14, when the small segment 331 manufactured by the method of the present embodiment and the large segment 332 manufactured by the conventional method are used, the innermost diameter side included in the head-side coil end portion 31 and It is possible to prevent the side surface of the straight portion of the large segment 331 on the outermost diameter side from inclining with respect to the circumferential direction. There is also an effect of reducing the possibility of interference with the housing 4.

  Further, in the above-described embodiment, when performing twist shaping on the head 33c of each segment 33 in the second twisting step, only movement along the axial direction of the head is restricted by the segment presser 316. In addition to this, the movement in the radial direction may be restricted.

  FIG. 15 is a view showing a modification of the twisting jig in which the shape of the segment presser is changed. A segment presser 316A shown in FIG. 15 includes an inner peripheral restraining portion 350 and an outer peripheral restraining portion 352 that perform twist shaping while restraining the inner peripheral side surface and the outer peripheral side surface of the large segment 331. When the amount of twisting each straight portion of the segment increases in the second twisting step, the head moves in a direction (radially inward) that linearly connects between the two segment insertion holes into which each straight portion is inserted. Although it becomes easy, this movement can be restricted by using the above-described segment presser 316A. This prevents the head from moving along the radial direction and easily interfering with the rotor 2 when each segment after twist shaping in the second twisting process is projected in the circumferential direction. it can.

  In the above-described embodiment, the case where the head portion 33c of the segment 33 has an arc shape having a predetermined radius has been described, but a straight portion may be formed on the head portion 33c. FIG. 16 is a diagram illustrating a modified example of the segment 33. As shown in FIG. 16, when the straight portion 33h is formed in the head portion 33c, only the straight portion 33h can be twisted and shaped into an S shape in the first twisting step. The deformation of the straight portions 33a and 33b can be reduced.

  In the embodiment described above, the two straight portions 33a and 33b of the segment 33 are displaced by one slot pitch along the first direction A shown in FIG. 9 when the first twisting process is completed. However, this deviation may be larger or smaller than one slot pitch. However, the head 33c is twisted so that the distance between the two straight portions 33a and 33b in the first direction A is set large and the two straight portions 33a and 33b are connected in a substantially straight line. When the segment 33 is set on the twisting jig 300 in the next second twisting process, the heads 33c of the adjacent segments 33 interfere with each other, and the subsequent process cannot be performed. In order to surely prevent such interference, it is desirable to set the interval along the first direction A between the two linear portions 33a and 33b to be 1 slot pitch or less.

  Even when the interval between the two straight portions 33a and 33b is set large, a portion that is actually shaped into an S shape by the first twisting process can be formed by one slot pitch by using a restraining jig. The following can be held: For example, as shown in FIG. 17, the storage unit 202 and the moving unit 204 of the fixed clamper 200 are used as restraining jigs, and the storage unit 212 and the moving unit 214 of the movable clamper 210 are used as restraining jigs. Regardless of the interval along the first direction A of the straight portions 33a and 33b, it is possible to set the range in which the head 33c is deformed in an S shape within one slot pitch. This makes it possible to form a segment 33 having two straight portions 33a and 33b having a large interval. Therefore, in this way, the interval between the linear portions 33a and 33b can be gradually increased to match the position of the linear portions 33a and 33b after the second twisting process is completed. The second twisting step can be omitted. Thereby, the process can be simplified.

  In the above-described embodiment, the case where the stator coil 3 used for the traveling motor 100 is manufactured has been described. However, the present invention is also applied to the case where a stator coil used for another rotating electrical machine, for example, an AC generator is manufactured. can do.

  In the above-described embodiment, the head portion 33c as the turn portion is deformed by moving the two straight portions 33a and 33b of the segment 33. However, the head portion 33c is deformed from both sides along the radial direction. You may make it deform | transform the head 33c by performing the direct shaping process, such as pressing with the restraining jig | tool which has a later shape, in a preliminary | backup process. By directly pressing and shaping the turn part and twisting the turn part, the relative position along the radial direction of the two linear parts can be reliably moved.

  Alternatively, by performing a preliminary process in which the two straight portions 33a and 33b are rotated in the same direction around the axis extending in the extending direction, the two straight portions 33a and 33b are aligned along the radial direction of the two straight portions 33a and 33b. The relative position can be moved reliably.

  18, FIG. 19, and FIG. 20 are explanatory diagrams of a preliminary process of rotating the straight portions 33a and 33b separately. FIG. 18 shows a side shape of the rotating jig before the preliminary process, and FIG. 19 shows a planar shape of the rotating jig shown in FIG. FIG. 20 also shows the shape of the head 33c of the segment 33 after the preliminary process is completed.

  As shown in FIGS. 18 and 19, rotating jigs 400 and 410 are used corresponding to the two straight portions 33a and 33b, respectively. One rotating jig 400 has a through hole that is slightly larger than the cross-sectional shape of one straight portion 33a, and the straight portion 33a is inserted into the through hole. Similarly, the other rotating jig 410 has a through hole that is slightly larger than the cross-sectional shape of the other straight portion 33b, and the straight portion 33b is inserted into this through hole. In this manner, with the straight portions 33a and 33b inserted into the through holes of the two rotating jigs 400 and 410, the one rotating jig 400 is rotated about the central axis along the extending direction of the linear portion 33a. And the other rotation jig 410 is rotated about the center axis along the extending direction of the straight portion 33b. These rotational directions are indicated by arrows in FIG. 19 and are in the same direction. When the straight portions 33a and 33b are thus rotated, as shown in FIG. 20, a segment shape in which the straight portions 33a and 33b are relatively moved is obtained as a result.

  Further, the rotation angle θ1 of the linear portion 33a and the rotation angle θ2 of the linear portion 33b can be set to different values. As a result, when the plurality of slots 35 are formed radially and the straight portions 33a and 33b are inserted into the different slots 35, the orientation of the straight portions 33a and 33b is changed to the orientation of the slots 35. It becomes easy to match individually.

1 is an axial cross-sectional view of a traveling motor as a rotating electrical machine according to an embodiment used for generating traveling power of a vehicle. It is a perspective view of the segment which makes a part of stator coil. It is a fragmentary sectional view which shows the accommodation state of the segment in the slot provided in the stator core. It is a figure which shows the state which inserts into the slot the segment set which consists of a large segment and a small segment. It is a front view of the U-shaped segment manufactured by the bending shaping process. It is a side view of the segment shown in FIG. It is a perspective view of the segment shown in FIG. It is a figure which shows the detail of a 1st twist process. It is a figure which shows the detail of a 1st twist process. It is a perspective view which shows the segment 33 after twist shaping was performed by the 1st twist process. It is sectional drawing of the twist jig | tool used at a 2nd twist process. It is a perspective view which shows the principal part of the twist jig | tool shown in FIG. It is a fragmentary perspective view of the stator coil manufactured using the manufacturing process of this embodiment. It is a fragmentary perspective view which shows the detailed shape of the head side coil end part which combined the small segment manufactured by the method of this embodiment, and the large segment manufactured by the conventional method. It is a figure which shows the modification of the twist jig | tool which changed the shape of the segment presser. It is a figure which shows the modification of a segment. It is a figure which shows the modification of the twist jig | tool used at a 1st twist process. It is explanatory drawing of the preliminary process which rotates each linear part separately. It is explanatory drawing of the preliminary process which rotates each linear part separately. It is explanatory drawing of the preliminary process which rotates each linear part separately.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Stator core 2 Rotor 3 Stator coil 4 Housing 7 Rotating shaft 31 Head side coil end part 32 End part side coil end part 33 Segment 33a, 33b Straight line part 33c Head part 100 Traveling motor 200 Fixed clamper 210 Movable clamper 202, 212 Storage part 204, 214 Moving unit 206, 216 Adjustment unit 331 Large segment 332 Small segment

Claims (5)

A twisting step of twisting a U-shaped segment having two straight portions whose positions along the radial direction are shifted by moving each of the straight portions relatively to the opposite side in the circumferential direction;
An insertion step of inserting each straight portion of the segment twisted by the twisting step into a slot formed in the stator core;
A bending step of bending the anti-turn portion side of the segment inserted into the slot in the circumferential direction;
A joining step of joining ends of adjacent segments folded by the folding step;
In the method of manufacturing a stator winding of a rotating electrical machine having
Before the twisting step, a preliminary step of shifting the radial position and the circumferential position of each linear portion by moving each linear portion of the segments arranged in the circumferential direction relative to each other in the radial direction relative to each other. Prepared,
A method of manufacturing a stator winding of a rotating electrical machine, wherein a direction in which the linear portion is moved in the preliminary step is different from a direction in which the linear portion is moved in the twisting step. In claim 1,
The U-shaped segment is manufactured by a bending and shaping process in which a linear wire is bent and shaped into a U shape,
The method for manufacturing a stator winding of a rotating electrical machine, wherein the preliminary process is performed for each of the segments manufactured by the bending and shaping process. In claim 1 or 2,
The method of manufacturing a stator winding of a rotating electrical machine, wherein an amount of shifting each linear portion of the segment along the radial direction in the preliminary step is substantially equal to a width along the radial direction of the segment. In any one of Claims 1-3,
The amount of shifting each linear portion of the segment along the circumferential direction in the preliminary step is equal to or less than the adjacent pitch of the slots formed along the circumferential direction of the stator core. Method of manufacturing the child winding. A stator winding of a rotating electrical machine manufactured by the manufacturing method according to claim 1 ,
The segment inserted into each slot of the stator core in the insertion step includes a small segment and a large segment surrounding the small segment,
A stator winding for a rotating electric machine, wherein at least the small segment uses the segment manufactured by using the preliminary process.

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