JP5304058B2 - Concentrated winding stator manufacturing method and concentrated winding stator - Google Patents

Description

  The present invention relates to a technique for a method of forming a concentrated winding type stator, and more particularly to a technique for eliminating insulation problems at coil end portions and problems of poor bonding by continuously forming coils.

The drive motor mounted on a hybrid vehicle or the like is required to be developed with a smaller size and higher output because it is mounted in the engine room. Therefore, development of a method for forming a rectangular conductor coil capable of realizing a higher current density is urgently required.
The same applies to a coil wound with a round wire, but when a rectangular conductor coil is used, connection at the coil end becomes a problem.

In order to form a lead portion for each coil and bond them in the same phase, it is necessary to bond the coils by crimping or joining them at the coil end. Since the caulking or joining at the coil end is required at two places per one coil, if 18 coils are used, caulking or joining at 36 places is required. As the number of bonding points increases, it tends to cause a decrease in yield such as a bonding failure or a caulking failure. In addition, a dedicated process such as a caulking process or a joining process is required, and thus costs are increased accordingly.
For this reason, conventionally, the stator which is not joined at the end has also been studied.

Patent Document 1 discloses an armature coil winding method for a rotating electrical machine.
The armature coil to be connected in a three-phase star is first wound around the U phase of the armature core without cutting the coil conductor, and after winding around the neutral point, the same applies to the V phase and W phase. The coil conductor is wound without being cut.
By winding the coil conductor continuously without cutting it, the coil conductors at the neutral point side and the secret sky side end of the armature coil of each phase are respectively neutral point side and non-neutral The number of times of performing the step of winding on the sex point side can be reduced, and the winding work efficiency of the armature coil can be improved.

JP-A-8-182236

However, Patent Document 1 is considered to have the following problems.
It is difficult to apply the method of Patent Document 1 when manufacturing a concentrated winding type stator. Unlike the electric motor core of Patent Document 1, the stator used in the concentrated winding motor must be wound on the inner peripheral side of the stator. For this reason, the area to be wound is limited, and there is a possibility that the problem of crossover or overlapping of crossovers may become a hindrance when an insulation measure is subsequently taken.
When a stator used for a multi-phase motor is formed by concentrated winding, the coils of each phase intersect at the crossover portion, so that it is difficult to wind from the inner peripheral side of the stator. This situation is the same even when the stator core is divided, and it is necessary to devise so that the crossover portions do not interfere with each other.

  SUMMARY OF THE INVENTION In order to solve such problems, an object of the present invention is to provide a concentrated winding stator that is easy to manufacture and a manufacturing method of the concentrated winding stator.

In order to achieve the above object, a concentrated winding stator manufacturing method according to the present invention has the following characteristics.
(1) A coil is formed by continuously forming a plurality of concentrated winding portions with the same conducting wire by providing an interval between adjacent concentrated winding portions so that the concentrated winding portions of other phase coil units can be inserted. A unit is formed, and the coil unit as a predetermined phase is rotated once for each of the concentrated winding portions of the coil unit as the other phase, and between the concentrated winding portions of the coil unit of the other phase, By repeating the operation of arranging the concentrated winding portion of the coil unit of the predetermined phase, the concentrated winding portions of the coil unit of each phase are arranged in accordance with the arrangement order on the stator, and all the phases are arranged. A tooth portion included in the stator is fitted into the concentrated winding portion of the coil unit group formed by arranging and arranging the coil units.

In order to achieve the above object, the concentrated winding stator according to the present invention has the following characteristics.
(2) A coil unit in which a plurality of concentrated winding portions are continuously formed with the same conducting wire with an interval provided between adjacent concentrated winding portions so that the concentrated winding portions of other phase coil units can be inserted. The coil unit as a predetermined phase is rotated once for each concentrated winding portion of the coil unit as a different phase, so that the predetermined phase is interposed between the concentrated winding portions of the coil unit of the other phase. The concentrated winding portion of the coil unit is arranged.

(3) In the concentrated winding stator according to (2),
The coil unit has a connecting wire portion that connects the adjacent concentrated winding portions, and the length from the upper end of the concentrated winding portion to the lower end of the connecting wire portion is the length of the conductive wire forming the coil unit. It is characterized by being formed longer than the width.

The following actions and effects can be obtained by the concentrated winding stator manufacturing method according to the present invention having such characteristics.
First, in the invention described in (1), a plurality of concentrated winding portions are arranged in the same manner by providing an interval between adjacent concentrated winding portions so that the concentrated winding portions of coil units of other phases can be inserted . A coil unit is formed by continuous molding with a conductive wire, and the coil unit as a predetermined phase is rotated once for each concentrated winding part of the coil unit as the other phase, and the concentrated winding of the coil unit of the other phase. By repeating the operation of arranging the concentrated winding part of the coil unit of a predetermined phase between the parts, the concentrated winding part of the coil unit of each phase is arranged in accordance with the arrangement order on the stator, and all the phases are arranged. A tooth portion included in the stator is fitted into a concentrated winding portion of a coil unit group formed by arranging and arranging the coil units.

For example, when forming a three-phase stator, three coil units for the U phase, the V phase, and the W phase are continuously formed with the same conductor. Since all the coil units used for each phase may have the same shape, a mass production effect can be expected. Further, it is not necessary to manage a plurality of types of coil units in the production process.
A coil unit for a predetermined phase, for example, a U-phase coil unit, is assembled by rotating it once for each concentrated winding portion of a coil unit for another phase, for example, a V-phase coil unit. The concentrated winding portion of the unit can be disposed between the concentrated winding portions of the V-phase coil unit. The W-phase coil unit is assembled in the same manner.

Since the coil unit of the predetermined phase is rotated for each concentrated winding part of the coil unit of the other phase, the connecting wire part of the coil unit of each phase is arranged so as to straddle each other unit when assembled to the stator. Even in this case, assembly is possible.
By using a coil unit formed continuously with the same conducting wire in this way, it is not necessary to join the connecting wire between the concentrated winding portion and the concentrated winding portion after being assembled to the stator. Can be reduced. Joining at the coil end portion has problems such as poor bonding and increased resistance at the joining portion. However, both problems can be solved by using a coil unit formed continuously for each phase.
As described above, according to the invention described in (1), it is possible to provide a method of manufacturing a concentrated winding stator that can form a stator at low cost.

Further, the concentrated winding stator according to the present invention having such characteristics can provide the following operations and effects.
First, in the invention described in (2), a plurality of concentrated winding portions are the same by providing an interval between adjacent concentrated winding portions so that the concentrated winding portions of coil units of other phases can be inserted . A plurality of coil units continuously formed by conducting wires are provided, and a coil unit having a predetermined phase is rotated once for each concentrated winding portion of the coil unit having the other phase, so that the concentrated winding portion of the coil unit of the other phase is A concentrated winding portion of a coil unit of a predetermined phase is arranged between them.

  The concentrated winding stator formed in this way can minimize the joining portion of the coil unit, so that poor joining is unlikely to occur and quality improvement can be expected. In addition, since it is not necessary to prepare a plurality of coil units, the management of the coil units is facilitated, which can contribute to cost reduction.

The invention described in (3) is the concentrated winding stator described in (2), wherein the coil unit has a crossover portion connecting adjacent concentrated winding portions, and the concentrated winding portion The length from the upper end to the lower end of the crossover portion is formed longer than the width of the conducting wire forming the coil unit.
By forming the length from the upper end of the concentrated winding part to the lower end of the crossover part longer than the width of the conducting wire, the other coil unit is rotated once for each concentrated winding part with respect to one coil unit. Interference between coil units can be prevented when assembling.

If the coil units interfere with each other, there is a risk that the insulating member provided around the conducting wire will be peeled off when assembled. Ultimately, resin or varnish is used to insulate the coil end, but it is not desirable to peel the insulating member from the conductive wire in order to ensure the insulation more reliably. In the present invention, since one coil unit is assembled to rotate with respect to the other coil unit, it is necessary to avoid interference between the coil units.
For this reason, by forming the length from the upper end of the concentrated winding portion to the lower end of the crossover portion longer than the width of the conducting wire, it is possible to provide a concentrated winding stator that solves such a problem. Become.

First, an embodiment of the present invention will be described.
FIG. 1 shows a perspective view of the stator before resin molding. FIG. 2 is a perspective view of a stator in which a coil end is resin-molded.
The stator 10 is a stator used in a motor, and includes an outer ring 12, a split stator core 13, and a concentrated winding portion 22.
The stator core 13 is a laminated steel plate obtained by laminating electromagnetic steel plates formed by a press or the like, and has a substantially sector shape because it is a split type. A tooth portion 13a is provided on the inner peripheral side of the stator core 13, and a slot portion 13b is formed between adjacent tooth portions 13a.
In the present embodiment, 18 stator cores 13 are prepared as shown in FIG. Then, after being assembled into an annular shape, the outer ring 12 is shrunk on the outer peripheral surface to constitute the stator 10.

FIG. 3A is a perspective view of the stator core 13. FIG. 3B shows a state in which the insulator is inserted into the stator core 13. FIG. 3C shows a state in which the concentrated winding portion 22 is inserted into the stator core 13.
The insulator 11 is first inserted into the teeth portion 13 a of the stator core 13, and then the concentrated winding portion 22 is inserted. As shown in FIG. 3B, the insulator 11 includes a bottom portion 11a sandwiched between the concentrated winding portion 22 and the stator core 13, an annular portion 11b formed along the outer periphery of the teeth portion 13a, and an annular portion 11b. Positioning protrusions 11c provided on two sides are provided. The insulator 11 is preferably made of an insulating material having a high thermal conductivity, and a resin mixed with a filler is often used.

FIG. 4 shows a front view of the coil unit 15.
As shown in FIG. 4, the coil unit 15 has the same shape for all of the U phase, the V phase, and the W phase. The coil unit 15 is formed by winding a flat conductor 25. Here, the coil unit 15 used for the U phase is called a U phase coil unit 20, the coil unit 15 used for the V phase is called a V phase coil unit 30, and the coil unit 15 used for the W phase is called a W phase coil unit 40.
In the case of simply certifying the coil unit 15, any one or all of the U-phase coil unit 20, the V-phase coil unit 30, and the W-phase coil unit 40 are indicated.

The flat rectangular conductor 25 is a copper material having a rectangular cross section, and an insulating coating is provided on the periphery thereof. The insulating coating may be a relatively flexible member having high insulating properties such as imidoamide. Enamel or the like may be used.
The U-phase coil unit 20 includes a concentrated winding portion 22, a jumper wire portion 21, and a rising portion 23 that connects the concentrated winding portion 22 and the jumper wire portion 21.
The rising portion 23 is a portion from the upper end of the concentrated winding portion 22 to the lower end of the crossover portion 21, and its length is set longer than the width of the flat conductor 25.
The concentrated winding portion 22 is a coil formed by edgewise bending the flat conductor 25 for ten or more turns, and is wound so that the cross section has a substantially trapezoidal shape.

The concentrated winding part 22 is wound so that the shorter side on the outer peripheral side becomes longer when the concentrated winding part 22 is inserted into the tooth part 13a of the stator core 13 having a shorter side and a longer side. This is because the teeth portion 13a of the stator core 13 is formed in a substantially trapezoidal shape.
The connecting wire portion 21 and the rising portion 23 drawn from the concentrated winding portion 22 connect the concentrated winding portions 22 to each other. The rising portion 23 is disposed so as to be located at one location on the outer peripheral side and one location on the inner peripheral side when the concentrated winding portion 22 is assembled to the stator core 13. The rising part 23 on the outer peripheral side of the concentrated winding part 22 is connected to the rising part 23 on the inner peripheral side of the adjacent concentrated winding part 22 by the crossover part 21.
Between the adjacent concentrated winding portions 22, a gap is provided in which two concentrated winding portions 22 can be inserted.

Such a coil unit 15 is similarly formed in the same shape in all of the U-phase coil unit 20, the V-phase coil unit 30, and the W-phase coil unit 40. Therefore, after forming the coil units 15 in the same process, a necessary number of U-phase coil units 20, V-phase coil units 30, or W-phase coil units 40 may be divided.
Since the coil unit 15 is formed of a continuous rectangular conductor 25, when assembled as the stator 10, the rising portions 23 provided at both ends of the coil unit 15 are connected to the terminals 14 provided in the stator 10. Will be connected.

Next, the manufacturing procedure of the stator 10 will be described.
First, a coil unit 15 as shown in FIG. 4 is formed by winding a rectangular conductor 25. The coil unit 15 continuously forms the rectangular conductor 25 by edgewise bending, thereby forming a state in which the concentrated winding portion 22 is connected by the crossover portion 21 by the continuous rectangular conductor 25. As described above, since there is no difference in the shape of any of the U-phase coil unit 20, V-phase coil unit 30, and W-phase coil unit 40, by mass-producing the coil unit 15, the U-phase coil unit 20, V The phase coil unit 30 and the W phase coil unit 40 can be made.

5, 6, 7, 8, and 9 show the procedure for assembling the U-phase coil unit 20 and the V-phase coil unit 30. FIG.
FIG. 5 is a perspective view of steps in the middle of assembling the V-phase coil unit 30 to the U-phase coil unit 20. This is the first step. 6 is the second step, FIG. 7 is the third step, FIG. 8 is the fourth step, and FIG. 9 is the fifth step. Note that the U-phase coil unit 20 is a fixed side and the V-phase coil unit 30 is a rotating side, and only three concentrated winding portions 22 of each coil unit 15 are drawn for convenience of expression.

First, as shown in FIG. 4, the U-phase coil unit 20 is the fixed side, and the V-phase coil unit 30 is the rotating side. In FIG. 4, dot hatching is applied to the V-phase coil unit 30 on the rotating side for distinction, but the same coil unit 15 is used. For convenience of explanation, the V-phase coil unit 30 has already been rotated twice for each concentrated winding portion 22.
The V-phase coil unit 30 is rotated with respect to the U-phase coil unit 20 as shown in FIG.

That is, it is felt that the V-phase coil unit 30 is rotated 90 degrees spirally with respect to the U-phase coil unit 20. Further, as shown in FIGS. 7, 8, and 9, the V-phase coil unit 30 is rotated once in a spiral with respect to the U-phase coil unit 20 by rotating 90 degrees while moving forward.
By doing so, the concentrated winding portion 22 of the V-phase coil unit 30 advances by one pitch with respect to the concentrated winding portion 22 of the U-phase coil unit 20. In FIG. 9, it can be seen that the concentrated winding portions 22 of the V-phase coil unit 30 are arranged next to the concentrated winding portions 22 of the U-phase coil unit 20. Actually, since the coil unit 15 has six concentrated winding portions 22, the U-phase coil unit 20 and the V-phase coil unit 30 overlap each other when they are rotated six times.

Similarly, a unit in a state where the U-phase coil unit 20 and the V-phase coil unit 30 are overlapped is set as a fixed side, and the W-phase coil unit 40 is rotated, whereby the U-phase coil unit 20 and the V-phase coil unit 30 are On the other hand, the W-phase coil unit 40 can be assembled.
Thus, the concentrated winding portions 22 of the U-phase coil unit 20, the V-phase coil unit 30, and the W-phase coil unit 40 are aligned in order. The U-phase coil unit 20, the V-phase coil unit 30, and the W-phase coil unit 40 form one coil unit group 50.

The thus formed coil unit group 50 is bent into an annular shape, and the tooth portion 13a of the stator core 13 is inserted into the concentrated winding portion 22 of the coil unit group 50.
And the outer ring 12 heated is arrange | positioned to the outer peripheral part of the stator core 13 used as the outer side of the coil unit group 50 bent in the annular | circular shape, and it shrinks by cooling.
Thus, the stator core 13 is fixed in an annular shape, and the terminals 14 are joined to the coil ends of the stator 10. And finally, the stator 10 as shown in FIG. 2 is formed by resin-molding the coil end of the stator 10.

Since this embodiment is the structure demonstrated above, the effect as demonstrated below is shown.
As an effect of the present embodiment, firstly, the production efficiency of the stator can be improved.
In the present embodiment, a plurality of concentrated winding portions 22 are continuously formed with the same rectangular conductor 25 to form a plurality of coil units 15, and a predetermined phase coil unit 15 is replaced with another phase coil unit 15. Is repeated for each concentrated winding section 22 of the coil unit 15 and the operation of placing the concentrated winding section 22 of the coil unit 15 of the predetermined phase between the concentrated winding sections 22 of the coil unit 15 of the other phase is repeated. The concentrated winding portions 22 of the units 15 are arranged and arranged in accordance with the arrangement order on the stator 10, and the coil units 15 of all the plural phases are arranged and arranged to form the coil unit group 50, and the concentrated coil unit group 50 has. A tooth portion 13 a included in the stator 10 is fitted to the winding portion 22.

When forming the stator 10, the coil is generally formed in units inserted into the stator core 13. This is because there is a merit in terms of improving workability because it is necessary to insert a coil on the inner peripheral side of the stator core 13. However, since it is necessary to join the end portion of the coil to the crossover wire, there is a risk of causing poor bonding. If there are 18 concentrated winding portions 22 as in this embodiment, there will be 36 joint portions.
However, when the coil unit group 50 formed by combining the coil units 15 formed by the continuous flat conductor 25 is used for the stator 10, it is only necessary to join six places. Accordingly, the number of joints can be reduced to 1/6, and the risk of joint failure can be reduced.

In addition, in the manufacture of the stator 10, there is no need for a dedicated joining step for joining the end portions of the concentrated winding portion 22, and it is not necessary to prepare the connecting wire portion 21 separately. Advantages such as reduction and reduction of the joining process can be obtained.
And since the coil unit 15 of the same shape can be used for the U-phase coil unit 20, the V-phase coil unit 30, and the W-phase coil unit 40, it is also effective in reducing the cost of managing components.
That is, the production efficiency of the stator 10 can be improved.

Further, the coil unit 15 has a crossover portion 21 that connects the adjacent concentrated winding portions 22, and the length of the rising portion 23 from the upper end of the concentrated winding portion 22 to the lower end of the crossover portion 21 is: Since it is formed longer than the width of the conducting wire forming the coil unit 15, it is possible to reduce the possibility of interference when the coil units 15 are assembled together.
As for the assembly of the coil unit group 50, as shown in FIGS. 5 to 9, the U-phase coil unit 20 is fixed and the V-phase coil unit 30 is assembled while rotating. This is because when the coil unit group 50 is assembled, the crossover portions 21 of the U-phase coil unit 20 and the V-phase coil unit 30 are arranged in parallel as shown in FIG. This is because the U-phase coil unit 20 to the W-phase coil unit 40 intersect with each other through the concentrated winding portion 22 although the same relationship is obtained with the W-phase coil unit 40.

For this reason, by making the standing part 23 stand higher than the width of the flat conductor 25, interference between the coil units 15 can be prevented and assembly can be facilitated.
Interference between the connecting wire portions 21 may cause undesirable results such as peeling of the insulation coating applied on the surface and causing deformation of the connecting wire portion 21.
For this reason, setting the start-up portion 23 to be long and improving the assemblability is an important point for assembling the stator 10 with an automated line.
In addition, it is thought that the coil end of the stator 10 is lengthened by lengthening the rising portion 23. However, in this respect, the crossover portion 21 may be finally tilted to the stator core 13 side. The part never gets longer.

Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.
For example, in this embodiment, the coil unit 15 is connected to a coil wound with a flat conductor, but may be used for a coil wound with a round wire. It is considered that there is a merit if it is a concentrated winding type coil.
Moreover, since the material shown in this embodiment is an illustration to the last, it does not prevent changing suitably.

It is a perspective view of the stator before resin molding of this embodiment. It is a perspective view of the stator at the time of resin-molding the coil end of this embodiment. (A) It is a perspective view of the stator core of this embodiment. (B) It is a perspective view which shows a mode that the insulator was inserted in the stator core of this embodiment. (C) It is a perspective view which shows a mode that a concentrated winding part is inserted in the stator core of this embodiment. It is a front view of a coil unit of this embodiment. It is a perspective view of the 1st step which shows a mode that the V phase coil unit is assembled | attached to the U phase coil unit of this embodiment. It is a perspective view of the 2nd step which shows a mode that the V phase coil unit is assembled | attached to the U phase coil unit of this embodiment. It is a perspective view of the 3rd step which shows a mode that the V phase coil unit is assembled to the U phase coil unit of this embodiment. It is a perspective view of the 4th step which shows a mode that the V phase coil unit is assembled | attached to the U phase coil unit of this embodiment. It is a perspective view of the 5th step which shows a mode that the V phase coil unit is assembled | attached to the U phase coil unit of this embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Stator 12 Outer ring 13 Stator core 13a Teeth part 13b Slot part 14 Terminal 15 Coil unit 20 U-phase coil unit 21 Crossover part 22 Concentrated winding part 23 Rising part 25 Flat conductor 30 V-phase coil unit 40 W-phase coil unit 50 Coil unit group

Claims (3)

A coil unit is formed by continuously forming a plurality of concentrated winding portions with the same lead wire at intervals so that the concentrated winding portions of coil units of other phases can be inserted between adjacent concentrated winding portions. And
The coil unit of the predetermined phase is rotated between the concentrated winding portions of the coil unit of the other phase by rotating the coil unit as the predetermined phase for each concentrated winding portion of the coil unit of the other phase. By repeating the operation of arranging the concentrated winding portion of the unit, the concentrated winding portions of the coil units of each phase are arranged and arranged according to the arrangement order on the stator,
Manufacturing of a concentrated winding type stator, wherein a tooth portion provided in the stator is fitted to the concentrated winding portion of a coil unit group formed by arranging and arranging all the coil units of each phase. Method. Provided with a plurality of coil units in which a plurality of concentrated winding portions are continuously formed with the same conductive wire with an interval provided between adjacent concentrated winding portions so that the concentrated winding portions of coil units of other phases can be inserted. ,
The coil unit of the predetermined phase is rotated once for each concentrated winding portion of the coil unit of the other phase, so that the coil unit of the predetermined phase is interposed between the concentrated winding portions of the coil unit of the other phase. A concentrated winding type stator in which the concentrated winding portion is disposed. The concentrated winding stator according to claim 2,
The coil unit has a crossover portion connecting the adjacent concentrated winding portions,
The concentrated winding stator, wherein a length from an upper end of the concentrated winding portion to a lower end of the connecting wire portion is longer than a width of a conducting wire forming the coil unit.

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