JP5039598B2 - Manufacturing method of rotating electrical machine - Google Patents

Description

  The present invention relates to a coil, a rotating electrical machine, and a method for manufacturing the rotating electrical machine.

  As a coil used for a rotating electrical machine, a film insulating material formed by winding a thermoplastic film is used, and a temporary fixing tape is wound around an original coil having a pair of linear portions serving as coil sides, and the original coil It is known that a wire insulation film is welded by an ultrasonic welding apparatus provided with a fixing device only for the linear portion, and then ground insulating tape is wound and then inserted into a slot (for example, see Patent Document 1). ).

Japanese Unexamined Patent Publication No. 64-1444

  For example, when inserting a coil into a slot of a rotating electrical machine, when the coil is formed into a winding shape and then deformed into a shape for insertion into the slot, the entire coil should be flexible. However, when it is inserted into the slot after being deformed, it is necessary to fix the slot insertion portion so as not to be loosened. The prior art has not fully considered the compatibility of these two properties.

  An object of the present invention is to increase the productivity of a rotating electrical machine by considering the above.

In order to solve the above problems, for example, the configuration described in the claims is adopted. The present application includes a plurality of means for solving the above-mentioned problems. To give an example, the step of forming the winding by rotating the coil a plurality of times and the opposing part of the wound coil are each thermoplastic. in the step of securing a bundle with an insulator, inserting at least a portion of the coil portions bundled by an insulator in the stator slot, pulling the different parts from the slot insertion portion of the coil, the slot have a, and inserting a different other slots and, in the step of fixing a bundle of opposing portions of the orbiting coils in each insulator, each of the end portions of the insulator has around the coils to each other The overlapping part is provided and wound around the coil, and heat is applied to the overlapping part and the ends are welded together. The pulling different parts, in the step of inserting the different other slots and the slot, the coil, the winding shape, manufacturing method of a rotating electric machine is deformed into a shape for insertion into another slot It is.

  According to the present invention, the productivity of a rotating electrical machine can be increased.

  Hereinafter, a rotating electrical machine and a coil constituting one embodiment of the present invention will be described. Here, it is an example of the coil used for the stator of a rotary electric machine.

  In a stator composed of a core and windings used in various rotating electrical machines, it is necessary to increase the winding density and pursue high efficiency. In the distributed winding, a coil in which a wire consisting of a rectangular wire having a substantially rectangular cross section is wound a plurality of times around a plurality of slots provided so as to open to the inner peripheral side of the stator core. In this case, one of the opposing straight portions of the tortoiseshell-shaped coil in which the wires wound around a plurality of times are fixed by bundling with an insulator and the other are overlapped in the circumferential direction and mounted in the slot. Put the coil to be placed on the outer circumference side of the core first, and then put the coil to be placed on the inner circumference side later, but part of one of the linear parts of the coil that will be the inner circumference side of the core that has already been inserted Must be taken out of the slot, the other linear part of the coil on the outer peripheral side of the core is inserted into the slot, and then one of the linear parts of the coil on the inner peripheral side of the core is inserted into the slot again. There is.

  For this reason, when a coil that has been wound multiple times is bundled and fixed with an insulator, when the coil is deformed from a wound shape to a shape for insertion into a slot, the coil as a whole is made flexible and after deformation Therefore, when inserting into the slot, it is necessary to satisfy both of the properties of fixing so that the slot insertion portion does not come loose.

  For example, a self-bonding wire in which a fusion layer is arranged on an insulating coating is used as the element wire to form a coil shape, and then insulating paper is positioned and adhered to the outer periphery thereof. In this state, it is possible to fix the element wire and the insulating paper by passing an electric current through the element wire and melting the fusion layer on the surface of the element wire by the heat generation.

  In this method, the entire wire is heated, and there is a possibility that the coil end part may be fused in addition to the fixing of the insulating paper in the slot part, so that the wound shape is deformed to be inserted into the slot. Sometimes harmful effects such as peeling off of the insulation coating occur. Further, since there is no fused layer in the overlapping portion of the insulating paper, it is necessary to fix it as it is or by another means such as an adhesive. Furthermore, there is a demerit that the price of the self-bonding wire is higher than that of the non-bonding wire.

  As another conventional method, a method of winding an insulating tape diagonally over the entire coil or a portion corresponding to the core slot can be considered. In this tape winding, if there is not enough space corresponding to the core slot of the coil, no manpower or mechanism is required.

  The insulating material winding mechanism can be applied as long as it does not get in the way even if it is disposed between the opposing linear portions of the coil. Since there are overlapping portions on the entire outer periphery, there is a limit to improving the space factor, which is the ratio of the area of the wire to the slot area. Moreover, since the ratio of the cross-sectional area of the insulating tape is small with respect to the cross-sectional area of the coil, the influence that causes a problem in terms of the space factor is small. However, in the coil of a small motor, the coil size is small, so that it is difficult to arrange the insulating material winding mechanism between the opposing linear portions of the coil. There is a possibility that the ratio of the area becomes large and it is disadvantageous in terms of the space factor.

  In this embodiment, as a method for applying an insulating material to a coil that has been wound a plurality of times, an insulating material is supplied separately from the wire, and the coil end portion is not wound and covered around the entire coil circumference of the slot insertion portion. Wrap the material and fix part of it. Thus, when winding a coil that has been wound a plurality of times around a plurality of slots that are provided so as to open to the inner peripheral side of the stator core, the coil that has been wound a plurality of times is bundled and fixed with an insulator. In addition, when deforming from a wound shape to a shape for insertion into the slot, the coil as a whole has flexibility, and when inserted into the slot after deformation, it is fixed so that the slot insertion portion does not come loose. Therefore, it is possible to realize a coil having both properties.

  In addition, a highly reliable motor can be obtained by firmly fixing the core slot portion and ensuring the flexibility of the coil end portion. Further, since the material surface has lubricity, workability when the coil is assembled to the core is improved.

  In FIG. 47, in one embodiment of the present invention, a coil 4131 provided with an insulating material 422 is inserted into a slot 411 on the outer periphery of a coil 4131 in which an element wire 421 having a substantially rectangular cross section is turned around a plurality of times. The cross-sectional shape of the state made is shown. An opening of the slot 411 is provided on the inner peripheral side of the stator, and the coil 4131 provided with the insulating material 422 is inserted into the inner side of the slot 411 (in this case, the outer peripheral side of the stator) through the opening.

  Here, the coil 4131 to be used is mounted by connecting one of the pair of opposing linear portions of the turtle shell-shaped coil and the other with a slot 411 that is not adjacent to the adjacent slot 411 but separated by two or more slots in the circumferential direction. Therefore, two sets of the coils 42 to which the insulating material 422 is applied are inserted into the slots 411. At this time, the coil 4131 located on the outer periphery side of the stator in the slot 411 is called an outer coil, and the coil 4131 located on the inner periphery side of the stator is called an inner coil.

Next, the arrangement direction of the overlapping portion 4221 of the insulating material 422 with respect to the slot 411 will be described. When the insulating material 422 is applied to the coil 4131, the outer coil and the inner coil are arranged on the same inner peripheral side of the stator. FIG. 47A . When the insulating material 422 is applied to the coil 4131, the outer coil and the inner coil are used. There is FIG. 47 (b) in which they are arranged on the outer peripheral side and the inner peripheral side of the stator opposite to each other. Conversely the other in FIG. 47 (a), in the case of providing the insulating material 422 to the coil 4131, and a method of placing the same stator outer periphery outside the coil and the inner coil, an outer coil opposite to FIG. 47 (b) Although a method of arranging the inner coils on the inner peripheral side and the outer peripheral side of the stator opposite to each other can be considered, an explanatory diagram is omitted here.

  FIG. 48 shows a schematic diagram of the process of applying the insulating material 422 to the coil 4131. Here, the coil 4131 has two terminal wires 423 protruding from the coiled portion of the two tortoiseshell-shaped coils. In a normal coil, there are two terminal wires 423 extending from the outer peripheral side and the inner peripheral side with respect to one set of turtle shell-shaped coils, and four terminal wires 423 are generated when there are two sets of turtle shell-shaped coils. However, by sharing the terminal wires 423 on the inner circumference side by devising the winding method, the terminal wires 423 that protrude from the coiled portion of the turtle shell-shaped coils as shown in the figure have two sets, as shown in the figure. Two can be used. Such a winding method is called alpha winding.

  An insulating material 422 is wound around and fixed to the coil 4131 using an applying means (not shown). A plurality of sets of coils 4131 provided with the insulating material 422 are prepared, and the stator 4 is formed in the stator core 412 using a mounting means (not shown) as will be described later.

  FIG. 49 is an explanatory diagram of the process of this example. Tortoise shell that fixes a wire consisting of a rectangular wire having a substantially rectangular cross section to a plurality of slots provided so as to open to the inner peripheral side of the stator core, and then bundles and fixes it with an insulator. The process which provides the insulating material 422 with respect to the one side of a pair of linear part which a shape coil opposes is shown.

  FIG. 49A shows a wire 421 having a substantially rectangular cross section, which is wound a plurality of times (three times this time). As a method of preventing the strands 421 from being separated at this time, the portion of the stator core 412 where the coil is mounted (referred to as the slot portion) to the portion where the coil 4131 protrudes (referred to as the coil end portion) is not shown. By using the strand holding member, the strand 421 can be held without being separated.

  FIG. 49B is a diagram in which an insulating material 422 is supplied and positioned on a wire 421 formed of a rectangular wire having a substantially quadrangular cross section, which is wound around a plurality of times. In this figure, the end length of the U-shaped insulating material 422 with respect to the strand 421 is different. This is a consideration in which the insulation thickness is substantially the same in a state where the insulation materials are overlapped. However, the end length of the insulating material 422 may be the same as long as the overlapping portion can be secured.

  FIG. 49 (c) shows a case where an insulating material 422 is supplied to and positioned on a wire 421 having a substantially square rectangular cross section, and is wound around a plurality of turns, and one end of the U-shaped insulating material 422 is attached. It is in a bent state. In this state, the side close to the strand 421 in the overlapping portion of the insulating material is bent using a bending mechanism (not shown) from the state shown in FIG. 49 (b).

  FIG. 49 (d) shows that the insulating material 422 is supplied to and positioned on a wire 421 consisting of a rectangular wire having a substantially rectangular cross section, and the end of the U-shaped insulating material 422 is bent. It is in the state. This is a state in which the remaining end portion of the insulating material 422 is bent using a bending mechanism (not shown) from the side close to the strand 421 in the overlapping portion 4221 of the insulating material from the state of FIG. 49 (c). It is.

  FIG. 49 (e) shows an example in which an insulating material 422 is supplied and positioned on a wire 421 formed of a rectangular wire having a substantially rectangular cross section, and the end portion of the U-shaped insulating material 422 is bent. In this state, the fixing head 16 is positioned on the overlapping portion 4221. 49D, the fixing head 16 is positioned with respect to the insulating material overlapping portion 4221, and the insulating material overlapping portion 4221 is dissolved by the function to fix the insulating materials 422 to each other. Is. In the case where a thermoplastic resin is used for the insulating material 422, by using a means (for example, a heating head, an ultrasonic head, etc.) such that the resin reaches a softening temperature or higher, among the overlapping portions 4221 of the insulating material, The insulating material 422 on the side close to the element wire 421 and the insulating material 422 on the upper side thereof are melted and solidified to exhibit the fixing strength. As a temperature condition for the means for the resin to reach the softening temperature or higher, the minimum thickness of the insulating material overlapping portion 4221 after melting and solidification is selected to be equal to or greater than the thickness of the insulating material 422.

  FIG. 49 (f) shows that the insulating material 422 is supplied and positioned on a wire 421 having a substantially square rectangular cross-section, and the end portion of the U-shaped insulating material 422 is bent. In this state, the overlapping portion 4221 is fixed.

  These series of steps are performed simultaneously or sequentially on the other side of the pair of opposing straight portions of the turtle shell-shaped coil, so that the wire consisting of a rectangular wire having a substantially rectangular cross section is insulated after being circulated a plurality of times. Obtain a tortoiseshell shaped coil that is bound and fixed by the body.

  Moreover, since the rotary electric machine of the present embodiment uses the coil 4131 having a substantially rectangular cross section, the space factor in the slot 411 of the stator core can be improved. In particular, by using lap winding, the coil 4131 having a substantially rectangular cross section can be wound in a stacked state. For this reason, high output and good rotation characteristics can be achieved.

  Further, in the rotating electrical machine of the present embodiment, the cross section of the coil 4131 is substantially rectangular with the normal direction of the stator core being long and the radial direction being short. For this reason, the number of the coils 4131 in the slot 411 can be increased as much as possible, and the loss reduction effect due to the harmonics can be further increased. Moreover, since the length of the side protruding to the coil end side is shortened also in terms of space, the protruding amount of the coil end can be further reduced. Further, although it is difficult to form the thin coil 4131 by deforming it one by one, in this embodiment, it can be easily formed because it is wound and bundled.

  In the rotating electrical machine of this embodiment, since the insulating member is fixed to the slot insertion portion of the coil 4131, damage to the coating on the coil surface can be avoided when the coil 4131 is molded or inserted into the slot.

  Further, in the rotating electrical machine of the present embodiment, the coil insertion portion in the slot is an open slot having a circumferential width substantially equal to or greater than the portion where the coil 4131 is mounted in the slot. The coil 4131 can be easily inserted from the slot insertion portion, and the space factor of the coil 4131 in the slot is not lowered.

  In the rotating electrical machine of the present embodiment, since the holding member for preventing the movement of the coil 4131 to the inner peripheral side is mounted on the inner peripheral side of the coil insertion portion in the slot, the coil 42 comes out of the coil insertion portion of the slot. Can be prevented.

  Details of other embodiments will be described with reference to the drawings.

  FIG. 50 shows another embodiment. If the insulation performance of the element wire 421 can be ensured, the insulating material 422 is applied to one of the opposing linear portions of the coil that is fixed by bundling the coil that has been wound a plurality of times with an insulator. Wrap, do not wind the other.

  FIG. 51 shows another embodiment. In FIG. 49, when the insulating material 422 is applied to the outer periphery of the coil 4131 in which the wire 421 having a substantially rectangular cross section is wound a plurality of times, the width of the overlapping portion 4221 is approximately equal to the width of the wire 421. The dimensions were the same. However, from the characteristics of the insulating material 422, if desired insulating characteristics can be secured even if the width of the overlapping portion 4221 is reduced, the width of the overlapping portion 4221 can be reduced. Further, by narrowing the width of the fixing head 16, it is possible to reduce the output for melting the overlapping portion 4221 of the insulating material 422, or to shorten the time until the softening temperature is reached if the output is the same.

  FIG. 52 shows another embodiment. In FIG. 49, when the insulating material 422 is applied to the outer periphery of the coil 4131 in which the wire 421 having a substantially rectangular rectangular cross section is wound a plurality of times, the width direction of the slot 411 (circumferential direction as the stator 4) ) Portion so that the overlapping portion 4221 comes to the portion. This is a setting for minimizing the length of the overlapping portion 4221, that is, maximizing the space factor. However, when it is desired not to be affected by the size of the space factor and to increase the fixing area, as shown in FIG. Further, it is also possible to arrange so that the overlapping portion 4221 comes in the depth direction (radial direction as the stator 4) portion of the slot 411. The fixing head 16 at that time has a shape that matches the position and width of the overlapping portion 4221.

  FIG. 53 shows another embodiment. In the embodiments so far, the smoothness of the surface of the insulating material has been used as it is in order to reduce the insertion resistance into the slot 411 because the surface called conventional insulating paper is fibrous. However, when used as a stator of a rotating electrical machine, this insulating material is provided with a separate member called a wedge at the opening of the slot 411 so that the coil 4131 does not fall out of the slot 411 due to electromagnetic force or vibration. Providing protrusions on the surface of the surface 422 produces advantages such as not using the wedges, reducing the thickness of the wedges, and using even weak materials.

  In FIG. 53A, when the insulating material 422 is a raw material, it is used with its original surface smoothness, and is fixed to the strand 421 in the width direction of the slot 411 (the circumference of the stator 4 is the circumference). Protrusions are placed at locations opposite to the direction. By making the protrusion shape at this time easy to move with respect to the insertion direction of the coil 4131 and difficult to move in the direction in which the coil 4131 comes out, it is effective for preventing the coil 4131 from falling off.

  FIG. 53B shows a state in which the insulating material 422 is a raw material and has a projection on the surface. In this case, the same device as that having no projection on the surface of the insulating material 422 can be used as a material, and it is also effective in preventing the coil 4131 from falling off.

  In the above embodiment, the positioning of the wire 421 and the insulating material 422 can be optimized immediately before inserting the stator by controlling the degree of fixing so that the wire 421 and the insulating material 422 are not fixed. It becomes.

  In the method of fixing the wire 421 and the insulating material 422, when the length of the insulating material 422 is determined, the protrusion length from the stator thickness considering the insulating distance is secured, and then the insulating material 422 with respect to the coil is secured. Considering the fixing positioning accuracy, it was set longer. By not fixing the wire 421 and the insulating material 422 as in the present embodiment, the length of the insulating material 422 is not affected by the fixing positioning accuracy of the insulating material 422 with respect to the coil and is adjusted immediately before the stator is inserted. It is possible to reduce the thickness to the necessary minimum.

  Further, in the above embodiment, by controlling the degree of fixing so that the wire 421 and the insulating material 422 are not fixed, even if a malfunction occurs when the stator is inserted, the wire 421 is not damaged and the insulating material 422 is not damaged. In the case where only the substrate is damaged, it is possible to reduce the number of waste coils by removing it once and exchanging / refixing the insulating material 422.

  In the above-described embodiment, when the insulating material 422 is fixed, the insulating material 422 used for the coil end portion can be fixed together with the insulating material 422 used for the coil slot portion at the same time or in a separate process. Thereby, what changed the kind and thickness of the insulating material 422 can be selected for the ground insulation of a coil slot part, and the phase insulation of a coil end part. In addition, even if the same material has the same thickness, if the shape required for each part is different, the parts cut out in consideration of the yield of use of the insulating material 422 can be integrated in the fixing process. .

  Further, in the above embodiment, the method of inserting the coil from the opening provided on the inner peripheral side of the stator and incorporating it toward the outer peripheral side of the stator has been described, but the coil is inserted from the opening provided on the outer peripheral side of the stator, The present invention can also be applied to a method of incorporating toward the stator inner peripheral side.

  As another example, a thermosetting resin is used for the insulating material 422. Before the slot is assembled, the insulating material 422 is temporarily fixed by spot fixing. It is also possible to perform the main curing by a heating process such as varnish treatment.

  All the embodiments described above are suitable for the rotating electrical machine and its coils described below.

  A rotating electrical machine that constitutes an embodiment of the present invention will be described based on an electric motor used in a hybrid vehicle. The electric motor for a hybrid vehicle according to the present embodiment has both a function of a driving motor for driving wheels and a function of a generator for generating power, and the functions are switched depending on the running state of the vehicle. ing. Here, an induction type rotating electrical machine will be described as an example, but it may be applied to other types, for example, a synchronous rotating electrical machine.

  FIG. 1 is a side sectional view of an induction type rotating electrical machine. FIG. 2 is a perspective view of a cross section of the rotor. FIG. 3 is an exploded perspective view of each part related to the induction type rotating electrical machine of the present embodiment.

  The induction type rotating electrical machine includes a bottomed cylindrical housing 1 that is open at one end in the axial direction, and a cover 2 that seals the open end of the housing 1. A water channel forming member 22 is provided inside the housing 1, one end of the water channel forming member 22 is fixed between the housing 1 and the cover 2, and a water channel 24 is formed between the stator 4 and the housing 1. Is done. Cooling water is taken into the water channel 24 from the cooling water inlet 32, and the cooling water is discharged from the water channel 24 to the outlet 34 to cool the rotating electrical machine. The housing 1 and the cover 2 are fastened by a plurality of, for example, six bolts 3.

  A water channel forming member 22 is provided on the inner periphery of the housing 1, and the stator 4 is fixed inside the water channel forming member 22 by shrink fitting or the like. As shown in FIG. 6, the stator 4 includes a stator core 412 having a plurality of slots 411 and three-phase stator windings 40 wound in the slots 411 at equal intervals in the circumferential direction. And is composed of. In this embodiment, there are 8 poles and 48 slots, and the stator winding 40 is connected by star connection, and each phase is a 2Y connection in which a pair of stator coils 413 are connected in parallel as shown in FIG. It has become.

  In addition, the rotor 5 is disposed on the inner periphery of the stator core 412 so as to be rotatable through a minute gap so as to face the stator core 412. The rotor 5 is fixed to the shaft 6 and rotates integrally with the shaft 6. The shaft 6 is rotatably supported on both sides thereof by ball bearings 7a and 7b acting as bearings provided on the housing 1 and the cover 2, respectively. Among these ball bearings 7 a and 7 b, the ball bearing 7 a on the cover 2 side is fixed by a substantially rectangular fixing plate 8 shown in FIG. 3, and the ball bearing 7 b on the bottom side of the housing 1 is fixed to the housing 1. It is being fixed to the recessed part provided in the bottom part. For this reason, the rotor 5 is rotated relative to the stator 4, and the pulley 6 attached to the cover 2 side end of the shaft 6 by the nut 11 via the sleeve 9 and the spacer 10 is used for the shaft 6. A rotational force is output to the outside, or a rotational force from the pulley 12 is input to the shaft 6. Since the outer periphery of the sleeve 9 and the inner periphery of the pulley 12 are slightly conical, the pulley 12 and the shaft 6 are firmly integrated by the tightening force of the nut 11 so that they can rotate integrally. It has become.

  The rotor 5 has conductor bars 511 extending in the rotation axis direction at equal intervals over the entire circumference in the circumferential direction, and a pair of short-circuit rings 512 are provided to short-circuit each conductor bar 511 at both ends in the rotation axis direction. It is a connected cage rotor. The conductor bar 511 is embedded in a rotor core 513 made of a magnetic material. FIG. 2 shows a cross-sectional structure taken along a plane perpendicular to the rotation axis to clearly show the relationship between the rotor core 513 and the conductor bar 511, and the short-circuit ring 512 and the shaft 6 on the pulley 12 side are visible. Absent.

  The rotor core 513 is formed of a laminated steel plate formed by punching or etching an electromagnetic steel plate having a thickness of about 0.05 to 1 mm and laminating the formed electromagnetic steel plates. As shown in FIGS. 2 and 3, substantially fan-shaped cavities 514 are provided at equal intervals in the circumferential direction on the inner peripheral side for weight reduction. A plurality of spaces in which the respective conductor bars 511 are arranged are provided on the outer peripheral side. The rotor core 513 has a conductor bar 511 on the stator side, and a rotor yoke 530 for forming a magnetic circuit inside the conductor bar 511.

  In this embodiment, the stator has an 8-pole stator winding, and the thickness of the magnetic circuit formed in the rotor yoke 530 in the radial direction is larger than that of an induction motor having two or four poles. Can be thinned. The thickness can be reduced by increasing the number of poles compared to 8 poles, but there is a problem in that the output and efficiency are lowered if 12 poles or more. Accordingly, the rotating electric machine for running the vehicle including the engine start function is preferably 6 to 10 poles, particularly 8 or 10 poles.

  Each conductor bar 511 and short-circuit ring 512 of the rotor 5 are made of aluminum, and are formed so as to be integrated with the rotor core 513 by die casting. The short-circuit rings 512 arranged at both ends of the rotor core are provided so as to protrude from the rotor core 513 to both ends in the axial direction. The conductor bar and the short-circuit ring 512 may be made of, for example, copper. In that case, the conductor bar and the short-circuit ring 512 can be formed by die casting. The conductor bar and the short-circuit ring 512 may be joined and fixed by joining.

  A detection rotor 132 is provided on the bottom side of the housing 1, and the rotation sensor 13 for detecting the rotation speed and the rotor position detects the teeth of the detection rotor 132 to detect the position and rotation of the rotor 5. An electric signal for detecting the rotation speed of the child 5 is output. The rotation sensor 13 may use a resolver.

  Next, the operation of the induction motor according to the present embodiment will be described with reference to FIGS.

  First, the power running operation of the rotating electrical machine that functions as a driving motor for driving the wheels and the engine will be described. FIG. 4 shows a system for explaining electrical connection. For example, a secondary battery 612 for high voltage corresponding to a voltage of 100 V to 600 V and a DC terminal of the inverter device 620 are electrically connected. The AC terminal of the inverter device 620 is electrically connected to the stator winding 40. As will be described later, each phase of the stator winding 40 has a stator coil 413 connected in parallel.

  In the power running operation, DC power is supplied from the secondary battery 612 to the inverter device 620, and AC power is supplied from the inverter device to each stator coil 413 of the three-phase stator winding 40 wound around the stator core 412. Is done. Due to this AC power, a rotating magnetic field having a rotational speed based on the frequency of the AC power is generated in the stator core 412, and a magnetic flux having the rotor 5 as a magnetic path is generated by the rotating magnetic field as shown in FIG. 5. FIG. 5 shows the state of the rotating magnetic field generated by the stator winding 40. The winding structure of the stator winding 40 is, for example, an 8-pole distributed winding as described in the following embodiment. FIG. 5 shows a simulation result when a general iron core virtually having no conductor bar is arranged in a state where the influence of the rotor is removed. A core back 430 is provided on the outer peripheral side of the slot of the stator core 412 to form a magnetic circuit for the rotating magnetic field. In this simulation, since the stator winding 40 has eight poles and a large number of poles, the radial thickness of the magnetic circuit in the core back 430 can be reduced. The radial thickness of the magnetic circuit on the rotor 5 side is also thin. The rotating magnetic field shown in FIG. 5 rotates based on the AC frequency supplied to the stator winding 40.

  In FIG. 4, the inverter device 620 generates an alternating current necessary for generating the torque required for the rotating electrical machine and supplies the alternating current to the stator winding 40. In a state where the rotation speed of the rotor 5 is slower than the rotation speed of the rotating magnetic field, the conductor bar 511 is linked to the rotating magnetic field generated in the stator core 412, and current flows through the conductor bar 511 according to Fleming's right-hand rule. . Further, when a current flows through the conductor bar 511, rotational torque is generated in the rotor 5 according to Fleming's left-hand rule, and the rotor 5 rotates. Since the difference between the rotational speed of the rotor 5 and the rotational speed of the rotating magnetic field of the stator 4 affects the magnitude of the torque, it is necessary to appropriately control the speed difference, that is, “slip”. For this reason, the rotational speed of the rotor 5 is detected based on the output of the rotation sensor 13 to control the switching frequency of the inverter, thereby controlling the frequency of the alternating current supplied to the stator 4.

  FIG. 6 is a simulation result showing the state of magnetic flux when the rotation speed of the rotor 5 having the conductor bar 511 is slower than the rotation speed of the rotating magnetic field generated in the stator core 412. The rotation direction of the rotor 5 is counterclockwise. Magnetic flux generated by the stator winding 40 disposed in the slot 411 passes through a magnetic circuit including the core back 430 and the rotor yoke 530 of the rotor core 513. The magnetic flux of the rotor core 513 is shifted to the delay side in the rotation direction of the rotor from the magnetic flux of the stator core 412. Since the number of poles of the stator winding is as large as eight, the magnetic flux of the rotor's rotating yoke 530 is coarser on the rotating shaft side than on the conductor bar 511 side.

  Next, a case where the rotating electrical machine operates as a generator that generates electric power will be described. When operating as a generator, the rotational speed of the rotor 5 rotated by the rotational force input from the pulley 12 is higher than the rotational speed of the rotating magnetic field generated in the stator core 412. When the rotational speed of the rotor 5 exceeds the rotational speed of the rotating magnetic field, the conductor bar 511 is linked to the rotating magnetic field, so that a braking force acts on the rotor 5. By this action, electric power is induced in the stator winding 40, and power generation is performed. In FIG. 4, when the frequency of the AC power generated by the inverter device 620 is lowered and the rotational speed of the rotating magnetic field generated in the stator core 412 is made slower than the rotational speed of the rotor 5, the inverter device 620 changes to the secondary battery 612. DC power is supplied. Since the electric power generated by the rotating electric machine is based on the difference between the rotation speed of the rotating magnetic field and the rotation side of the rotor 5, the generated electric power can be controlled by controlling the operation of the inverter device. If the loss or reactive power of the rotating electrical machine is ignored, if the rotating magnetic field of the rotating electrical machine is made faster than the rotational speed of the rotor 5, electric power is supplied from the secondary battery 612 to the rotating electrical machine via the inverter device 620. If the rotating magnetic field of the rotating electrical machine is the same as the rotational speed of the rotor 5, power is not transmitted and received between the secondary battery 612 and the rotating electrical machine, and if the rotating magnetic field of the rotating electrical machine is slower than the rotational speed of the rotor 5. Electric power is supplied from the rotating electrical machine to the secondary battery 612 via the inverter device 620. However, since the loss or reactive power of the rotating electrical machine cannot be ignored in practice, power is not supplied from the secondary battery 612 to the rotating electrical machine when the rotating magnetic field of the rotating electrical machine is slightly slower than the rotational speed of the rotor 5.

  Next, details of the stator 4 will be described with reference to FIGS. 4 and 7 to 13.

  FIG. 7 is a perspective view of the stator 4. The stator 4 shown in FIG. 7 includes a plurality of stators that constitute a stator core 412 having 48 slots 411 formed at equal intervals in the circumferential direction and a stator winding 40 wound around the slots 411. And a coil 413. The stator core 412 is made of a laminated steel plate formed by, for example, punching or etching a magnetic steel plate having a thickness of about 0.05 to 1 mm and laminating the formed magnetic steel plates, and is equally spaced in the circumferential direction. A plurality of slots 411 arranged radially are formed. In this embodiment, the number of slots is 48. Teeth 414 are provided between these slots 411, and each tooth 414 is integrated with an annular core back 430. That is, each tooth 414 and the core back 430 are integrally formed. Further, the inner peripheral side of the slot 411 is open, and the stator coil 413 constituting the stator winding 40 is inserted from this opening. The circumferential width of the opening of the slot is substantially equal to the width of the slot at the position where the coil is mounted, that is, the width of the coil mounting portion of each slot, or slightly larger than the coil mounting portion of the slot. It is formed as follows. Each slot is formed into an open slot, and a holding member 416 is provided at the distal end side of each tooth 414 in order to prevent the coil inserted in each slot from moving toward the outlet side of the slot, that is, the inner peripheral side of the stator. Is to be installed. The holding member 416 is made of a non-magnetic material such as resin or a non-magnetic metal material, and has a shaft in a holding groove 417 formed on the both sides in the circumferential direction on the tip side of the teeth 414 so as to extend in the axial direction. It comes to be mounted from the direction.

  Next, the stator coil 413 constituting the stator winding 40 will be described with reference to FIGS. 8 and 9. FIG. 8 is a perspective view of a stator coil 413 made up of one continuous insulated conductor constituting the stator coil 40. FIG. 9 is a perspective view of the stator coil 413 for one phase. In the present embodiment, the three-phase stator winding 40 is provided. First, one phase will be described. In addition, the stator coil 413 of this embodiment uses a conductor whose cross-sectional shape called a flat wire is substantially rectangular and whose outer periphery is covered with an insulating film, and the cross-section of the conductor in a wound state is used. In the rectangular shape, the circumferential direction of the stator core 412 is long and the radial direction is short. Further, as described above, the surface of the conductor of the stator coil 413 is coated for insulation.

  Before describing FIG. 8, the connection of the stator winding 40 will be described with reference to FIG. In this embodiment, the stator winding 40 has two star connections in a system constituted by two stator coils 413 in which windings of respective phases constituting the stator winding 40 are connected in parallel. is doing. If the two star connections are a Y1 connection and a Y2 connection, the Y1 connection has a U-phase winding Y1U, a V-phase winding Y1V, and a W-phase winding Y1W. The Y2 connection has a U-phase winding Y2U, a V-phase winding Y2V, and a W-phase winding Y2W. The Y1 connection and the Y2 connection are connected in parallel, and each neutral point is also connected.

  The coil Y1U includes a coil U11, a coil U12, a coil U13, and a coil U14 connected in series. The coil Y2U includes a coil U21, a coil U22, a coil U23, and a coil U24 connected in series. The coil Y1V includes a coil V11, a coil V12, a coil V13, and a coil V14 connected in series. The coil Y2V includes a coil V21, a coil V22, a coil V23, and a coil V24 connected in series. The coil Y1W includes a coil W11, a coil W12, a coil W13, and a coil W14 connected in series, and the coil Y2W includes a coil W21, a coil W22, a coil W23, and a coil W24 connected in series. As shown in FIG. 4, the coils U11 to W24 each further include two sets of coils. For example, the coil U11 is configured by connecting the coil 2 and the coil 1 in series. Here, the numbers of the coils 2 and 1 indicate the slot numbers on the rotor side in which the coils are inserted. That is, the coil U11 is a series connection of a slot number 2 coil and a slot number 1 coil. Similarly, the coil U12 is a series connection of a coil of slot number 38 and a coil of slot number 37. Similarly, the coil number in FIG. 4 represents the number of the inserted rotor side slot. The last coil W24 is a series connection of a coil with slot number 11 and a coil with slot number 12. It should be noted here that each series coil is inserted in the adjacent slot. As described below, this makes it easy to manufacture and further reduces torque pulsation. The winding state of each coil will be described in detail later.

  Since the coils Y1U, Y1V, Y1W, Y2U, Y2V and Y2W have the same structure, the coil Y1U will be described as a representative example with reference to FIG.

  If the structure of the stator coil 413 is described as a representative of the coil Y1U, the coil Y1U is constituted by a series connection of a coil U11, a coil U12, a coil U13, and a coil U14. Since the coils are arranged at equal intervals, the coils are arranged at a mechanical angle of 90 °. The coil U11 has two element coils 4131a and 4131b, and the element coil 4131a has a structure that goes around the rotor side of the slot 2 and the bottom side of the slot 7. In this embodiment, the slot 2 and the slot 7 are paired a plurality of times, and in this embodiment, the slot 2 and the slot 7 are rotated three times. Since these laps are performed by continuous conducting wires, there is no need for connection work in the lap of the coil 4131.

  The element coil 4131b constituting the coil U11 has a structure in which the rotor side of the slot 1 and the bottom side of the slot 6 are rotated three times. The element coil 4131a and the element coil 4131b each have a structure that circulates between two slots, and these coils are arranged on the rotor side in one slot of each coil, and the bottom of the slot in the other slot. Arranged on the side. The element coil 4131a and the element coil 4131b are connected in series by an inter-coil connection line 4134. This serially connected portion is also composed of continuous conductors, and no special connection work is required. The coil 4131, which is a circulating part of the two slots, has a substantially turtle shell shape when attached to the stator core 412, and has an inner circumference on the rotor side of one slot 411 at the coil end. It is wound so as to straddle the outer peripheral side which is the bottom side of the side and the other slot. The interval between the slot 2 or slot 1 as one slot and the slot 7 or slot 6 as another slot is wound by a distributed winding method determined based on the number of slots and the number of poles of the stator.

  As described above, the element coils 4131a and 4131b having a circular structure are made of continuous conductors, and the number of places requiring connection work can be reduced. Further, according to the following method, the two element coils 4131a and the element coil 4131b can be made of a continuous conductor in the inter-coil connection line 4134 that connects them. For this reason, in this embodiment, the number of turns of the stator coil 413 is increased, but an increase in the number of connection points requiring connection work is suppressed.

  Further, a set is formed by two element coils 4131a and 4131b which are rotating portions, and arranged at a plurality of positions spaced apart in the circumferential direction by using this set as a unit, in this embodiment, at four positions at intervals of 90 °. The coil extending from the inner peripheral side of the spiral portion in the set of element coils 4131a and 4131b and the coil extending from the outer peripheral side in the set of other element coils 4131a and 4131b are connected to each top of the coil end. They are connected by a crossover 4132. In the present embodiment, the coil extending from the inner peripheral side of the spiral portion in the set of element coils 4131a and 4131b and the coil extending from the outer peripheral side of the spiral portion in the set of the other element coils 4131a and 4131b are wound continuously. As a result, a set of four pairs of rotating portions formed so as to be adjacent to each other is formed by a coil made of one continuous conductor. The connecting wire 4132 is provided only on one axial end side of the stator 4 and converges so as to cross from the outer peripheral side of the stator core 412 to the inner peripheral side of the stator core 412. .

  One coil shown in FIG. 8 is half of one phase of the stator winding, and the stator winding constituting one phase is the winding Y1U described in FIG. 8 as shown in FIG. The winding Y2U having the same structure is arranged at a mechanical angle of 45 ° with respect to the winding Y1U in the circumferential direction. A set of element coils 4131a and 4131b of a coil molded body formed in the same manner is arranged with a 45 ° shift in mechanical angle. The element coil 4131a constituting the coil U11 is arranged on the rotor side of the slot 2, and the element coil 4131b constituting the coil U11 is arranged on the rotor side of the slot 1. The element coil 4131a that constitutes the coil U21 that is shifted by 45 ° by the mechanical angle has a structure that goes around the rotor side of the slot 44 and the bottom side of the slot 1. The element coil 4131b constituting the coil U21 has a structure that goes around the rotor side of the slot 43 and the bottom side of the slot 48.

  A stator coil 413, which is a three-phase coil molded body, is formed by disposing the stator coil 413, which is a coil molded body formed as shown in FIG. 9, so as to be shifted by 15 ° and 30 ° in the circumferential direction. The Thus, in this embodiment, the stator coils 413 for three phases can be wound around the stator core 412 with a structure that reduces the number of connection points that require connection work.

  FIG. 10 is a front view of the stator. FIG. 11 is a side view of the stator. 12 is a connection diagram, and is a connection diagram of the 2Y-connected stator winding 40 shown in FIG. As shown in FIG. 10, the connecting wire 4132 in each coil molded body is disposed so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412, so that the connecting wire 4132 is substantially spiral as a whole. Will be configured. For the neutral point of the star connection, it is necessary to connect the terminal of each coil and the connecting wire provided separately from each other by TIG welding or the like instead of the continuous coil 4132. Note that the connecting wire serving as the neutral point is also arranged so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412. By adopting such a structure, the stator coils 413 are arranged in a regular structure, and space is efficiently used. As a result, the rotating electrical machine can be miniaturized.

  FIG. 13 is a diagram showing the relationship between the slot numbers of the stator and the coils constituting the stator coil, and the arrangement relationship between the slots and the surrounding portions of the stator coil 413 constituting the stator winding 40. In the figure, a slot number column 442 indicates a slot number, and 48 slots are given as a reference, and numbers are assigned in order from that slot. Each of the coils U11 to W24 constituting the stator coil 413 of FIG. 4 is composed of a coiled portion with a slot number arranged on the rotor side, and these configurations are related to the slots in the column 442. Shown below. In the column 442, the coil W13 has slot numbers 29 and 30. This indicates that the coil W13 is constituted by a serial connection of the coil portion disposed on the rotor side of the slot number 29 and the coil portion disposed on the rotor side of the slot number 30. . This is also indicated by coil numbers 29 and 30 constituting the coil W13 of FIG. In the column 442 of FIG. 13, the coil U22 has slot numbers 31 and 32, and the coil portion arranged on the rotor side of the slot number 31 and the coil portion arranged on the rotor side of the slot number 32 It shows that the coil U22 is configured in series connection. This is also indicated by coil numbers 31 and 32 constituting the coil U22 of FIG. Looking at the coil U11 described with reference to FIG. This indicates that the coil U11 is constituted by a series connection of the coiled portion arranged on the rotor side of the slot number 1 and the coiled portion arranged on the rotor side of the slot number 2. This can also be seen from the fact that the coil numbers 1 and 2 constituting the coil U11 of FIG.

  A column 444 in FIG. 13 indicates the phase of the stator coil 413 and the order of arrangement in the phase. In column 442, coil U11 is slot numbers 1 and 2. As shown above, this indicates that the coil is arranged in series at the coil portions arranged in the slot numbers 1 and 2. This coil U11 is marked “U1” in column 444. This indicates that the stator coil 413 is disposed at the first position of the U phase, that is, at the reference position of the U phase. Coil U21 is labeled "U2" in column 444. This indicates that the second U-phase of the stator coil, that is, a mechanical angle of 45 ° from the U-phase reference position is arranged. Similarly, coil U12 is labeled “U3” in column 444. This indicates that the stator coil is arranged at the third position of the U phase, that is, at a mechanical angle of 90 ° from the reference position of the U phase. This is as already described with reference to FIG.

  With respect to the coil U11, the coil V11 is shifted by 15 ° in mechanical angle. Accordingly, the coil V21 of “V2” shown in the column 444 is positioned at a position shifted by 45 ° from the position of the coil V11 with respect to the coil V11 at a position shifted by 15 ° by the mechanical angle with respect to the reference position of the coil U11. is there. Hereinafter, since all the V-phase coils are based on the coil V11, they are shifted by 15 ° with respect to the U-phase coil. Similarly, since the coil W11 is shifted by 30 ° in mechanical angle from the position of the coil U11, all the W-phase coils are shifted by 30 ° with respect to the U-phase coils.

  Next, the column 446 will be described. In this embodiment, the coil 4131 that circulates has a structure that circulates through two slots. That is, the element coil 4131a shown in FIG. 8 circulates through the slot 2 and the slot 7, the element coil 4131a is arranged on the rotor side, the second slot is the element coil 4131a, and the other slot is arranged on the back side. No. 7. The column 442 shows the one slot number, whereas the column 446 shows the other slot number. That is, the column 446 of the slot number 2 in the column 442 is “7”. This indicates that the coil is circulating with slot number 2 as one slot and slot number 7 as the other slot. The following columns 442 and 446 show one and the other slots of the coil that similarly circulates.

  A column 448 indicates the phase of the coil located behind the slot number shown in the column 442 and the order of arrangement of the coils in the phase. A column 450 indicates a slot around the coil described in the column 448. For example, the coil arranged behind slot number 2 in column 442 indicates that it is the second coil located in the V phase. In addition, the description “45” in the column 450 indicates that the coil arranged behind slot number 2 circulates through two slots with one slot number “45” and the other slot number “2”. Show. Looking at the slot number 45 in the column 442, the column 446 is described as “2”. This description refers to the same coil as above. That is, it is indicated that the coil that circulates through one slot number “45” and the other slot number 2 is the second coil arranged in the V phase.

  FIG. 12 shows the connection state of the final stator winding 40 thus connected. In addition, although the winding part of the coil 4131 in FIG. 12 is displayed for one round, in fact, as described above, the coil 4131 is turned for three rounds. In addition, the number displayed in the center of the winding portion of the coil 4131 in FIG. 12 is the slot number, and the portion where the coil is a broken line is the coil located on the inner peripheral side of the slot 411, that is, the slot opening side The portion where the coil is a solid line is a coil located outside the slot 411, that is, on the slot bottom side. Furthermore, the places where the intersections of the lines are displayed as circles are the places where connection work such as welding is necessary. As can be seen from FIG. 12, only nine locations need to be connected by welding.

  In the structure described with reference to FIGS. 4 and 13, a plurality of conductors are arranged in the radial direction in each slot, and a coil having a shape in which these conductors circulate through two slots is formed. Since this circulating coil is composed of continuous conductors, in this embodiment, the number of turns is increased, but the increase in the number of connection points is suppressed. Further, only one conductor is inserted in the circumferential direction of each slot, and this structure is easy to manufacture as described below. Further, since the conductor has a shape that is wide in the circumferential direction and thin in the radial direction, an eddy current generated in the conductor in the slot due to leakage magnetic flux is suppressed. For this reason, the efficiency of the rotating electrical machine is improved and heat generation is suppressed.

  Further, as shown in FIG. 11, these connecting wires 4132 are positioned on substantially the same plane on one end side in the axial direction of the stator 4, so that the coil end can be shortened. As described above, in the present embodiment, the crossover wires are arranged outside the coil ends in the rotation direction, and the arrangement is orderly as a whole, and the entire rotating electrical machine is downsized. In addition, reliability can be ensured in terms of electrical insulation. In particular, recently, rotating electric machines for driving automobiles have a high operating voltage, and many of them exceed 100V. Depending on the case, a voltage of 400V or 600V may be applied, and the reliability between the lines of the stator coil is important.

  Furthermore, in the above-described embodiment, the element coil 4131b wound a plurality of times is connected to the element coil 4131b wound a plurality of times by the inter-coil connection line 4134. Crossover wires are arranged outside the inter-coil connection wires 4134, and the arrangement is orderly as a whole. As described above, this reduces the overall size of the rotating electrical machine. In addition, reliability can be ensured in terms of electrical insulation.

  The rotating electrical machine described in the present embodiment has a structure that can provide a relatively large output and improve productivity even though it is relatively small applied to a drive motor of an automobile. As a conductor of the stator winding, not only a conductor having a circular cross section but also a conductor having a substantially rectangular cross section can be used, and the space factor in the slot can be improved, so that the efficiency of the rotating electrical machine is improved. In a conventional rotating electrical machine, when a conductor having a substantially rectangular cross section is used, there are many places to be electrically connected after inserting the conductor into the slot of the stator, which has a problem in terms of productivity. In the following embodiments, since a coil in which a conductor whose surface is insulated is continuously wound can be inserted into the slot, the number of electrical connection points is small and productivity is improved.

  In the present embodiment, one side of each of the plurality of circulation portions of the coil is inserted into the back side of the slot, and then the other side of each of the circulation portions and the one side By adjusting the distance to a predetermined distance and inserting the other side into the slot entrance side, the continuously wound coil can be efficiently inserted into the slot, and the productivity is improved.

  In this embodiment, the overlapped portion of the continuous winding coil is formed of a continuous line, and when one side constituting the coil of the overlapped portion is inserted into one slot, the other side constituting the coil is predetermined. It is arranged to be inserted into another slot that is spaced apart, and is arranged radially inside in the one slot, outside in the radial direction in the other slot, and from the inside to the outside of the slot at the coil end or It is structured to be wound so as to move from the outside to the inside. With such an arrangement, the continuously wound coils are regularly arranged, the number of turns of the coil can be increased, and an increase in electrical connection points with respect to an increase in the number of turns of the coil can be suppressed. Moreover, even if the number of turns of the coil is increased, the increase in the size of the rotating machine can be suppressed.

  In this embodiment, each slot has a structure in which a plurality of conductors constituting a coil are arranged in a row in the radial direction with respect to the rotation axis in a circumferential direction. With such a structure, the process of inserting the continuously wound coil into the slot becomes relatively simple, and the productivity is improved. In addition, since the coil is disposed so that currents in the same phase flow in the slots adjacent to each other in the circumferential direction, a rotating electrical machine having a structure that leads to an improvement in productivity can be provided. In addition, stator windings are made by connecting in-phase windings arranged in adjacent slots in series, and electrically connecting a stator coil with the series-connected windings as unit windings, This has the effect of easily balancing the electrical characteristics.

  The stator winding described in the present embodiment can be used for both a permanent magnet type rotating machine and an induction type rotating electrical machine. As an example in the case of being used as an induction type rotating electrical machine, in the following embodiment, the induction type rotating electrical machine has 8 poles. By setting the number of poles of the induction rotating electrical machine to 6 poles or more, particularly 8 poles or 10 poles, the radial thickness of the magnetic path of the core back of the stator core can be reduced. Similarly, with respect to the rotor, the thickness in the radial direction of the magnetic path of the rotor yoke can be reduced by using 6 poles or more, particularly 8 poles or 10 poles. In the case of an induction motor, if the number of stator poles is increased, the efficiency will be reduced due to the relationship with the rotor cage conductor, and 6 to 10 poles are preferred as a rotating electrical machine for use in an automobile drive system. Among them, 8 to 10 are better, and 8 is very good. A rotating electrical machine used for a drive system of an automobile is a rotating electrical machine that starts a stopped engine, generates a torque for traveling a vehicle together with the engine, or travels a vehicle with a single torque.

  Next, a method for manufacturing a rotating electrical machine will be described with reference to FIGS. One of the features of this embodiment is a method of inserting a coil into a slot of a stator, and this method will be described. FIG. 14 is a flowchart showing the manufacturing process of this embodiment. FIG. 15A is a perspective view of a state where a coil is wound around a core. FIG. 15B is an enlarged view of the portion (B) in the diagram of FIG. FIG. 16 is a perspective view of a state in which a coil wound around a core is further press-formed. FIG. 17 is a perspective view of a preformed coil. FIG. 18A and FIG. 18B are side views in which the preformed coil is further deformed. FIG. 19 is a perspective view showing a state in which the preformed coil is mounted in the slot of the stator core. FIG. 20 is a perspective view illustrating a state in which the pushing portion of the inner jig is retracted. FIG. 21 is a perspective view illustrating a state in which the extruded portion of the inner jig protrudes. FIG. 22 is a cross-sectional perspective view of the stator core with the teeth support jig attached, with the upper portion in the figure cut away. (A) in FIG. 23 is a perspective view showing a state in which the preformed coil is mounted in the slot of the stator core, and the inner jig and the support jig are further mounted. FIG. 23B is an enlarged partial cross-sectional view of FIG. FIG. 24 is a partial cross-sectional perspective view of a state in which the pressing jig is mounted. FIG. 25 is a perspective view of a stator that has been temporarily formed. FIG. 26 is a diagram showing deformation of the coiled portion in the insertion step. FIG. 27 is a perspective view showing a state where the coil is inserted into the slot of the stator core.

  In the manufacturing method of the present embodiment, in step 111 in the flowchart of FIG. 14, first, a wire having an insulating coating on its surface, for example, an enameled wire, is wound around the core wire 14 a plurality of times, and the element coil 4131a and the element coil 4131b are thereby connected. to make. As shown in FIG. 15 (B), the core glass 14 has a thin flat plate shape with rounded corners as shown in FIG. 15 (A), and is adjacent to the thin surface on the long side as shown in FIG. 15 (B). Four pairs of the two pinned pins 15 provided at substantially equal intervals are provided.

  Here, the insulation-coated wire is wound a plurality of times (in this embodiment, 3 times so that the element coil 4131a and the element coil 4131b are spirally hooked on one side surface of the curled pin 15 on one end side in the long side direction of the core rod 14. Lap) lap. Thereafter, the pair of element coils 4131a and 4131b are formed by further rotating the insulation-coated wire a plurality of times (in this embodiment, three laps) so as to be hooked on the side surface of the adjacent curled pin 15. Since the pair of element coils 4131a and 4131b formed in this way are both spirally wound from the inner peripheral side to the outer peripheral side, the two element coils 4131a and 4131b are adjacent to each other from the outer peripheral side of the spiral portion. Continuing on the inner peripheral side of the spiral portion in the circular portion.

  In addition, the coil terminals on the winding end side of the pair of element coils 4131a and 4131b are on the outer peripheral side of the spiraling part that circulates, and the terminal part of the stator coil 413 on the outer peripheral side is tangled in the core rod 14. Along the thin surface on the long side where the pins 15 are provided, the element coils 4131a and 4131b are separated by a slot pitch × 11 which is a length corresponding to the mechanical angle of 90 ° in the circumferential direction. Then, it is hooked on the next curled pin 15 and the insulation coated wire is circulated in the same manner. That is, four pairs of the tangled pins 15 provided adjacent to each other are provided for every length necessary for the pair of element coils 4131a and 4131b to shift in the circumferential direction by 90 ° in mechanical angle. The stator coil 413 wound around the core rod 14 is formed as shown in FIG. 15A by repeating the same operation four times in order to form four pairs of rotating portions.

  Next, as shown in step 112 in the flowchart of FIG. 14, the stator coil 413 is pressure-molded to complete the preforming. In addition, the process 111 and the process 112 in the flowchart of FIG. 14 become a preforming process. In order to press-form the stator coil 413 wound around the core rod 14, first, as shown in FIG. The two blocks 16 are sandwiched and pressurized, and the bulges on both sides of the stator coil 413 are removed. In order to facilitate the subsequent molding, it is preferable to use a self-bonding wire for the stator coil 413 and harden it to be integrated by energization.

  Next, the stator coil 413 wound around the core rod 14 is removed from the core rod 14. In order to take out the stator coil 413 from the core rod 14, it is possible to make the pin 15 detachable, or to divide the core rod 14 in the height direction so as to reduce the distance in the height direction after winding. It is only necessary that the tapping pin 15 can be withdrawn into the core glass 14. The stator coil 413 removed from the core rod 14 as described above includes a linear portion 4133 that forms a pair of sides that are spirally wound a plurality of times (three in this embodiment) as shown in FIG. There are four pairs of oval-shaped element coils 4131a and 4131b, and the pairs of the surrounding portions are continuous via a crossover 4132.

  Next, as shown in FIG. 18A, the straight portion 4133 in each of the revolving portions 4131 formed into an oval shape is pressed from the side surface. The apparatus used for pressing is a flat die 17 on one side and a substantially trapezoidal punch 18 on the other side, so that the oval-shaped circumferential portion 4131 in the stator coil 413 is the die 17. And is punched by the punch 18, and is formed into a substantially P-shape in which the side surface on one end side on the coil end side is recessed. In this way, by forming the oval-shaped circumferential portion 4131 of the stator coil 413 into a substantially P-shape and disposing the recessed side on the outer peripheral side of the stator core 412, the stator coil 413 is disposed on the inner peripheral side. And the hindrance to the insertion of the rotor 5 is eliminated.

  As another means for preventing the stator coil 413 from projecting to the inner peripheral side, the one shown in FIG. 18B can be considered. FIG. 18B shows that when the stator coil 413 is sandwiched between the punches 18 by forming a substantially trapezoidal recess in the die 171 in the longitudinal direction longer than the punch 18, and the stator coil 413. The oval-shaped circumferential portion 4131 in 413 is formed into a substantially U-shaped cross section in which the coil ends are deformed in one direction, that is, both ends connecting the linear portions 4133 in the circumferential portion. If the deformed side of the molded portion 4131 formed here is arranged on the outer peripheral side of the stator core 412, the stator coil 413 protrudes more toward the inner peripheral side than in FIG. This can be surely prevented, and the height of the coil end can be lowered.

  In this preforming step 112, the insulating paper described with reference to FIGS. 47 to 53 is attached. Note that the insulating paper may be attached after being removed from the core 14 shown in FIG. 17 and before pressing in FIG. 18, or after the pressing in FIG. 18.

  Thus, the preforming step 112 of the stator coil 413 is completed. Next, as shown in step 113 in the flowchart of FIG. 14, the outer peripheral straight portion 4133 a is inserted into the slot 411 of the stator core 412 so that the outer peripheral straight portion 4133 a of the preliminarily formed peripheral portion 4131 is inserted into the circumference. An arrangement step of arranging in the direction is performed. That is, it arrange | positions so that the short-axis direction in the oval-shaped surrounding part 4131 may become radial. Here, since the pair of the element coils 4131a and 4131b is connected by the crossover wire 4132, it is necessary to arrange them while deforming the crossover wire. A series of these operations is an arrangement process. FIG. 19 shows a state where one side of the rotating portion 4131, for example, the outer peripheral side straight portion 4133a, is inserted into the slot 411 of the stator core 412. Note that FIG. 19 shows a state in which only some of the coils 4131 are inserted into the slots 411 for easy understanding, and the connecting wire 4132 is also omitted.

  Further, in the arranging step 113, the protruding portion deformed in FIG. 18 (A) or FIG. 18 (B) is inserted so as to face the outer peripheral side of the stator core 412 and continuously preformed. In the stator coil 413, a pair of element coils 4131 a and 4131 b wound next to each other is inserted into an adjacent slot 411 and a pair of other element coils 4131 a and 4131 b that are continuous by a crossover 4132. Each of the outer peripheral side straight portions 4133a is inserted into a slot 411 shifted by 90 ° in mechanical angle. Further, the outer peripheral side straight portion 4133a of the continuous circulation portion 4131 preliminarily formed also in the other slots 411 is inserted from the axial direction, and the outer peripheral side straight portion 4133a of the stator coil 413 for three phases is entirely the slot 411. Inserted inside.

  Further, the crossover 4132 portion connecting the pair of element coils 4131a and 4131b in the stator coil 413 is substantially spiral so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412 as shown in FIG. However, it is desirable to form in a projecting shape in a substantially V shape or a substantially U shape in the axial direction in preparation for an insertion process to be performed later.

  Next, as shown in step 114 in the flowchart of FIG. 14, the inner jig 19 is mounted from the axial direction of the stator core 412 on the other side of the rotating portion 4131, for example, the inner peripheral linear portion 4133 b. Note that the steps 113 and 114 in the flowchart of FIG. 14 are the placement steps. Here, details of the inner jig 19 will be described with reference to FIGS. 20 and 21. FIG.

  As shown in FIG. 20, the inner jig 19 has the same number of outer peripheral opening grooves 191 as the slots 411 of the stator core 412 on the outer periphery, and these outer peripheral opening grooves 191 can be opposed to the slots 411. It has become. In addition, the circumferential width of the outer circumferential opening groove 191 is smaller than or equal to the circumferential width of the inner circumferential opening of the slot 411, and the axial length of the outer circumferential opening groove 191 is 411 is longer than the axial length. In addition, slits 192 are formed at the bottom of each outer peripheral opening groove 191, and a plate-like extrusion member 193 is provided from these slits 192 so as to be able to appear and exit in the inner and outer peripheral directions, that is, radially. . Further, an expansion member 194 is provided on the inner peripheral side of these push-out members 193 so as to be movable in the axial direction. The enlarged member 194 is provided with a tapered portion having a continuously small diameter in the inserting direction. When the enlarged member 194 is inserted into the inner periphery of each pushing member 193, the cam action by the tapered portion is shown in FIG. Thus, the pushing member 193 is pushed out from the slit 192.

  The inner jig 19 is inserted from the axial direction of the stator core 412 so that the inner circumferential linear portion 4133b of each circumferential portion 4131 is inserted into each outer circumferential opening groove 191 of the inner jig 19 configured as described above. . 23 (A) and 23 (B) show a state where the inner jig 19 is inserted into the inner periphery of the stator core 412, but for ease of understanding, FIG. 23 (A) shows only a part of the coils 4131. The state inserted in the slot 411 is shown, and the detailed shape of the inner jig 19 and the connecting wire 4132 are omitted. As described above, as clearly shown in FIG. 23B, the axial dimension of the inner jig 19 is longer than the axial dimension of the slot 411 of the stator core 412. That is, the axial length of the outer peripheral opening groove 191 is longer than the axial length of the slot 411.

  Next, as shown in step 115 in the flowchart of FIG. 14, the support member 20 and the teeth support jig 21 are attached to the stator core 412. First, the substantially rod-shaped teeth support jig 21 along the slot 411 is inserted from the axial direction of the stator core 412 into the gap between the bottom of each slot 411 and the outer straight portion 4133a of the circumferential portion 4131. FIG. 22 is a cross-sectional view of the stator core 412 in the upper side in the figure. As shown in this figure, all the slots 411 include the teeth support jig 21 and the linear portion on the outer circumference side of the coil 4131. 4133a is inserted as a pair. Here, when a force in the rotational direction of the stator core 412 is applied to each of the outer peripheral side straight portions 4133a of the coil 4131, a force to tilt the teeth 414 in the circumferential direction acts, but the teeth support treatment is applied to all the slots 411. Since the tool 21 is inserted, the teeth 414 cannot be tilted in the circumferential direction. For this reason, even if a force in the rotational direction of the stator core 412 is applied to the outer peripheral side straight portion 4133a of the coil 4131 in a temporary forming step performed later, the teeth 414 can be prevented from falling.

  Further, as shown in FIG. 23, at both ends in the axial direction of the stator core 412, rod-like support members 20 formed in a taper shape slightly tapered toward the inner periphery at all locations corresponding to the teeth 414 from the outer periphery side. The coil 4131 is mounted between the outer peripheral straight portions 4133a. As shown in FIG. 23 (B), the support member 20 is configured so that the height in the axial direction is substantially equal to the inner jig 19 in the mounted state. What is the contact surface with the stator core 412? Both sides in the circumferential direction on the opposite side have a generally rounded shape that forms a gentle curved surface.

  Next, as shown in step 116 in the flowchart of FIG. 14, the pressing jig 23 is attached to the stator core 412. As shown in FIG. 24, the pressing jig 23 is attached to both ends of the stator core 412 in the axial direction, and both ends connecting the linear portions 4133 of the rotating portion 4131, that is, the tops of the coil ends are connected to the axis of the stator core 412. It is comprised so that it can press from the direction both sides. For this reason, the pressing jig 23 includes a pressing jig 23a on the side where the crossover 4132 is provided and a pressing jig 23b on the opposite side, and the pressing jigs 23a and 23b are arranged on the inner periphery. It has a ring shape having a hole 231 into which the inner jig 19 can be inserted. Further, the pressing jig 23a on the side where the connecting wire 4132 is provided is formed with grooves 232 along the shape of the connecting wire 4132. By inserting the connecting wires 4132 into these grooves 232, the connecting wire 4132 is inserted. While adjusting the shape of 4132, a pressing force can be applied to the top of the coil end.

  Next, as shown in step 117 in the flowchart of FIG. 14, the inner jig 19 is rotated with respect to the stator core 412 to widen both ends of the circumferential portion 4131, and as a result, the circumferential portion 4131 that is an oval shape is substantially omitted. Molded into a turtle shell shape. This operation is a temporary molding process. Specifically, in a state in which a fixing member is fixed to a groove for welding a plurality of electromagnetic steel plates provided on the outer periphery of the stator core 412, both ends of the stator core 412 in the axial direction of the top end of the coil end are pressed by the pressing jig 23. The inner jig 19 is rotated by a predetermined angle in the clockwise direction while pressing from above, and the inner circumferential straight portion 4133b in the circumferential portion 4131 overlaps with the outer circumferential linear portion 4133a in another circumferential portion 4131 to form a line in the radial direction. Mold as follows. In the present embodiment, the inner peripheral straight portion 4133b in the rotating portion 4131 is rotated by an angle that is shifted by five slots 411 in the stator core 412. That is, the stator core 412 is arranged so that the inner peripheral side straight portion 4133b of the coil 4131 inserted into the five slots 411 overlaps the inner side of the outer peripheral side linear portion 4133a of the coil 4131 formed in a turtle shell shape. The slot 411 and the outer peripheral opening groove 191 of the inner jig 19 are opposed to each other. In the present embodiment, the inner jig 19 is rotated with respect to the stator core 412, but the stator core 412 may be rotated with respect to the inner jig 19.

  47 to 53, according to the installation of the insulating paper, when the shape is changed from a wound shape to a shape for insertion into the slot, the coil as a whole has flexibility, and after the deformation, the inside of the slot When inserting into the coil, it is possible to realize a coil having both properties of fixing the slot insertion portion so as not to be loosened, which is advantageous in this step 117. In addition, a highly reliable motor can be obtained by firmly fixing the core slot portion and ensuring the flexibility of the coil end portion. Further, since the material surface has lubricity, workability when the coil is assembled to the core is improved.

  FIG. 25 shows a state in which all the circumferential portions 4131 are spread out in an aligned state, that is, a state in which they are formed in a substantially turtle shell shape, but for the sake of clarity, the detailed shape of the inner jig 19 and the crossovers are shown. 4132 and the pressing jig 23 are omitted. As for the crossover 4132, since the tops of the coil ends are connected to each other, the shape of the crossover 4132 is not changed even if the winding portion 4131 is formed in a substantially turtle shell shape, and the entire crossover 4132 is maintained while maintaining the shape. Only rotates. That is, the pressing jigs 23 a and 23 b with the connecting wire 4132 inserted follow the inner jig 19 and rotate.

  Thus, in this embodiment, since it forms in a turtle shell shape, pressing the rotation part 4131 with the pressing jig 23, the stress which acts when the rotation part 4131 deform | transforms can be disperse | distributed, and shaping | molding is easy. In addition, the insulating coating such as varnish applied to the surface of the stator coil 413 can be prevented from being damaged. Furthermore, the axial length of the coil end can be shortened.

  Next, as shown in step 118 in the flowchart of FIG. 14, the inner peripheral side straight portion 4133 b of the rotating portion 4131 is inserted into the slot 411 of the stator core 412. This operation is an insertion process. After the provisional molding process is completed and before the insertion process is performed, first, the support member 20 and the teeth support jig 21 are removed. Thereafter, the enlarged member 194 of the inner jig 19 is inserted into the inner periphery of each pusher member 193, and the pusher member 193 is pushed out from the slit 192 as shown in FIG. Into the slot 411. Here, the circumferential width of the slot 411 and the outer circumferential side opening groove 191 is the same, or the circumferential width of the slot 411 is larger, and each of the circumferential portions 4131 is larger than the axial length of the slot 411 in the stator core 412. Since the length in the axial direction of the straight portion 4133 is long, the rotating portion 4131 can be prevented from being caught by the tip of the tooth 414 in the stator core 412. Therefore, in the state where the stator coil 413 is inserted into the slot 411 of the stator core 412, as shown in FIG. 26, the extending portion 418 extending in the continuous direction from the slot 411 of the stator core 412 has a slot. 411 extends to both ends in the axial direction.

  Further, since the slots 411 are formed in a radial shape, it is necessary to widen the space between the pair of linear portions 4133 in the rotating portion 4131 as shown in FIG. Therefore, as in the temporary molding step, the stator coil 413 is inserted by inserting the inner peripheral side straight portion 4133b while pressing the top of the coil end from both axial sides of the stator core 412 with the pressing jig 23. This can be facilitated, and the axial length of the coil end can also be shortened. Further, as the distance between the pair of straight portions 4133 widens, it is necessary to increase the length of the crossover 4132 in the radial direction. However, in the arrangement process, the projecting shape becomes a substantially V shape or a substantially U shape in the axial direction. The length of the connecting wire 4132 in the radial direction can be extended by deforming the connecting wire 4132 that has been formed into a substantially identical surface in the axial direction.

  Next, as shown in step 119 in the flowchart of FIG. 14, the pressing jig 23 and the inner jig 19 are taken out from the inner circumference of the stator core 412, and both circumferential sides on the distal end side of the teeth 414 in the stator core 412. A holding member 416 is mounted in each holding groove 417 provided on the surface from the axial direction of the stator core 412. 27 and 28 show the stator core 412 from which the pressing jig 23 and the inner jig 19 have been removed. 27 and 28 are also shown with the crossover 4132 omitted for easy understanding. In the present embodiment, since the temporary forming step and the insertion step are performed while pressing the top of the coil end in the circumferential portion 4131 with the pressing jig 23, the width α between the respective linear portions 4133 in the coil 4131 is clear from FIG. Rather, the width β between the coils 4131 at the coil end inclined with respect to the axial direction of the stator core 412 is smaller. Thus, the axial length of the coil end in this embodiment can be shortened.

  The holding member 416 has substantially the same length in the axial direction of the stator core 412, and the holding member 416 has a substantially trapezoidal cross section with a short inner peripheral side. On the other hand, since each holding groove 417 is also formed in a shape that matches the holding member 416, the holding member 416 has as large an area as possible when a force that causes the stator coil 413 to be pulled toward the inner peripheral side is generated. And the holding groove 417 can be brought into contact with each other.

  Next, as shown in step 120 in the flowchart of FIG. 14, the terminals of each stator coil 413 are not continuous with the stator coil 413 as shown in FIG. 10 in order to connect the terminals as shown in FIGS. The four connecting wires 4132a provided separately are connected by welding, for example, TIG welding. This operation is a connection process. The connecting wire 4132a provided separately converges so as to straddle the outer peripheral side and the inner peripheral side of the stator core 412, so that the entire connecting wire 4132 is arranged in a substantially spiral shape.

  As described above, the stator 4 is completed. As shown in step 121 in the flowchart of FIG. 14, as the rotating electric machine, the stator 4 is fixed in the housing 1 in which each component is assembled. It is manufactured by rotatably supporting the rotor 5 on the circumferential side using ball bearings 7a and 7b as bearings. This operation is an attachment process that is an assembly process of the rotating electrical machine.

  Although the first embodiment has been described above, the operational effects of the first embodiment are described below.

  The insulation-coated conductor is formed into a continuous coil shape, and then the coil is placed inside the stator 4, and one side of each turn constituting the coil is opened in each slot 411 of the stator 4. Are inserted into the slots, and the other side of each turn constituting the coil is inserted into the slots from the openings of the slots 411 of the stator 4 and the continuous coils are inserted into the stator. A rotating electrical machine is produced by inserting the coil into the slot, and then electrically connecting the coil ends, rotating the stator 4 inside, and rotatably mounting 4. In this production method, since continuously wound coils are mounted in the slots, the number of connection points that require electrical connection work can be reduced, and productivity is improved. Here, the coil may be turned once or plural times. In particular, since the effect is greater in a plurality of times, the embodiment has a structure in which a turn portion having a plurality of turns is placed in each slot. As described above, it is possible to reduce the number of connection points that require connection work for the entire stator winding even if the number of turns is one.

  The manufacturing method of the rotating electrical machine according to the first embodiment includes a preforming step of performing a preforming by rotating a continuous coil in a spiral shape including a pair of opposing linear portions a plurality of times, and the preformed coil An arrangement step of arranging a plurality of circumferential portions in the circumferential direction so that the respective linear portions are located on the inner peripheral side and the outer peripheral side, and relative rotation of the linear portions on the inner peripheral side and the outer peripheral side in the peripheral portion of the coil A temporary forming step, and the linear portion on the outer peripheral side of the temporarily formed coil is positioned on the bottom side of the slot, and the linear portion on the inner peripheral side is positioned on the coil insertion portion side. An insertion step for inserting the rotor, a connection step for connecting a terminal portion of the coil to each location according to the application, and an attachment for mounting the rotor in the stator so as to be relatively rotatable by a bearing. It is characterized in that it consists of a degree. In this way, the number of connection portions does not increase regardless of how many turns around the coil, so that the coil can be easily wound around the stator core with as few connection points as possible. For this reason, reduction of connection man-hours, reduction of insulation processing, and improvement of strength reliability can be realized. In addition, since the coil ends are wound so as to straddle the inner and outer peripheral sides of the slots, the coil ends extending from different slots are not aligned in the axial direction of the stator core, but do not interfere in the circumferential direction. Therefore, the axial length of the coil end and thus the rotating electric machine can be reduced. Further, the cooling performance of the coil can be improved. Further, since the coils are continuously circulated, the number of coils in the slot can be increased, so that loss due to harmonics can be reduced. In addition, since the coil can be easily mounted on the stator core, the manufacturing can be automated and the mass production can be realized.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, when performing the temporary forming step, before performing the temporary forming step so that both ends of the linear portion of the coil are positioned away from the slot. The linear portions on the inner peripheral side and the outer peripheral side are relatively rotated with support jigs inserted at both ends of the linear portion. For this reason, it is possible to prevent the bent portion of the coil from being caught by the teeth tip of the stator core in the insertion step, so that the straight portion can be easily inserted into the slot.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said linear parts of the other said surrounding parts may overlap an inner periphery in a temporary formation process. For this reason, it is easy to insert the straight portion into the slot, and furthermore, since the coils are aligned in the radial direction, the space factor of the coil in the slot can be improved. In particular, in this embodiment, since a coil having a substantially rectangular cross section is used, the space factor can be further improved. For this reason, high output and good rotation characteristics can be achieved.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that a pair of said circumference | surroundings part arrange | positioned by the circumferential direction at the said preliminary shaping process may continue via a crossover. For this reason, the surrounding part in each phase can be arrange | positioned efficiently, and a connection location can be reduced as much as possible.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said connecting wire may be provided only in the axial direction one end side in the said stator at the said pre-forming process. For this reason, the axial direction length of a stator can be shortened rather than the connecting wire in the axial direction both ends in a stator.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that it may become a substantially spiral shape so that the said crossover might straddle the outer peripheral side and inner peripheral side of the said stator core at the said preliminary forming process. For this reason, the number of places where the crossovers overlap in the axial direction of the stator can be reduced as much as possible, and the axial length of the stator can be shortened.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that the said crossover wire may be located on the axial direction substantially the same surface in the said stator at the said preforming process. For this reason, the axial direction length of the stator can be further shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, the linear portion on the outer peripheral side of the coil is arranged in the slot of the stator core in the arranging step, and the inner portion in the coil is arranged in the temporary forming step. Temporary molding is performed by relatively rotating the linear portion on the circumferential side and the slot by an inner jig. This eliminates the need to take out the temporarily formed coil from the jig and rearrange it in the stator core. For this reason, workability | operativity can be improved and a manufacturing process can be shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the first embodiment, before performing the temporary forming step, a tooth support jig is inserted between the bottom of each slot and the coil, and temporary forming is performed in that state. Like to do. For this reason, when pre-molding, a force in the rotational direction is applied to the coil and a force to tilt the teeth in the circumferential direction acts, but since the teeth support jigs are inserted in all slots, the teeth are tilted in the circumferential direction. I can't. For this reason, even if a rotational force is applied to the coil, it is possible to prevent the teeth from falling.

  In addition, the rotating electrical machine manufacturing method according to the first embodiment includes the same number of outer peripheral opening grooves as the slots so that the inner jig faces the coil insertion portion, and extends from the bottom of the outer peripheral opening groove to the inner and outer periphery. A push-out part capable of appearing and retracting is provided, and the inserting step is performed by projecting the push-out part. For this reason, it is sufficient to arrange the inner jig in the stator core from the temporary molding process to the insertion process. As described above, in this embodiment, the number of work steps can be reduced as much as possible by minimizing the insertion and removal of the jig. Moreover, even if this inner jig | tool changes the inner / outer diameter of a stator core, it can respond with the same inner jig | tool.

  In the method for manufacturing a rotating electrical machine according to the first embodiment, a holding member having an insulating function is fixed to the coil insertion portion in the slot after the insertion step and before the connection step. For this reason, even if a magnetic flux is generated between the rotor and the rotor, the coil can be prevented from jumping out of the slot toward the rotor.

  Moreover, the manufacturing method of the rotating electrical machine according to the first embodiment is performed while pressing both end portions connecting the linear portions of the coil in the temporary forming step and the inserting step. For this reason, stress acting on the coil can be dispersed in the provisional molding step and the insertion step, so that molding is facilitated and it is possible to prevent damage to the insulating coating such as varnish applied to the surface of the coil. . Furthermore, the axial length of the coil end can be shortened.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment is shape | molded so that a pair of said surrounding part may adjoin by the coil which continued in the said preforming process. For this reason, since adjacent surrounding portions are inserted into adjacent slots, the number of slots can be increased as compared to the case where adjacent surrounding portions are inserted into the same slot. For this reason, since the waveform which synthesize | combined the magnetomotive force of each phase can be made into a smooth waveform, it becomes possible to reduce a torque pulsation and noise. Moreover, since the number of slots can be increased, eddy current loss due to harmonics can be reduced. Furthermore, since the surrounding parts in the coil are separated from each other in the circumferential direction, the cooling performance can be improved.

  Further, in the method for manufacturing the rotating electrical machine according to the first embodiment, both end sides connecting the linear portions in the circumferential portion are formed in a substantially P shape in the preliminary forming step, and the substantially P-shaped convex portion is formed in the arranging step. Is arranged on the outer peripheral side of the stator. For this reason, the coil does not protrude to the inner peripheral side, and it does not become an obstacle when the rotor is inserted in the attachment process. In addition, if both end sides connecting the straight line portions in the circular portion are deformed in one direction, and the arranging step is arranged so that the deformed direction is the outer peripheral side of the stator, the coil It can prevent more reliably that it protrudes to an inner peripheral side.

  Moreover, the manufacturing method of the rotary electric machine of 1st Embodiment adheres each wire material integrally after performing the said preforming process. For this reason, the coil wires are not separated from each other in the steps after the preforming step, and can be easily inserted into the slot. Moreover, since the coil laminated | stacked can be integrally deformed when shape | molding the surrounding part of the preformed coil in a substantially turtle shell shape, a moldability is also improved.

  In the rotating electrical machine according to the first embodiment, the coil cross section has a substantially rectangular shape in which the normal direction of the stator core is long and the radial direction is short. For this reason, the number of coils in the slot can be increased as much as possible, and the loss reduction effect due to harmonics can be further increased. Moreover, since the length of the side protruding to the coil end side is shortened also in terms of space, the protruding amount of the coil end can be further reduced. Furthermore, although it is difficult to form thin coils by deforming them one by one, in this embodiment, they can be easily formed because they are overlapped and bundled.

  In the rotating electrical machine of the first embodiment, since the connecting wire connects the terminals drawn to the outer peripheral side of the rotating portion, the connecting wire and the rotating portion do not cross each other. For this reason, the axial direction length of a stator can be shortened.

  In the rotating electrical machine of the first embodiment, the coil insertion portion in the slot is an open slot having a circumferential width that is substantially equal to or greater than the portion where the coil is mounted in the slot. The coil can be easily inserted from the slot insertion portion, and the space factor of the coil in the slot is not reduced.

  Next, 2nd Embodiment in the manufacturing method of a rotary electric machine is described based on FIGS. FIG. 30 is a simplified representation of how to wind a pair of winding portions in the coil of the second embodiment. FIG. 31 is a diagram for explaining a preforming method in the second embodiment. FIG. 31 (A) is a view of the state where the preforming is performed as viewed from the front, and FIG. 31 (B) is a view of FIG. 31 (A) as viewed from the side AA. FIG. 32 is a perspective view of a coil molded using the preforming method of the second embodiment. In addition, about the site | part which is common in 1st Embodiment, it represents with the same name and the same code | symbol.

  Although the first embodiment and the second embodiment are different in how the pair of element coils 4131a and 4131b wound in a spiral shape in the stator coil 413 are continuously formed, the preforming process is different. Since other processes are the same as those in the first embodiment, description thereof is omitted.

  In this case, it is preferable to mount the insulating paper described in FIGS. 47 to 53 at the time of this preforming.

  In the first embodiment, the first element coil 4131a is wound so that the coil terminal at the beginning of winding is on the inner peripheral side and spirals on the outer peripheral side, and then the coil extending to the outer peripheral side is the second element coil. The second element coil 4131b is wound so as to extend to the inner peripheral side of the 4131b and further spiral on the outer peripheral side. That is, since the inter-coil connection line 4134 for connecting the first element coil 4131a and the second element coil 4131b is directed from the outer peripheral side to the inner peripheral side, a portion where the coil lines intersect with each other. Will occur.

  On the other hand, in the second embodiment, as shown in FIG. 30, the first element coil 4131a is wound so that the winding start is on the outer peripheral side of the first element coil 4131a and spirals on the inner peripheral side. Next, the coil extending to the inner peripheral side is extended to the inner peripheral side of the second element coil 4131b, and the second element coil 4131b is wound so as to form a spiral on the outer peripheral side. That is, since the inter-coil connection line 4134 for connecting the first element coil 4131a and the second element coil 4131b is connected on the inner peripheral side, a portion where the coil lines intersect does not occur. Such a winding method is generally referred to as α winding, and by adopting this winding method, the coil end can be further simplified and the axial length of the stator 4 can be shortened. In FIG. 30, only one pair of element coils 4131a and 4131b is shown, but actually, as shown in FIG. 32, four pairs of rotating portions are formed by continuous lines.

  Next, a preforming process for preforming such a pair of rotating portions will be described.

  In the pre-forming step of the second embodiment, as shown in FIG. 31A, first, a continuous coil is formed so as to be substantially U-shaped irregularities. At this time, the length between the vertices of the concavo-convex portion, that is, the length in the vertical direction in FIG. 31A, is the length corresponding to the pair of element coils 4131a and 4131b, and finally the concavo-convex portion that becomes the connecting wire 4132 The length of the apex, that is, the length in the left-right direction in FIG. Further, all the intermediate positions between the vertices of the concave and convex portions are bent in a crank shape by the length of the cross section of the coil, and the inter-coil connection portion 4134 is formed.

  Next, the coil formed in the concavo-convex shape is mounted on the α winding forming jig 25 having the oval shaped forming groove 253 on the outer periphery. The α-winding forming jig 25 has a plurality of partitions 252 that are detachably attached to the plate-like member 251, and a plurality of forming grooves 253 are configured by each partition 252. These forming grooves 253 are arranged adjacent to each other as a pair, and further, the pair of forming grooves 253 adjacent to the four positions in the longitudinal direction of the plate-like member 251 are spaced apart by the length of the crossover line 4132. Is provided. Further, the partition 252 between the forming grooves 253 in the pair of adjacent forming grooves 253 is provided with an insertion groove 254 into which one coil can be inserted, and the insertion groove 254 has one end in the long axis direction of an oval shape. Located on the side. In addition, although detailed description is abbreviate | omitted, the plate-shaped member 251 can be expanded-contracted.

  The inter-coil connecting portion 4134 of the coil is inserted through the insertion groove 254 of the α winding forming jig 25 configured as described above. FIG. 31 shows a state where the inter-coil connecting portion 4134 of the coil is inserted into the insertion groove 254.

  Next, the rotating portion is formed by rotating the coil while pressing the coil against the forming groove 253 side with a roller 255 as shown in FIG. 31B provided in each forming groove 253. In addition, the direction of the circumference | surroundings of the roller 255 provided in each pair of the adjacent shaping | molding groove | channel 253 differs.

  Next, all the partitions 252 on both sides of each forming groove 253 are removed, and the coil formed by expanding and contracting the plate-like member 251 is removed from the α-winding forming jig 25. In this way, the coil shown in FIG. 32 is formed. Further, similarly to the first embodiment, the operation 112 in FIG. 14 is performed to complete the preforming process. In addition, processes other than a preforming process are performed similarly to 1st Embodiment.

  Thus, the manufacturing method of the rotary electric machine of 2nd Embodiment is shape | molded so that a pair of said surrounding parts may continue in the terminal of an inner peripheral side at a preforming process. For this reason, since the inter-coil connection lines for connecting the pairs of the surrounding portions 4131 are connected to each other on the inner peripheral side, a portion where the coil lines intersect does not occur. Therefore, the coil end can be further simplified, and the axial length of the stator can be shortened.

  Further, in the method of manufacturing the rotating electrical machine according to the second embodiment, in a state where the unevenness is previously formed in the preliminary forming step, the top of the unevenness is formed so as to circulate along the forming die. For this reason, it is possible to easily form a pair of circulation parts that are formed so that the circulation parts are continuous with each other on the inner peripheral side, and it is also possible to automate the manufacture.

  Next, based on FIGS. 33-41, 3rd Embodiment in the manufacturing method of a rotary electric machine is described. FIG. 33 is a flowchart showing the manufacturing process from the placement process to the insertion process, which is a feature of the present embodiment. FIG. 34 is a perspective view of a state where a coil is arranged on a slide jig. FIG. 35 is a perspective view of a state where the slide jig is slid to form the coiled portion in a substantially turtle shell shape. FIG. 36 is an enlarged perspective view of a fixed groove portion in the slide jig. FIG. 37 is a perspective view showing a state in which the fixing groove on one side in FIG. 36 is inclined. FIG. 38 is a perspective view of a state in which a substantially turtle-shaped coil molded body is wound around the inner jig. FIG. 39 is a perspective view of a state in which the inner jig with the coil mounted is disposed in the stator core. FIG. 40 is a perspective view of a state where the insertion process has been performed. FIG. 40A is an overall view. FIG. 40B is a perspective view showing a state where the pushing member of the inner jig is retracted, and FIG. 40A is a perspective view showing a state where the pushing member of the inner jig is protruding. . FIG. 41 is a perspective view showing a state where the inner jig is taken out. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  This embodiment is different from the second embodiment from the placement step to the insertion step, but the other steps are the same as those of the second embodiment. For this reason, this embodiment demonstrates from an arrangement process to an insertion process.

  In the manufacturing method of the present embodiment, the preforming step is performed in the same manner as in the second embodiment, and a coil molded body extending in the longitudinal direction is mounted on the slide jig 35 as shown in Step 221 in the flowchart of FIG. This operation is an arrangement process. The slide jig 35 is divided into a fixed side jig 35a and a movable side jig 35b, each of which is formed in a substantially plate shape extending in the longitudinal direction, and the movable side jig 35b is fixed to the fixed side jig 35a. Can be moved in the longitudinal direction. The movement side jig 35b moves along a guide 352 as shown in FIGS.

  Further, fixing grooves 351 as the same number of fixing portions as the stator cores 412 extending in the short side direction are provided in parallel at equal intervals on each surface where the fixing jig 35a and the moving jig 35b face each other. The lengths of the fixing grooves 351 are longer than the lengths of the slots 411 of the stator core 412. Further, as shown in FIGS. 36 and 37, the moving side jig 35b is configured such that each fixed piece 353 constituting the fixed groove 351 is movable, and each fixed piece 353 is moved with respect to the bottom surface shown in FIG. As shown in FIG. 37, the fixed pieces 353 are simultaneously movable from the vertical state to the state in which each fixed piece 353 is inclined. Although a detailed description of the structure of the movable mechanism is omitted, the fixed pieces 353 can be moved simultaneously by employing a link mechanism, a cam mechanism, or the like.

  In the slide jig 35 configured as described above, first, as shown in FIG. 34, all the fixed grooves 351 of the fixed side jig 35a and the movable side jig 35b face each other, and the short side of the slide jig 35 is set. From the direction, an oval-shaped circumferential portion 4131 of a coil that has been preformed is inserted into each fixed groove 351. Note that, in FIG. 34, for the sake of clarity, only one coil molded body in which a pair of rotating portions of the four coils 4131 is formed by a continuous coil is shown inserted in the fixed groove 351. , The winding portion of the coil 4131 is inserted into all the fixing grooves 351.

  Next, as shown in step 222 in the flowchart of FIG. 33, the moving side jig 35b is slid in the longitudinal direction with respect to the fixed side jig 35a, and the coiled portion 4131 is temporarily formed into a substantially turtle shell shape. FIG. 35 shows a state in which the moving side jig 35b is slid in the longitudinal direction with respect to the fixed side jig 35a. Finally, the moving side jig 35b is moved from the state of FIG. The fixed groove 351 is moved to a position facing the fifth fixed groove 351 in the fixed jig 35a. Although not shown, as in the first embodiment, when the moving jig 35b is slid while pressing the coil top of the coil 4131, the coil 4131 is easily formed into a substantially turtle shell shape. can do.

  Next, as shown in step 223 in the flowchart of FIG. 33, the linear portion 4133 on the moving side jig 35b side in the winding portion of the substantially tortuous-shaped coil 4131 is bent so that the cross section has a predetermined angle. Note that step 222 and step 223 in the flowchart of FIG. 33 are temporary forming steps. As a method of bending, as shown in FIG. 37, all the fixing pieces 353 of the moving side jig 35b are inclined simultaneously. Here, since the stator coil 413 employs a rectangular wire having a rectangular cross section, the stator coil 413 is formed so that the cross section of the linear portion 4133 of the coil is inclined as the fixing piece 353 is inclined. The inclination angle is set such that when the coil molded body is formed into an annular shape in the next step, the cross sections of the linear portions 4133 of the coils respectively inserted in the fixed side jig 35a and the moving side jig 35b overlap radially. Good.

  Next, as shown in step 224 in the flowchart of FIG. 33, a coil molded body in which the circumferential portion 4131 is formed in a turtle shell shape is attached to the inner jig 36. Similar to the inner jig 19 in the first embodiment, the inner jig 36 includes outer peripheral side opening grooves 361 similar to the number of slots 411 of the stator core 412 on the outer periphery, and the periphery of these outer peripheral side opening grooves 361. The width in the direction is smaller than or equal to the width in the circumferential direction of the inner circumferential side opening of the slot 411, and the axial length of the outer circumferential side opening groove 361 is longer than the axial length of the slot 411. Yes. In addition, as shown in FIG. 40, slits 362 are formed at the bottom of each outer peripheral opening groove 361, and from these slits 362, plate-like extrusion members 363 are arranged in the inner and outer peripheral directions, that is, radially. It is provided so that it can appear and disappear. Although a detailed description of the structure is omitted, the pushing member 363 appears and disappears radially from the slit 362 by rotating the lever 364 provided on one end side in the axial direction of the inner jig 36 in the circumferential direction. .

  As shown in FIG. 38, winding is performed so that the linear portions 4133 of the circumferential portion of the coil 4131 are inserted into the respective outer opening grooves 361 of the inner jig 36 thus configured. At this time, the linear portions 4133 of the coils respectively inserted into the fixed side jig 35a and the moving side jig 35b are overlapped and inserted into the respective outer peripheral opening grooves 361, but at both ends of the coil molded body extending in the longitudinal direction. The five straight portions 4133 are inserted into the outer peripheral opening groove 361 so as to overlap each other. Here, the cross section of the linear portion 4133 of the coil inserted into the moving side jig 35b and the cross section of the linear portion 4133 of the coil inserted into the fixed side jig 35a are shown in the step 223 in the flowchart of FIG. Since the coils are angled with each other, the coil cross-sections formed on the flat wire can be radially overlapped only by winding the coil molded body extending in the longitudinal direction around the inner jig 36. Thus, the temporary molding process is completed. In FIG. 38, the detailed structure of the inner jig 36 and the coil connecting wire 4132 are omitted for the sake of clarity.

  Next, as indicated by step 225 in the flowchart of FIG. 33, each linear portion 4133 of the coil is inserted into the slot 411 of the stator core 412. This operation is an insertion process. As shown in FIG. 39, the inner jig 36 around which the stator coil 413 is wound in the temporary forming step is arranged on the inner peripheral side of the stator core 412. The slots 411 of the stator core 412 in the present embodiment are different from those in the first embodiment, and each slot 411 is inclined in one circumferential direction. In this manner, by inclining the slot 411 in the circumferential direction, the stator coil 413 formed in an annular shape can be easily inserted. In FIG. 39, the coil crossover 4132 is omitted for the sake of clarity.

  Next, as shown in FIG. 40A, the lever 364 of the inner jig 36 is rotated in the circumferential direction. As described above, by rotating the lever 364, the state in which the pushing member 363 in FIG. 40B is retracted from the slit 362 and the state in which the pushing member 363 in FIG. 40C is projected from the slit 362 can be switched. . More specifically, when the lever 364 is in the state shown in FIG. 40A, the pushing member 363 is retracted from the slit 362 as shown in FIG. 40B, and the lever 364 is moved in the direction of the arrow in FIG. As shown in FIG. 40C, the pushing member 363 protrudes from the slit 362 and pushes each linear portion 4133 of the coil into the slot 411 of the stator core 412. By rotating the lever 364 in this manner, the stator coil 413 is inserted into the slot 411. Further, as shown in FIG. 41, the lever 364 is rotated in the direction of the arrow to cause the pushing member 363 to retract from the slit 362. The inner jig 36 is taken out from the inner periphery of the stator core 412. Thereafter, the joining step and the attaching step may be performed as in the first embodiment. 40 and 41 also omit the coil crossover 4132 for the sake of clarity.

  As mentioned above, although 3rd Embodiment was demonstrated, the manufacturing method of the rotary electric machine of 3rd Embodiment preliminarily shape | molds the continuous coil by carrying out multiple turns to the spiral shape containing a pair of opposing linear part. A step of separately fixing to a fixing portion provided opposite to each of the different molds so that the linear portions of the preformed coils are aligned in the axial direction; and Temporary molding in which at least one of the fixed separate molding dies is linearly moved relative to each other to form a coil molded body extending in the longitudinal direction, and then annularly molded so that both longitudinal ends of the coil molded body overlap. And the slot of the coil so that the linear portion on the outer peripheral side of the temporarily formed coil is positioned on the bottom side of the slot and the linear portion on the inner peripheral side is positioned on the coil insertion portion side. An insertion step of inserting within a connecting step of connecting to the location of people each according to the application of the terminal portion in the coil, becomes the rotor within the stator and a mounting step of mounting to be relatively rotatable by bearings. For this reason, this embodiment can prevent force from acting on the teeth of the stator core in addition to the effects of the first embodiment. For this reason, even if the width | variety of a tooth | gear is small and it is what is easy to fall down, the continuous lap winding coil can be inserted.

  Further, in the method of manufacturing the rotating electrical machine according to the third embodiment, when the coil is formed using a rectangular wire having a rectangular cross section and the coil molded body is formed into an annular shape in the temporary forming step, the linear portion of the coil is formed. The fixed part of at least one of the molding dies is moved in a state where the coil molded body is fixed to the fixed part of the molding die so that the cross section is radial. For this reason, when the coil molded body is formed into an annular shape, the linear portion on the outer peripheral side and the linear portion on the inner peripheral side can be overlapped, and the insertion work in the insertion step can be facilitated.

  Moreover, the manufacturing method of the rotary electric machine of 3rd Embodiment winds the said linear part in the said coil molded object around the inner side jig | tool provided with the some outer periphery opening groove | channel at the said temporary forming process, and is shape | molded cyclically | annularly. For this reason, a coil molded object can be made cyclic | annular along the inner periphery of a stator iron core, and the insertion operation | work in an insertion process can be made easy.

  Further, in the method of manufacturing the rotating electrical machine according to the third embodiment, the inner jig is provided with an extruding portion that can be projected and retracted from the bottom of the outer peripheral opening groove to the inner and outer peripheries, and the inserting step projects the extruding portion. I do that. For this reason, the number of jigs can be reduced as much as possible, and the jigs can be kept in and out of the stator core to a minimum.

  The above is an embodiment of the method for manufacturing a rotating electrical machine according to the present invention. Other embodiments of the coil and other embodiments of the rotor will be described below.

  Next, a fourth embodiment will be described with reference to FIG. FIG. 42 is a diagram showing connecting a set of coils including the element coil 4131a and the element coil 4131b, that is, connecting the connecting wires connecting the coil pairs. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  As shown in FIG. 8, the stator coil 413 of the first embodiment is formed of four sets, that is, four pairs of element coils 4131a and 4131b formed by continuous wires. A different stator coil 413 is formed for each pair of rotating parts, and finally a pair of element coils 4131a and 4131b is connected by welding or the like. Specifically, one end side of the coil terminal of the pair of element coils 4131a and 4131b is lengthened by a length corresponding to the connecting wire 4132, and the connecting wire 4132 is inserted into the slot 411 of the stator core 412. It is deformed and connected to another pair of surrounding parts by TIG welding or the like.

  Thus, if the connecting wire 4132 can be connected later, it is not necessary to consider the deformation of the connecting wire 4132 when the coil molded body is inserted into the slot 411 of the stator core 412 while expanding the diameter. For this reason, although a connection location increases a little, the arrangement | positioning freedom degree of the crossover 4132 can be improved. In addition, since the connecting wire 4132 is a coil terminal on one side of the winding portion 4131, the number of parts and the connection points can be reduced as compared with the case where only the connecting wire is configured by another wire. Note that the pair of winding portions in FIG. 42 are wound by the winding method described in the second embodiment.

  Next, a fifth embodiment will be described with reference to FIG. FIG. 43 is a perspective view of the stator of the fifth embodiment. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  The fifth embodiment is different from the first embodiment in the way of connecting the crossover 4132, and further, a pair of element coils 4131a and 4131b are wound by α winding as in the second embodiment. However, the other configuration is the same. Although the connecting wire 4132 of the first embodiment is configured to extend from the top of the coil end in each of the surrounding portions 4131, the connecting wire 4132 of the fifth embodiment is formed from the bottom side of the slot 411 in each of the surrounding portions 4131. It is provided so as to straddle the coil insertion part side. More specifically, the coil terminal positioned on the bottom side of the slot 411 among the coil terminals positioned on the outer peripheral side of each of the rotating portions 4131 is deformed in a stepped manner from the rotating portion 4131 toward the outer peripheral side of the stator core 412. Extend to the top of the end. Furthermore, it extends in a substantially spiral shape from the outer peripheral side to the inner peripheral side of the coil end in the same manner as in the first embodiment, and continues to the coil insertion portion side in the other rotating portion 4131. Similarly to the bottom side of the slot, this coil insertion part side is also deformed stepwise toward the inner peripheral side of the stator core 412 and is continuous with the top side of the coil end. In FIG. 43, the portion connecting the coil molded bodies formed of the crossover lines that are neutral points and the continuous lines is omitted.

  As described above, in the fifth embodiment, since the connecting wire 4132 does not extend from the top of the coil end, the axial length of the stator 4 can be further reduced. Further, since the connecting wire is configured such that the long side direction of the flat wire is directed to the axial direction of the stator 4, the connecting wire can be sufficiently arranged even with the stator core 412 having a small diameter.

  Note that the crossover 4132 of the fifth embodiment does not extend from the top of the coil end, but extends from the slot insertion portion, so that the length greatly changes when the coiled portion 4131 has a substantially turtle shell shape. End up. For this reason, as described in the first embodiment, before forming the winding portion 4131 into a substantially turtle shell shape, the connecting wire 4132 is folded into a substantially V shape or a substantially U shape in the axial direction or the radial direction. Then, the folded crossover 4132 may be extended when it is molded into a substantially turtle shell shape or inserted into the slot 411 of the stator core 412. The pair of element coils 4131a and 4131b may be wound not only by the winding method described in FIG. 30 but also by the winding method as in the first embodiment described above.

  Next, a sixth embodiment will be described with reference to FIG. FIG. 44 is a perspective view of the stator according to the sixth embodiment. In addition, about the site | part which is common in other embodiment, it represents with the same name and the same code | symbol.

  The sixth embodiment is the same as the fifth embodiment except for the shape and arrangement of the crossover 4132 compared to the fifth embodiment. The crossover wire 4132 of the sixth embodiment is spiral in the tip side from the top of the coil end as in the fourth embodiment, but the crossover wire 4132 of the sixth embodiment is not spiral but the bottom of the slot 411. It is formed in a spiral shape on the side, that is, on the outer peripheral side of the stator core 412, and is connected to another rotating portion 4131. In the sixth embodiment, the connecting wire 4132 is formed in a spiral shape on the outer peripheral side of the stator core 412 and connected to the coil terminal of the rotating portion 4131 at the coil end portion. The state before welding coils is shown. However, actually, since the wires protruding in the axial direction of the stator 4 are melted and joined from the state of FIG. 44 using TIG welding or the like, the portion protruding in the axial direction almost reaches the position of the coil end. It will melt and leave.

  As described above, in the sixth embodiment, although the number of connection points is slightly increased, the connecting wire 4132 can be disposed without protruding so much in the axial direction of the stator 4 from the top of the coil end. In addition, the axial direction of the stator 4 can be further shortened. In addition, if a shaping | molding method is devised, it is also possible to comprise the connecting wire 4132 by the line which followed the surrounding part 4131. FIG. Furthermore, the portion to be formed in a spiral shape may be spiral on the coil insertion portion side, that is, on the inner peripheral side of the stator core 412, and both the inner peripheral side and the outer peripheral side of the stator core 412 It does not matter if it is spiral.

  As mentioned above, although the effect of each embodiment was demonstrated, in the present invention, various other composition can be adopted. For example, in the above embodiment, a rectangular wire having a substantially rectangular rectangular cross-sectional shape is adopted, but it may not be a complete rectangular shape, for example, finally in the slot. Each side may be a deformed curve instead of a straight line. The coil may have a substantially circular, elliptical, or substantially polygonal shape other than the four sides. When a rectangular shape is used, the coil may have a substantially square cross section or a stator. The core may have a substantially rectangular shape with a short normal direction and a long radial direction.

  In the above embodiment, an induction motor has been described as an example of a rotating electrical machine. However, a magnetic synchronous motor having a permanent magnet in the circumferential direction of the rotor may be used. When such a magnet synchronous motor is employed, a surface magnet rotor in which a plurality of magnets are arranged on the surface of the rotor and fixed by a non-magnetic ring or the like on the inner peripheral side of the rotor. It is conceivable to employ a built-in magnet rotor in which holes extending in the axial direction are formed at a plurality of locations in the direction and magnets are built in the holes. Furthermore, when used as an AC generator for a vehicle, a Landell type rotor having a field coil wound therein can be used.

  Moreover, in the said embodiment, although the magnetic body part in a stator iron core and a rotor was comprised with the laminated steel plate, even if it employ | adopts the powder iron core which compressed and hardened the iron powder by which the insulation coating was given to the surface Good. Further, the stator core may be a split stator core configured by fixing a plurality of members.

  Moreover, in the said embodiment, although the conductor bar and the short circuit ring were comprised with aluminum, you may make it use copper. If copper is used for the conductor bar and the short-circuit ring, the electric resistance can be lowered as compared with the case where aluminum is used, so that the efficiency of the electric motor can be improved.

  In the above embodiment, the number of slots of the stator core is 48, but the number of slots can be changed according to the specification. When the number of slots is changed in this way, it is necessary to change the arrangement of the coiled portion.

  Moreover, in the said embodiment, although the surrounding part of the coil was comprised with the continuous line 1 pair so that it might adjoin, if it may increase the number of connection points, it may connect by welding etc. after inserting in a stator core. Is possible. Furthermore, the number of adjacent winding portions of the coil is not limited to two, and the number of times of spiral winding can be freely set according to the specification.

  Moreover, in the said embodiment, although it adhered to the coil using the self-bonding wire, it is also possible to adhere using other members, such as an adhesive agent and a tape. Further, depending on the molding method, it is possible to mold without fixing.

  Moreover, in the said embodiment, although the slot was set as the open slot, you may comprise so that the inner peripheral end in each teeth may extend in the circumferential direction. Further, in the case of an open slot, a holding member is provided, but the holding member may be configured so that the inner peripheral end of the teeth is molded with resin or the like.

  Moreover, in the said embodiment, although the surrounding part of the coil was inserted in the fixed iron core as a substantially tortoiseshell shape, it may not be a tortoiseshell shape but a large oval shape.

  In the above embodiment, the stator winding is a 2Y connection in which a pair of stator coils are connected in parallel. However, a 1Y connection in which a plurality of stator coils are connected in series is also possible. is there. When such 1Y connection is employed, the number of connection points can be further reduced.

  The above-described stator winding can be used not only for an induction motor but also for a permanent magnet rotating electric machine. A permanent magnet rotating electric machine using the above-described stator winding will be described with reference to FIGS. 45 and 46. FIG. 45 is a cross-sectional view of the permanent magnet rotating electric machine 200. 46 is an AA cross section of the stator 230 and the rotor 250 shown in FIG. In this figure, the housing 212 and the shaft 218 are not shown.

  A stator 230 is held inside the housing 212, and the stator 230 includes a stator core 232 and the above-described stator winding 238. A rotor 250 having a permanent magnet 254 is arranged with respect to the stator core 232 through a gap 222. The housing 212 has end brackets 214 on both sides in the rotation axis direction of the shaft 218, and the shafts 218 having the rotor core 252 are rotatably held by bearings 216 on the end brackets 214.

  The shaft 218 is provided with a rotor position sensor 224 that detects the position of the rotor pole and a rotation speed sensor 226 that detects the rotation speed of the rotor. Based on the outputs of these sensors, the three-phase alternating current supplied to the stator winding is controlled.

  A specific structure of the stator 230 and the rotor 250 shown in FIG. 45 will be described with reference to FIG. The stator 230 has a stator core 232, and the stator core 232 has a large number of slots 234 and teeth 236 equally in the circumferential direction as in the above-described structure, and the slot 234 has the above-described structure. The stator coil 238 is provided. As shown in FIG. 46, in this embodiment, the number of slots of the stator core is 48, but is not limited to this.

  The rotor core 252 is provided with permanent magnet insertion holes for inserting permanent magnets 254 and 256, and the permanent magnets 254 and 256 are inserted into the permanent magnet insertion holes. The magnetization direction of the permanent magnets 254 and 256 is a direction in which the side surface of the stator of the magnet is an N pole or an S pole, and the magnetization direction is reversed for each pole of the rotor.

  In the embodiment shown in FIG. 46, the permanent magnets 254 and 256 act as one pole of the rotor 250. The poles of the rotor 250 including the permanent magnets 254 and 256 are arranged at equal intervals in the circumferential direction of the rotor 250, and in this embodiment, there are eight poles. However, it is not fixed to 8 poles, but may be 10 poles or more and 30 poles or more in some cases, and the number of poles is determined by conditions such as output required for the rotating electrical machine. Further, when the number of poles is increased, the number of magnets increases and workability decreases. In some cases, it may be 8 poles or less. The portion of the rotor core existing on the stator side of the permanent magnets 254 and 256 acting as each pole of the rotor 250 acts as a magnetic pole piece 280, and the magnetic lines of force entering and exiting the permanent magnets 254 and 256 are fixed through this magnetic pole piece 280. Enter and exit the child core 232.

  As described above, the permanent magnets 254 and 256 acting as the poles of the rotor 250 are magnetized in the opposite directions for each pole so that the magnets 254 and 256 of a certain pole are the N pole on the stator side and the S pole on the shaft side. Are magnetized such that the permanent magnets 254 and 256 acting as poles on both sides thereof are S-pole on the stator side and N-pole on the shaft side. A portion acting as an auxiliary magnetic pole 290 exists between the poles of the rotor 250, and the reluctance is determined by the difference in magnetic resistance between the q-axis magnetic flux passing through the auxiliary magnetic pole 290 and the d-axis magnetic flux passing through the magnet. Generate torque. Between the auxiliary magnetic poles 290 and the magnetic pole pieces 280, there are bridge portions 282 and 284, respectively. In the bridge portions 282 and 284, the magnetic circuit 262 and 264 narrow the cross-sectional area of the magnetic circuit. Yes. For this reason, a magnetic saturation phenomenon occurs in each of the bridge portions 282 and 284, and the amount of magnetic flux passing between the magnetic pole piece 280 and the auxiliary magnetic pole 290, that is, passing through the bridge portions 282 and 284 is suppressed to a predetermined amount or less.

  45 and 46, the switching operation of the inverter device shown in FIG. 4 is controlled based on the outputs of the rotation speed sensor 226 and the rotor position sensor 224 of the rotor. The operation of converting the supplied DC power into three-phase AC power is controlled. The three-phase alternating current power is supplied to the stator coil 238 shown in FIGS. 45 and 46, and the frequency of the three-phase alternating current is controlled based on the detection value of the rotational speed sensor 226, and the detection of the rotor position sensor 224 is performed. Based on the value, the phase of the three-phase alternating current with respect to the rotor is controlled.

  A rotating magnetic field based on the phase and frequency is generated in the stator 230 by the three-phase alternating current. The rotating magnetic field of the stator 230 acts on the permanent magnets 254 and 256 of the rotor 250, and magnet torque based on the permanent magnets 254 and 256 is generated in the rotor 250. The rotating magnetic field acts on the auxiliary magnetic pole 290 of the rotor 250, and the reluctance torque is applied to the rotor 250 based on the difference in magnetic resistance between the magnetic circuit passing through the magnets 254 and 256 of the rotating magnetic field and the magnetic circuit passing through the auxiliary magnetic pole 290. Is generated. The rotational torque of the rotor 250 is a value determined based on both the torque of the magnet based on the permanent magnet and the reluctance torque based on the auxiliary magnetic pole.

  The reluctance torque is generated by the difference between the magnetic resistance that the rotating magnetic field generated by the stator winding passes through the magnet and the magnetic resistance that passes through the auxiliary magnetic pole 290. Therefore, the inverter device 620 shown in FIG. The resultant vector of the armature magnetomotive force by 238 is controlled so as to be on the advance side in the rotation direction from the center position of the auxiliary magnetic pole, and reluctance torque is generated by the advance side phase of the rotating magnetic flux with respect to the auxiliary magnetic pole 290 of the rotor.

  Since the reluctance torque is generated in the rotor 250 in the direction added to the magnet torque by the permanent magnets 254 and 256 in the start-up state and the low-speed operation state of the rotating electrical machine, the reluctance torque rotates with the addition torque of the magnet torque and the reluctance torque. The required torque that the electric machine must generate can be created. Therefore, the generation of magnet torque can be reduced by the amount corresponding to the reluctance torque, and the magnetomotive force of the permanent magnet can be lowered. By lowering the magnetomotive force of the permanent magnet, it is possible to suppress the induced voltage caused by the permanent magnet during high-speed operation of the rotating electrical machine, and it becomes easy to supply power to the rotating electrical machine during high-speed rotation. Furthermore, the amount of magnets can be reduced by increasing the reluctance torque. Since rare earth permanent magnets are expensive, it is desirable from an economical viewpoint that the amount of magnets used can be reduced.

  The stator winding can be applied to induction type rotating electric machines and permanent magnet type rotating electric machines. By using these stator windings, it is possible to obtain rotating electric machines that are easy to produce and have high reliability. Further, by having one conductor in the circumferential direction of the slot, it is possible to obtain a rotating electrical machine that can reduce torque pulsation and is excellent in productivity. In the above-described embodiment, it is possible to produce a coil that circulates a plurality of times with a continuous conductor, and it is possible to obtain a rotating electrical machine with few connection points and excellent productivity.

It is side surface sectional drawing of an electric motor. The cross section of a rotor is made into the perspective view. It is a perspective view of each component in an electric motor. It is a system diagram for demonstrating electrical connection. It is a figure which shows the state of the rotating magnetic field which generate | occur | produces with a stator winding | coil. It is a figure which shows the mode of the magnetic flux in case the rotational speed of a rotor is slower than the rotational speed of the rotating magnetic field which generate | occur | produces in a stator core. It is a perspective view of a stator. It is a perspective view of one continuous coil for constituting a stator winding. It is a perspective view of the coil for 1 phase. It is a front view of a stator. It is a side view of a stator. It is a connection diagram of a stator winding. It is a figure which shows the relationship between the coil which comprises the slot number of a stator, and a stator winding. It is a flowchart which shows the manufacturing process of 1st Embodiment. It is a figure explaining the method of shape | molding an oval-shaped coil in 1st Embodiment. It is a perspective view of the state which further press-molded the oval-shaped coil in 1st Embodiment. It is a perspective view of the coil preformed by the method of a 1st embodiment. It is the side view which deform | transformed further the coil preformed by the method of 1st Embodiment. It is a perspective view of the state where the coil preformed by the method of the first embodiment is mounted in the slot of the stator core. It is a perspective view explaining the state which the extrusion part of the inner side jig | tool used in 1st Embodiment has retracted. It is a perspective view explaining the state which the extrusion part of the inner side jig | tool used in 1st Embodiment protrudes. It is a section perspective view in the state where the upper part in a figure of a stator iron core which equipped with a tooth support jig in a 1st embodiment was cut off. It is a figure of the state which mounted | wore with the coil previously preform | molded in 1st Embodiment in the slot of a stator core, and also mounted | worn the inner side jig | tool and the support jig | tool. It is a partial section perspective view in the state where a pressing jig was equipped in a 1st embodiment. It is a perspective view of the stator which performed temporary molding by the method of a 1st embodiment. It is a figure which shows the deformation | transformation of the surrounding part of the coil in the insertion process of 1st Embodiment. It is a perspective view of the state where the coil was inserted in the slot of a stator core by the method of a 1st embodiment. It is the perspective view which expanded the coil end of the stator manufactured by the method of 1st Embodiment. It is front sectional drawing of the stator manufactured by the method of 1st Embodiment. It is a simplified representation of how to wind a pair of winding portions in the coil of the second embodiment. It is a figure explaining the preforming method in 2nd Embodiment. It is a perspective view of the coil shape | molded using the preforming method of 2nd Embodiment. It is a flowchart which shows the manufacturing process from the arrangement | positioning process used as the characteristic of 3rd Embodiment to an insertion process. It is a perspective view in the state where a coil was arranged in a slide jig used in a 3rd embodiment. It is a perspective view of the state where the slide jig used in a 3rd embodiment is slid and the circumference part of a coil is shape | molded in the substantially turtle shell shape. It is the perspective view which expanded the part of the fixed groove in the slide jig | tool used by 3rd Embodiment. FIG. 37 is a perspective view of a state in which a fixing groove on one side in FIG. 36 is inclined. It is a perspective view in the state where the substantially turtle shell-shaped coil molding is wound around the inner jig in the third embodiment. It is a perspective view of the state which arrange | positions the inner side jig | tool equipped with the coil in 3rd Embodiment in a stator core. It is a perspective view of the state which performed the insertion process of 3rd Embodiment. It is a perspective view in the state where an inner side jig is taken out in a 3rd embodiment. It is a figure which shows connecting the connecting wire which connects coil pairs in 4th Embodiment. It is a perspective view of the stator of 5th Embodiment. It is a perspective view of the stator of 6th Embodiment. It is sectional drawing of a permanent magnet rotary electric machine. It is an AA cross section of the stator and rotor shown in FIG. It is sectional drawing which shows the coil shape which makes one Example of this invention. It is explanatory drawing which shows the assembly process of a stator. It is explanatory drawing which shows the adhering process of the insulating material which makes one Example of this invention. It is sectional drawing which shows the coil shape of another Example. It is explanatory drawing which shows the adhering process of the insulating material of another Example. It is explanatory drawing which shows the adhering process of the insulating material of another Example. It is explanatory drawing which shows the insulating material of another Example.

Explanation of symbols

4 Stator 5 Rotor 7a, 7b Ball bearing
16 Fixing heads 19 and 36 Inner jig 20 Support member 21 Teeth support jig 23 Press jig 35 Slide jigs 191 and 361 Outer opening grooves 193 and 363 Extrusion member 351 Fixing groove (fixing portion)
411 Slot 412 Stator core 413 Stator coil 416 Holding member 421 Elementary wire 422 Insulating material 4131 Coil winding part 4132 Crossover wire 4133 Straight line part 4221 Overlapping part

Claims (3)

Configuring the winding by rotating the coil multiple times;
Bundling and fixing the opposed portions of the wound coil with a thermoplastic insulator,
Inserting at least a part of the coil portion bundled with the insulator into a slot of a stator ;
Pulling a portion of the coil different from the slot insertion portion and inserting it into another slot different from the slot;
I have a,
In the step of bundling and fixing the opposed portions of the wound coil with an insulator, an overlapping portion is provided in which the end portions of the insulator that have wrapped around the coil overlap each other, and are wound around the coil And the ends are welded together by applying heat to the overlapping portion,
In the step of pulling a portion of the coil different from the slot insertion portion and inserting the coil into another slot different from the slot, the coil is inserted from the wound shape into the other slot. A method of manufacturing a rotating electrical machine that is deformed into a shape . It is a manufacturing method of the rotary electric machine according to claim 1,
A method of manufacturing a rotating electrical machine , wherein the wound shape of the coil is an oval shape, and a shape for insertion into the other slot is a substantially turtle shell shape . A method of manufacturing a rotating electrical machine according to claim 1 or 2 ,
In the step of pulling a portion different from the slot insertion portion of the coil and inserting it into another slot different from the slot,
After the coil is deformed, the coil is disposed on the stator side in the slot, and the rotating electrical machine is disposed on the rotor side in the other slot .

Images