JP5298556B2 - Manufacturing method of stator coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a stator coil which facilitates the work for inserting an assembled stator coil from the aperture of a slot. <P>SOLUTION: Conductor portions 40 each receiving the slot of a previously manufactured one turn of cylindrical wave winding coil are contained separately in the guide grooves 301 of an insertion tool 300, pushed out radially outward, and pushed into the slots 401 of a stator core 400 separately from the guide grooves 301. The circumferential pitch, i.e. the circumferential interval of two slot receiving conductor portions 40, 40 of one turn of wave winding coil adjoining in the circumferential direction, is substantially equalized to the aperture of the slot 401 in the stator core 400. Since the circumferential pitch of the slot receiving conductor portions 40, 40 is not required to be reduced by reducing the previously manufactured one turn of cylindrical wave winding coil, the work for inserting the slot receiving conductor portions 40 into the stator core 400 is facilitated. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

The present invention relates to a stator coil manufacturing method in which a stator coil formed by rounding a circumferentially developed stator coil can be efficiently inserted into a slot of a stator core of an inner rotor type motor.

A stator in which a wave-wound stator coil formed by rounding a circumferentially developed stator coil in which coil end conductor portions and slot accommodating conductor portions are alternately arranged and linearly deployed is inserted into a slot of a stator core of an inner rotor type motor. A coil manufacturing method is described, for example, in Patent Document 1 below. In this specification, the slot accommodating conductor portion means a portion of the stator coil that is accommodated in the slot, and the coil end conductor portion is a portion of the stator coil that extends in the circumferential direction along the end face of the stator core. Means. The slot accommodating conductor portions and the coil end conductor portions are alternately connected to constitute a stator coil.

  In this stator coil manufacturing method (more precisely, the stator core assembling method), since the assembled stator coil is assembled into the slots of the stator core, the coil end conductor portions of the stator coil can be densely packed, and as a result, the coil A compact motor can be realized by shortening the axial length of the end.

The following two methods are known for assembling this assembled stator coil having great rigidity to the stator core of the inner rotor type radial gap motor. The first method uses a stator core having a split core structure. In the second method, each slot accommodating conductor portion of the stator coil is inserted into each slot from a slot opening that opens radially inward of the stator core having an open slot structure, and then each slot accommodating conductor portion is moved radially outward. This is a method of reaching a desired conductor accommodating position in the slot. According to the latter method, since a split core structure is not required, there is an advantage that reduction of magnetic resistance, reduction of magnetic vibration and magnetic noise, and omission of a split core fastening mechanism can be realized.
Patent 3894004

  However, in the above-described method of pushing from the slot opening, in order to insert the assembled stator coil inside the stator core in the radial direction, the assembled stator coil must be deformed in such a direction that the interval between the slot accommodating conductor portions is reduced. However, the rigidity of the assembled stator coil is very large, and there is a problem that this deformation work is not easy.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a method of manufacturing a stator coil that can be easily inserted from the slot opening of the assembled stator coil.

  In the stator coil manufacturing method of the present invention for solving the above-mentioned problems, a long insulation coated conductor wire (30) is bent to alternately have a slot accommodating conductor portion (40) and a coil end conductor portion (42). Stator coil producing step of producing a round stator coil by rounding a circumferentially developed coil formed by combining a plurality of phase coils developed in the direction into a plurality of phases, and the slot accommodating conductor portion of the round stator coil By pushing (40) into the slot of the stator core from the slot opening on the radially inner side of the stator core, the plurality of slot-accommodating conductor portions (40) at the same position in the circumferential direction are radially adjacent in the slot. The method is applied to a method for manufacturing a stator coil having a stator coil insertion step of inserting the conductor coil into a conductor housing position. That is, in the stator coil manufacturing method of the present invention, the circumferentially expanded coil is rounded to form a round stator coil, and the round stator coil is accommodated inside the stator core of the inner rotor type radial gap motor in the radial direction. This is used in a system in which each slot accommodating conductor portion (40) of the stator coil is inserted into each slot from the slot opening.

Particularly in the present invention, in the stator coil manufacturing step, the circumferential pitch of the slot receiving conductor portion (40) substantially coincides with the slot opening pitch of the stator core, and the axial projection of the coil end conductor portion (42). The round stator coil is formed in a shape whose length is larger than the final axial protruding length, and the stator coil insertion step includes inserting the round stator coil inside the stator core in the radial direction, A step of aligning the slot receiving conductor portion (40) with the slot opening at the same position in the circumferential direction, and moving the slot receiving conductor portion (40) radially outward to move the slot receiving conductor portion (40) After being inserted into the slot through the slot opening, the circumferential pitch of the slot accommodating conductor (40) is increased. And, by reducing the axial projection length of the coil end conductor portion (42), and a pushing step to reach the slot accommodating conductor portion (40) to a predetermined conductor accommodation positions of said slot, said The stator coil manufacturing step includes a first slot accommodating conductor (40) having a first diameter and a second slot accommodating radially adjacent to the first slot accommodating conductor (40). A plurality of conductor portions (40), and the first slot accommodating conductor portion (40) and the second slot accommodating conductor portion (40) are connected to each other by the coil end conductor portion (42). A step of making half the number of the conductor receiving positions of one slot as the round stator coil, which is a wave-wound one-turn coil that makes one turn around the stator core, The step of inserting a coil is a step of inserting each of the wave-wound circular coils separately into the slot, and the coil end conductor portion (42) Steps (3A) in the thickness direction are provided toward the second slot accommodating conductor (40), the same number of temporary holding grooves (201) as the slots, and the two temporary holding grooves (circumferentially adjacent to each other) 201), and using a temporary jig (200) having a partition wall (202) extending in the axial direction, the slot accommodating conductor (40) is positioned at the same position in the circumferential direction as the slot opening. It is characterized in that the set step of aligning is performed.

  The round stator coil described above may be a final shaped stator coil or a part thereof. In the latter case, it may be one turn of a wave winding or lap winding stator coil, or a part of one turn, for example, a half turn.

  That is, according to the present invention, the stator coil manufactured so that the circumferential pitch of the two slot accommodating conductor portions (40) adjacent to each other of the stator coil substantially matches the slot opening pitch of the stator core is inserted into the stator core. For this reason, when inserting the stator coil from the slot opening of the stator core, it is not necessary to increase the circumferential pitch of the slot accommodating conductor portion, and each slot accommodating conductor portion of the round stator coil having high bending rigidity can be inserted into the slot very easily. can do.

  In this case, it is necessary to increase the circumferential pitch of the slot accommodating conductor portion in the pushing step of moving the slot accommodating conductor portion inserted into the slot from the slot opening to the outside in the radial direction of the slot. In the invention, the coil end conductor portion of the stator coil before being inserted into the stator core is previously projected outward in the axial direction (outside in the direction of the slot accommodating conductor portion). That is, the axial protruding length of the coil end conductor portion (42) of the circumferentially expanded coil is set to be larger than the final axial protruding length. Thereby, in the above-mentioned pushing process, the circumferential direction pitch of a coil end conductor part (42) can be easily increased as a coil end conductor part is moved to the radial direction outer side of a slot. When the slot accommodating conductor (40) in the slot moves radially outward, the coil end conductor (42) may or may not be biased inward in the axial direction of the stator core. Also good.

  Further, the round stator coil formed by rounding the circumferentially expanded coil is composed of a wave winding coil for one round occupying two conductor accommodating positions adjacent to each other in the slot. Therefore, when one slot has 2n (a positive integer) conductor accommodating position, n round stator coils are manufactured in advance. Each round stator coil is inserted into the slot separately and connected after insertion. In this way, the pushing force of the slot accommodating conductor portion (40) into the slot can be reduced. As is well known, the slot accommodating conductor portion of the wave winding circular coil is disposed at two conductor accommodating positions adjacent to each other in the slot.

In a preferred aspect, the coil end conductor portion (42) has the step in the thickness direction from the outermost vertex (1) in the axial direction toward the left and right first and second slot accommodating conductor portions (40). (3A) is formed stepwise.

  In a preferred aspect, in the setting step, a cylindrical insertion jig having a plurality of guide grooves radially arranged to be individually communicated with the slot openings of the stator core is prepared, and the guide grooves are provided in the guide grooves. A pair of each of the slot accommodating conductors (40) of the wave winding circuit coil is accommodated, and then the stator core is fitted concentrically on the radially outer side of the insertion jig to guide each slot opening to each guide. A step of communicating with the radially outer end of the groove, and the pushing step includes a step of pushing the slot accommodating conductor portions (40) in the guide grooves radially outward and inserting the slots into the slots. .

  That is, in this aspect, a cylindrical insertion jig is employed that is formed in a radial shape and has the same number of guide grooves as slots that communicate with each slot opening of the stator core in the radial direction. Insert each of the slot-containing conductors of the prepared wave-wound circular coil into each guide groove of the cylindrical insertion jig, fit the stator core into the cylindrical insertion jig, and guide the groove and the slot. Since the setting process is carried out by communicating with each other, the setting process can be greatly simplified. Further, each slot receiving conductor portion is guided in order to carry out the above pushing step by pushing out each of the two slot receiving conductor portions mainly in each guide groove of the cylindrical insertion jig by a pushing device. While moving along the groove, it can move smoothly and accurately outward in the radial direction, and the pushing process can be greatly simplified.

  In a preferred aspect, the setting step prepares a cylindrical temporary jig having a large number of temporary holding grooves radially arranged so as to be individually communicated with the guide grooves of the insertion jig, and A step of accommodating each of the slot accommodating conductors (40) of the circumferentially extending coil in the temporary holding groove, and then inserting the insertion jig concentrically inside the temporary jig in the radial direction; A step of communicating each temporary holding groove with a radially outer end of each guide groove; and each slot receiving conductor portion (40) in each temporary holding groove is pushed radially inward to be inserted into each guide groove. The process of carrying out.

  That is, in this aspect, a cylindrical temporary jig having the same number of temporary holding grooves as the guide grooves that are radially formed and communicate with each guide groove of the insertion jig in the radial direction is employed. Insert each of the slot-containing conductors of the prepared wave-wrapping coil into each temporary holding groove of the cylindrical temporary jig, and insert the insertion jig into the cylindrical temporary jig. Since the slot accommodating conductor portion (40) is pushed into the guide groove by communicating the holding groove and the guide groove, the setting of the round stator coil to the insertion jig can be greatly simplified.

  A preferred embodiment for forming a stepped coil end conductor portion on each coil conductor constituting a stator coil will be described below with reference to the drawings. It should be noted that the present invention should not be construed as being limited to the following embodiments, and the technical idea of the present invention may be realized by a combination of other known techniques.

(Description of stator coil)
First, a stator coil (hereinafter also referred to as a crank type stator coil) of this embodiment in which the coil end conductor portion of each coil conductor is formed in a step shape will be described with reference to FIGS. FIG. 1 is a partial perspective view showing an insulating covered rectangular wire 30 forming one coil conductor of the crank type stator coil, and FIG. 2 is a crank type coil which is an assembly of stepped coil end conductor portions 42. It is a fragmentary perspective view which shows an end.

  11 is a stator, 12 is a stator core, 13 is an end face of the stator core 12, and 20 is a stator coil. The stator 11 is used for a generator motor for driving a vehicle. A rotor (not shown) is rotatably accommodated inside the stator 11 in the radial direction. A large number of magnetic poles having different polarities alternately in the circumferential direction are formed by permanent magnets on the outer periphery of the rotor. The outer peripheral surface of the rotor faces the inner peripheral surface of the stator 11 via a minute air gap. The stator core 12 is formed by laminating electromagnetic steel plates having a predetermined thickness in the axial direction. The stator coil 20 is a three-phase winding. A single-phase wave winding is wound around the slot 14, and a single-phase wave winding is wound around the slot 15. In other words, a stator coil 20 having the same phase is wound around two slots 14 and 15 adjacent to each other to form a so-called two-slot structure for each pole per phase.

  The stator coil 20 is a star-connected three-phase winding that is distributedly wound (preferably wave-wound), and each phase coil having a wave-winding structure is formed by bending the insulation-coated rectangular wire 30 and then opening the stator core 12. The slot structure is formed in a slot 14 or 15. Of course, a split stator core structure may be employed instead of the open slot structure.

  The insulating covering rectangular wire 30 is formed by coating an enamel layer such as polyamide imide on a copper wire having a substantially rectangular cross section, and further covering an outer side with an extrusion covering resin layer such as PPS. The total thickness of the insulating film is set to 100 μm to 170 μm. However, the insulation coating structure of the insulation coating rectangular wire 30 may adopt another known method. In this embodiment, the plurality of insulation coated rectangular wires 30 are arranged in a line in the slot depth direction in the slot, but the present invention is not limited to this, and may be arranged in a matrix in the slot. In addition, it is usual to provide insulating paper on the inner surface of the slot. However, in this embodiment, the insulating paper is omitted because a two-layer insulating layer is formed. The stator coil 20 will be further described. The insulation-coated rectangular wire 30 forming the stator coil 20 is separated from the slot-accommodating conductor portions 40 accommodated in the slots 14 and 15 of the stator core 12 by approximately 1 magnetic pole pitch in the circumferential direction while extending in the axial direction and the circumferential direction. It has a coil end conductor portion 42 that connects the end portions of the two slot accommodating conductor portions 40 at both axial ends of the stator core 12.

(Description of shape of coil end conductor portion 42)
The coil end conductor portion 42 of the insulating coated rectangular wire 30 will be described in more detail with reference to FIG. 3 which is a schematic development view in the circumferential direction.

  At the center in the circumferential direction of the coil end conductor portion 42 is provided a crown 1 that is a circumferential line portion that is located on the outermost side in the axial direction and extends in the circumferential direction. It is bent stepwise from the circumferential line portion 1 to the slot accommodating conductor portions 40 on both sides. A step (also referred to as a step in the thickness direction) 3A is provided in the central portion of the top portion (circumferential line portion) 1 in the radial direction (thickness direction) by substantially the thickness of the insulating covering rectangular wire 30. The thickness direction step 3A is provided so that the circumferential end of the coil end conductor portion 42 and the other half portion of the coil end conductor portion 42 can be overlapped with other coil end conductor portions by radially separating one conductor line. It is a step. 2 to 4 are circumferential line portions extending in the circumferential direction, and 6 to 8 are axial line portions extending in the axial direction. C1 to C6 are corner portions forming a boundary portion between one adjacent circumferential line portion and one axial line portion. C7 is a corner portion that forms a boundary between the circumferential line portion 4 and the slot accommodating conductor portion 40. The coil end conductor portion 42 is formed in a stepped shape from the outermost crown 1 in the axial direction toward the left and right slot accommodating conductor portions 40. In FIG. 3, the corners C1 to C7 are shown at right angles, but in reality, the corners C1 to C7 are bent or curved with a predetermined radius of curvature within a range where high-density mounting with other adjacent coil end conductors 42 is possible. It only has to be done. By combining the coil end conductor portions 42, a crank type coil end of the stator coil is formed as shown in FIG.

  Eventually, in this embodiment, a phase coil that is a wave winding coil developed in the circumferential direction is formed by forming the coil end conductor portions 42 at a predetermined pitch in the longitudinal direction on the long coil conductor, that is, the insulation coated rectangular wire 30. A belt-shaped circumferentially developed stator coil is manufactured by combining the phase coil of each phase with the coil end conductor portions 42 at high density, and the circumferentially developed stator coil is sequentially inserted into the slots of the stator core to obtain the stator. Finalize.

(effect)
The stator coil of this embodiment has a crank type coil end that is very difficult to manufacture because the axial protrusion length is reduced to the limit, but each insulation coated rectangular wire 30, that is, the coil end conductor portion 42 of each coil conductor. The manufacturing process of the stator coil can be facilitated because the bending process and the combining process of the coil end conductor portions 42 are prepared in advance in a circumferentially expanded state before each coil conductor is wound around the stator core. There is an effect.

  That is, the stator coil according to this embodiment includes a coil conductor bending step in which the insulation coated rectangular wire 30, that is, the coil conductor is bent to alternately produce coil end conductor portions and slot accommodating conductor portions, and each insulation coated rectangular wire 30 is bent. That is, the stator coil is manufactured through three stages: a stator coil manufacturing process for manufacturing a stator coil by combining coil ends, and a stator coil insertion process for inserting the manufactured stator coil into a slot of the stator core. In this embodiment, the workability in the stator coil insertion process is improved.

(Description of stator coil manufacturing process)
(Preparation of circumferential deployment coil 101)
First, a circumferentially expanded phase coil 100 that is bent in the circumferential direction by alternately bending the elongated insulating rectangular wire 30 into a waveform and alternately having the slot accommodating conductor portions 40 and the coil end conductor portions 42 (FIG. 5) is produced. reference). What is important here is that the circumferential pitch of each slot accommodating conductor portion 40 matches the slot opening pitch of the stator core, and the axial protruding length of each coil end conductor portion 42 is the final (after the stator core is accommodated). It is the point formed in the shape larger than an axial protrusion length.

  The odd-numbered slot accommodating conductors 40 and the even-numbered slot accommodating conductors 40 of the circumferentially-deployed phase coil 100 are equal to the thickness of the slot accommodating conductors 40 in the thickness direction of the sheet in FIG. It is only shifted. In FIG. 5, two circumferentially expanded phase coils 100, 100 having different phases are illustrated.

  Next, the three-phase circumferentially-deployed phase coil 100 is knitted at the portions of the coil end conductor portions 42 to produce the three-phase circumferentially-deployed coil 101 (see FIG. 6). Therefore, the circumferentially expanded coil 101 has a thickness twice as large as the thickness of the slot accommodating conductor portion 40 in the radial direction. Note that the three-phase circumferentially expanded coil 101 shown in FIG. 6 has a total of twelve wave-wrapped insulating coated rectangular wires 30 at an electrical angle of π / 6 pitch. This is because a stator core having a two-slot structure for each pole and each phase is employed.

  The circumferential deployment coil 101 is rounded to produce a round stator coil.

(Temporary retention)
Next, a temporary holding step of setting the round stator coil in the temporary holding groove 201 of the cylindrical temporary jig 200 is performed. This temporary holding step will be described with reference to FIG.

  The temporary jig 200 is a cylindrical member having the same number of temporary holding grooves 201 as the slots of the stator core, which will be described later, at the same circumferential pitch as the slots, and between the two temporary holding grooves 201 and 201 adjacent to each other in the circumferential direction. Is provided with a long partition wall 202 extending in the axial direction. In FIG. 7, both ends in the radial direction of the temporary holding groove 201 are open, but at least the radial inner end of the temporary holding groove 201 may be open.

  In this embodiment, the temporary jig 200 is a cylindrical member having a large number of temporary holding grooves 201 and partition wall portions 202 that open radially inward, alternately in the circumferential direction. The opening at the radially inner end of the temporary holding groove 201 has the same diameter and the same width as the slot opening of the stator core.

  After the rounded stator coil that has been rounded is disposed coaxially inside the temporary jig 200 in the radial direction, each slot-accommodating conductor portion 40 of the round stator coil is opened at the radially inner end of the temporary holding groove 201. Are pushed into each temporary holding groove 201 one by one. The broken line shown in FIG. 7 indicates the position of the slot accommodating conductor portion 40 pushed into the temporary holding groove 201.

  Since the circumferential pitch of the openings at the radially inner end of the temporary holding groove 201 is equal to the circumferential pitch of the slot opening of the stator core, and the circumferential width of the temporary holding groove 201 is also equal to the circumferential width of the slot opening, the round stator coil The setting to the temporary jig 200 is very easy.

(Transfer from temporary jig 200 to insertion jig 300)
Next, the round stator coil set on the temporary jig 200 is transferred to the insertion jig 300. This transfer will be described with reference to FIG.

  The insertion jig 300 is a cylindrical member having the same number of guide grooves 301 as the slots of the stator core, which will be described later, at the same circumferential pitch as the slots, and is between the two guide grooves 301 and 301 adjacent to each other in the circumferential direction. A long partition wall 302 extending in the axial direction is provided. In FIG. 7, both ends in the radial direction of the guide groove 301 are open, but at least the outer ends in the radial direction of the guide groove 301 may be open.

  In this embodiment, the insertion jig 300 is a cylindrical member having a large number of guide grooves 301 and partition wall portions 302 that are opened radially outward, respectively, alternately in the circumferential direction. The opening at the radially outer end of the guide groove 301 is substantially the same diameter and substantially the same width as the slot opening of the stator core.

  The temporary jig 200 is coaxially fitted adjacent to the outer peripheral surface of the insertion jig 300, and the temporary holding groove 201 and the guide groove 301 are set at the same position in the circumferential direction. Next, using a pushing device (not shown), the slot accommodating conductor portion 40 of the round stator coil accommodated in the temporary holding groove 201 is urged radially inward, and as a result, each slot accommodating conductor portion 40 is Then, it moves radially inward and is received in each guide groove 301 of the insertion jig 300. Since the circumferential pitch of the guide grooves 301 is somewhat narrower than the circumferential pitch of the temporary holding grooves 201, the circumferential pitch of the slot accommodating conductor portions 40 is reduced by the transfer.

(Stator coil insertion process)
Next, a stator coil insertion step of transferring the round stator coil set on the insertion jig 300 to the stator core 400 is performed. This process will be described with reference to FIG.

  The stator core 400 is a soft magnetic cylindrical member having slots 401 at a predetermined pitch in the circumferential direction on the inner peripheral surface, and each slot 401 is partitioned by teeth 402. The opening at the radially inner end of the slot 401 is called a slot opening.

  The stator core 400 is coaxially fitted adjacent to the outer peripheral surface of the insertion jig 300, and the guide groove 301 and the slot 401 are set at the same position in the circumferential direction. Next, using a pushing device (not shown), the slot accommodating conductor portion 40 of the round stator coil accommodated in the guide groove 301 is urged radially outward. As a result, each slot accommodating conductor portion 40 is It moves to the outer side in the radial direction and is pushed to the first outermost conductor accommodating position in the radial direction of the slot 401 of the stator core 400 and the second outermost conductor accommodating position adjacent to the radial direction.

  In addition, since the circumferential pitch of the slot accommodating conductor portion 40 of the original round stator coil is equal to the circumferential pitch of the slot 401, the circumferential pitch of the slot accommodating conductor portion 40 is expanded by the above transfer, and accordingly. The axial protrusion length of the round stator coil is reduced.

(Subsequent steps)
Thereafter, by repeating the above-described steps, a plurality of round stator coils that occupy two conductor accommodation positions adjacent to each other in the radial direction of the slots are pushed into the slots 401 of the stator core 400. After the pressing of each round stator coil is completed, the ends of each round stator coil are connected to complete a three-phase stator coil having an external terminal and a neutral point. Each of the round stator coils corresponds to the wave-wrapping round coil referred to in the present invention. Eventually, a stator coil is produced by connecting half of the number of the conductor accommodating positions of one slot 401 to the round stator coil. It should be noted that the circumferential width of the coil end conductor portion 42 of each round stator coil 42 after completion of housing of the stator core differs because the conductor housing position in which the slot housing conductor portion 40 of each round stator coil is housed is different. I want.

(Modification)
In the above embodiment, the circumferential pitch of the slot accommodating conductor portions 40 of one circumferentially expanded coil 100 constituting the circumferentially expanded coil 101 is made equal to the circumferential pitch of the slots 401 of the stator core 400. Of course, manufacturing tolerances of This manufacturing tolerance is preferably less than 10%.

(Modification)
In the above-described embodiment, the wave-wound one-turn coil is adopted as the round-shaped stator coil that is simultaneously pushed. However, for example, the wave-wound half-turn coil may be a round-shaped stator coil. However, in this case, the number of connection locations after completion of pushing increases.

(Modification)
Note that the coil end conductor portion 42 may be urged inward in the axial direction when the slot accommodating conductor portion 40 is pushed radially outward. FIG. 9 shows a state in which the slot accommodating conductor portion 40 is urged radially outward while the coil end conductor portion 42 is urged inward in the axial direction.

It is a fragmentary perspective view which shows a part of one insulation coating flat wire which has a step-like coil end conductor part. It is a fragmentary perspective view which shows the shape of the crank type coil end which is an aggregate | assembly of a step-like coil end conductor part. FIG. 2 is an enlarged circumferential development view of a stepped coil end conductor portion shown in FIG. 1. FIG. 3 is a partial circumferential development view of the crank-type coil end shown in FIG. 2. It is a partial circumferential direction developed view showing a circumferential direction developed phase coil. It is a circumferential direction developed view showing a round stator coil which is a circumferential direction developed coil. It is a partial radial direction schematic cross section showing transfer of a round stator coil from a temporary jig to an insertion jig. It is a partial radial direction schematic cross section showing transfer of a round stator coil from an insertion jig to a stator core. FIG. 10 is a schematic explanatory view for explaining an urging operation of the coil end conductor portion toward the inner side in the axial direction when the slot accommodating conductor portion is pushed into the radially outer side of the slot.

Explanation of symbols

30 Insulating coated rectangular wire 40 Slot accommodating conductor portion 42 Coil end conductor portion 100 Circumferentially expanded phase coil 101 Circumferentially expanded coil 200 Temporary jig 201 Temporary holding groove 202 Partition wall portion 300 Inserting jig 301 Guide groove 302 Partition wall portion 400 Stator core 401 Slot 402 Teeth

Claims (4)

A long insulation-coated conductor wire (30) is bent to alternately have a slot accommodating conductor portion (40) and a coil end conductor portion (42), and are composed of a plurality of phases combined in a circumferential direction. A stator coil production step of rounding the circumferentially expanded coil into a cylindrical shape to produce a round stator coil;
By pushing the slot accommodating conductors (40) of the round stator coil into the slots of the stator core from the radially inner slot openings of the stator core, the plurality of slot accommodating conductors (40) in the same circumferential direction are A stator coil insertion step of inserting into a plurality of conductor housing positions radially adjacent in the slot;
In a method of manufacturing a stator coil having
In the stator coil manufacturing step, the circumferential pitch of the slot receiving conductor portion (40) substantially coincides with the slot opening pitch of the stator core, and the axial protruding length of the coil end conductor portion (42) is the final axis. A step of forming the round stator coil in a shape larger than the direction protruding length,
The stator coil insertion step includes the step of inserting the round stator coil into the radial inner side of the stator core and aligning the slot accommodating conductor (40) at the same position in the circumferential direction as the slot opening;
After inserting the slot accommodating conductor (40) into the slot from the slot opening by moving the slot accommodating conductor (40) radially outward, the circumferential pitch of the slot accommodating conductor (40) And pushing the slot accommodating conductor portion (40) to reach a predetermined conductor accommodating position of the slot by reducing the axial protruding length of the coil end conductor portion (42), and
Have
The stator coil manufacturing step includes a first slot accommodating conductor portion (40) having a first diameter and a second slot adjacent in the radial direction to the first slot accommodating conductor portion (40). A plurality of accommodating conductors (40), and the first slot accommodating conductor (40) and the second slot accommodating conductor (40) are connected by the coil end conductor (42). The step of making a half-turn wave coil around the stator core as the round-shaped stator coil, which is half the number of the conductor accommodation positions of one of the slots,
The stator coil insertion step is a step of separately inserting each of the wave winding circular coils into the slot,
The coil end conductor portion (42) is provided with a step (3A) in the thickness direction from the outermost vertex (1) in the axial direction toward the left and right first and second slot accommodating conductor portions (40). ,
A temporary holding groove (201) having the same number as the slot and a partition wall portion (202) provided between two temporary holding grooves (201) adjacent in the circumferential direction and extending in the axial direction. A method of manufacturing a stator coil, comprising: using the jig (200) to perform the setting step of aligning the slot accommodating conductor portion (40) at the same position in the circumferential direction as the slot opening . The coil end conductor portion (42) has a step in the thickness direction (3A) stepped from the axially outermost top portion (1) toward the left and right first and second slot accommodating conductor portions (40). The stator coil manufacturing method according to claim 1, wherein the stator coil is formed in a shape . The setting step includes
A cylindrical insertion jig having a large number of guide grooves radially arranged so as to be individually communicated with each slot opening of the stator core is prepared, and each slot of the wave-wound round coil is accommodated in each guide groove. A pair of conductor portions (40) are accommodated, and then the stator core is fitted concentrically on the radially outer side of the insertion jig so that the slot openings communicate with the radially outer ends of the guide grooves. Consists of
The pushing step includes
The method for manufacturing a stator coil according to claim 2, further comprising a step of pushing each slot accommodating conductor portion (40) in each guide groove radially outward and inserting it into each slot. The setting step includes
A cylindrical temporary jig having a large number of temporary holding grooves arranged radially so as to be individually communicated with the respective guide grooves of the insertion jig is prepared, and the circumferentially-expanding coil is provided in each temporary holding groove. A step of accommodating each of the slot accommodating conductor portions (40) one by one;
Thereafter, the step of inserting the insertion jig concentrically inside the temporary jig in the radial direction and communicating the temporary holding grooves with the radial outer ends of the guide grooves;
Inserting each slot accommodating conductor (40) in each temporary holding groove into the guide groove by pushing radially inward;
A method for manufacturing a stator coil according to claim 3.

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