JP5309674B2 - Stator coil manufacturing method - Google Patents

Stator coil manufacturing method Download PDF

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JP5309674B2
JP5309674B2 JP2008113682A JP2008113682A JP5309674B2 JP 5309674 B2 JP5309674 B2 JP 5309674B2 JP 2008113682 A JP2008113682 A JP 2008113682A JP 2008113682 A JP2008113682 A JP 2008113682A JP 5309674 B2 JP5309674 B2 JP 5309674B2
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winding
core member
stator coil
temporary
outer peripheral
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JP2009268221A (en
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正臣 土橋
利昭 大原
明人 秋本
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Denso Corp
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Denso Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a stator coil without using an adhesive for keeping the form of a stator coil, when employing a method for manufacturing for forming the stator coil by winding a band-shaped coil. <P>SOLUTION: The method includes a molding step, in which a plurality of molded objects are molded from an electric conductor, a built-in step, in which a plurality of molded objects are built in to form a band-shaped built-in body 47, a temporary winding step, in which the built-in body 47 is wound around the first core member 50 so as to form a temporary roll 51, and a regular winding step, in which the temporary roll 51 is wound around the second core member 60 so as to form a regular roll 61 being a stator coil 4. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

本発明は、回転電機の固定子に用いられる固定子コイルの製造方法に関するものである。   The present invention relates to a method of manufacturing a stator coil used for a stator of a rotating electrical machine.

近年、電動機及び発電機として使用される回転電機において、小型高出力及び高品質が求められている。例えば、車両に搭載される回転電機においては、回転電機を搭載するためのスペースが小さくなってきている一方で、出力の向上が求められている。従来の回転電機として、固定子に用いられる固定子コイルが連続巻線で形成されたものが知られている（例えば、特許文献１参照）。   In recent years, rotating electrical machines used as electric motors and generators have been required to have small size, high output, and high quality. For example, in a rotating electrical machine mounted on a vehicle, the space for mounting the rotating electrical machine is becoming smaller, while an improvement in output is required. As a conventional rotating electrical machine, a stator coil used for a stator is formed by continuous winding (for example, see Patent Document 1).

特許文献１に記載された固定子の製造方法は、まず帯状に成形したコイルを巻回することで、筒状の固定子コイルを成形する。成形された筒状の固定子コイルに対して、固定子コアを取り付ける。
特開２００４−３２０８８６号公報 In the stator manufacturing method described in Patent Document 1, a cylindrical stator coil is formed by first winding a strip-shaped coil. A stator core is attached to the molded cylindrical stator coil.
JP 2004-320886 A

しかし、特許文献１に記載の固定子の製造方法においては、帯状のコイルを巻回することで固定子コイルを成形しているため、コイルエンド部のスプリングバック（本の形状に戻る力）により、最外周端部が巻回された状態を維持できない。この状態のまま固定子コアに固定子コイルを配置した場合には、コイルエンド部によるスプリングバックにより、固定子コイルが固定子コアに対して大きな力で当接する状態となるおそれがある。この当接により、固定子コイルを構成する電気導体線の被膜が剥離し、電気導電体と固定子コアと短絡するおそれがある。   However, in the stator manufacturing method described in Patent Document 1, since the stator coil is formed by winding a strip-shaped coil, the coil end portion is springback (force to return to the shape of the book). The state where the outermost peripheral end is wound cannot be maintained. When the stator coil is arranged in the stator core in this state, the stator coil may come into contact with the stator core with a large force due to the spring back by the coil end portion. Due to this contact, the coating of the electric conductor wire constituting the stator coil may be peeled off, and there is a possibility that the electric conductor and the stator core are short-circuited.

また、固定子コアのスロットの大きさを大きくすることで、上記問題が解消されるが、スロットの大きさを大きくすると回転電機の性能の低下を招来する。従って、スロットの大きさが出来るだけ小さい方が望ましい。
上記の理由より、接着剤などにより、固定子コイルを巻回された状態で固定する必要があった。しかし、接着剤の塗布工程が必要であるため、製造工数が増大し、高コスト化を招来していた。 Further, the above problem can be solved by increasing the size of the stator core slot. However, if the size of the slot is increased, the performance of the rotating electrical machine is deteriorated. Therefore, it is desirable that the slot size be as small as possible.
For the above reasons, it is necessary to fix the stator coil in a wound state with an adhesive or the like. However, since an adhesive application step is required, the number of manufacturing steps is increased, resulting in high costs.

本発明は、このような事情に鑑みてなされたものであり、帯状のコイルを巻回することで固定子コイルを成形する製造方法を採用するにあたって、固定子コイルの形状を維持するための接着剤を用いることのない固定子コイルの製造方法を提供することを目的とする。   The present invention has been made in view of such circumstances, and in adopting a manufacturing method for forming a stator coil by winding a strip-shaped coil, an adhesive for maintaining the shape of the stator coil is provided. It is an object of the present invention to provide a method for manufacturing a stator coil without using any agent.

以下、上記課題を解決するのに適した各手段につき、必要に応じて作用効果等を付記しつつ説明する。   Hereinafter, each means suitable for solving the above-described problems will be described with additional effects and the like as necessary.

（手段１）手段１に係る固定子コイルの製造方法は、固定子コアのスロットに収容されるスロット収容部、および、隣り合った前記スロット収容部を連結し前記固定子コアの両端面からそれぞれ突出するコイルエンド部を備える固定子コイルの製造方法であって、電気導体線から複数の成形体を成形する成形工程と、複数の前記成形体を組み込んで帯状の組み込み体を形成する組み込み工程と、前記組み込み体を帯状の前記組み込み体の長手方向の一端から第一芯部材の外周面に巻き取って仮巻き取り体を形成する仮巻き取り工程と、前記仮巻き取り体を前記組み込み体の長手方向の他端から第二芯部材の外周面に巻き取って、前記固定子コイルである本巻き取り体を形成する本巻き取り工程と、を備えることを特徴とする。 (Means 1) A stator coil manufacturing method according to means 1 includes a slot accommodating portion accommodated in a slot of a stator core, and an adjacent slot accommodating portion connected to each other from both end faces of the stator core. A method for manufacturing a stator coil including a protruding coil end portion, a forming step of forming a plurality of formed bodies from an electric conductor wire, and an incorporating step of forming a strip-shaped incorporated body by incorporating the plurality of formed bodies. A temporary winding step of winding the built-in body from one end in the longitudinal direction of the belt-shaped built-in body onto the outer peripheral surface of the first core member to form a temporary winding body; and the other longitudinal end wound around the outer peripheral surface of the second core member, characterized in that it comprises, and the winding step of forming the winding body is the stator coil.

手段１によれば、最終的な形状とするための本巻き取り工程の前に、仮巻き取り工程を行っている。つまり、帯状の組み込み体に対してまず仮巻き取り工程を行うことで、仮巻き取り工程により得られた仮巻き取り体は、ほぼ平面状である帯状の組み込み体を、ある程度の湾曲した形状とすることができる。すなわち、コイルエンド部に相当する部位に巻き取り癖をつけることができる。従って、この状態から、本巻き取り工程を行って本巻き取り体を形成することで、本巻き取り体の最外周端部にコイルエンド部によるスプリングバックが生じることを抑制できる。その結果、接着剤を塗布することなく、本巻き取り体（固定子コイルに相当）の形状を維持することができる。   According to the means 1, the temporary winding process is performed before the final winding process for obtaining a final shape. In other words, by first performing a temporary winding process on the band-shaped built-in body, the temporary winding body obtained by the temporary winding process has a substantially flat band-shaped built-in body with a certain degree of curved shape. can do. That is, a winding rod can be attached to a portion corresponding to the coil end portion. Therefore, from this state, by performing the main winding process to form the main winding body, it is possible to suppress the occurrence of springback due to the coil end portion at the outermost peripheral end portion of the main winding body. As a result, the shape of this winding body (equivalent to a stator coil) can be maintained, without apply | coating an adhesive agent.

また、仮巻き取り工程において最初に巻き取られる部位が、本巻き取り工程において最外周部位となる。つまり、仮巻き取り工程にて確実に巻き取り癖のつけられる部位が、本巻き取り工程にて最外周部位となるため、最外周端部のスプリングバックを確実に抑制できる。 Moreover, the site | part wound up initially in a temporary winding process turns into an outermost periphery site | part in this winding process. That is, since the part where the winding rod is reliably attached in the temporary winding process becomes the outermost peripheral part in the main winding process, the springback at the outermost peripheral end can be reliably suppressed.

（手段２）手段１の固定子コイルの製造方法において、前記仮巻き取り工程は、前記組み込み体の少なくとも前記長手方向の一端部を、前記第一芯部材の外周面に巻き取るとよい。 (Means 2 ) In the stator coil manufacturing method of means 1 , in the temporary winding step, at least one end portion in the longitudinal direction of the built-in body may be wound around the outer peripheral surface of the first core member.

手段２によれば、仮巻き取り工程において少なくとも巻き取られる当該長手方向の一端部が、本巻き取り工程において最外周端部となる。つまり、仮巻き取り工程にて確実に巻き取り癖のつけられる当該長手方向の一端部が、本巻き取り工程にて最外周端部となるため、最外周端部のスプリングバックを確実に抑制できる。なお、当該長手方向の一端部とは、組み込み体の長手方向の一端から、所定の幅分を含む範囲を意味する。 According to the means 2 , at least one end portion in the longitudinal direction wound in the temporary winding step becomes the outermost peripheral end portion in the main winding step. That is, since the one end portion in the longitudinal direction to which the winding rod is reliably attached in the temporary winding step becomes the outermost peripheral end portion in the final winding step, the springback at the outermost peripheral end portion can be reliably suppressed. . In addition, the one end part in the longitudinal direction means a range including a predetermined width from one end in the longitudinal direction of the built-in body.

（手段３）手段２の固定子コイルの製造方法において、前記本巻き取り体は、前記第二芯部材の外周面に複数周巻き取られており、前記仮巻き取り工程は、少なくとも前記本巻き取り体における最外周全周に相当する部位を、前記第一芯部材の外周面に巻き取るとよい。 (Means 3 ) In the stator coil manufacturing method of means 2 , the main winding body is wound a plurality of times around the outer peripheral surface of the second core member, and the temporary winding step includes at least the main winding. It is good to wind up the site | part corresponding to the outermost periphery whole periphery in a take-up body on the outer peripheral surface of said 1st core member.

本巻き取り体が複数周巻き取られる場合に、最外周以外の部位に対しては、当該部位の外周側部分のコイルによる形状規制力が生じる。従って、最外周以外の部位は、最外周部位に比べて、比較的スプリングバックが小さい。これに対して、最外周部位は、その外周側には何も存在しないため、他の部材による形状規制力が働かない。そのため、最外周部位は、スプリングバックにより目的の位置にコイルを位置決めすることができないおそれがある。そこで、少なくとも、本巻き取り体における最外周全周に相当する部位を、仮巻き取り工程にて巻き取ることで、本巻き取り体の最外周全周に相当する部位に巻き取り癖をつけることができる。従って、本巻き取り体の最外周全周に亘って、スプリングバックが生じることを抑制できる。   When the winding body is wound a plurality of times, a shape regulating force is generated by a coil at an outer peripheral side portion of the portion other than the outermost periphery. Accordingly, the portion other than the outermost periphery has a relatively small spring back compared to the outermost periphery. On the other hand, since the outermost peripheral portion has nothing on the outer peripheral side, the shape regulating force by other members does not work. For this reason, the outermost peripheral portion may not be able to position the coil at a target position by the spring back. Therefore, at least a portion corresponding to the entire circumference of the outermost circumference in the main winding body is wound in a temporary winding process, so that a winding hook is attached to a portion corresponding to the entire outermost circumference of the main winding body. Can do. Therefore, it is possible to suppress the occurrence of springback over the entire outermost circumference of the winding body.

（手段４）手段２または３の固定子コイルの製造方法において、前記仮巻き取り工程は、前記第一芯部材の外周面に前記組み込み体を複数周巻き取るとよい。 (Means 4 ) In the method for manufacturing a stator coil according to means 2 or 3 , the temporary winding step may be performed by winding a plurality of the built-in bodies around the outer peripheral surface of the first core member.

手段４によれば、仮巻き取り工程において、複数周巻き取ることで、仮巻き取り体のうち最内周部位に対しては、その外周側部分のコイルによる形状規制力が生じる。従って、仮巻き取り体のうち最内周部位には、巻き取り癖が確実に形成される。ここで、仮巻き取り体のうち最内周部位は、本巻き取り体の最外周側に相当するため、本巻き取り体の最外周部位のスプリングバックを確実に抑制できる。 According to the means 4 , in the temporary winding process, a shape regulating force is generated by the coil on the outer peripheral side portion of the temporary winding body with respect to the innermost peripheral portion of the temporary winding body. Therefore, a winding rod is reliably formed in the innermost peripheral portion of the temporary winding body. Here, since the innermost peripheral portion of the temporary winding body corresponds to the outermost peripheral side of the main winding body, the spring back of the outermost peripheral portion of the main winding body can be reliably suppressed.

（手段５）手段２〜４の何れかの固定子コイルの製造方法において、前記仮巻き取り工程は、前記組み込み体全てを前記第一芯部材の外周面に巻き取るようにしてもよい。 (Means 5 ) In the method of manufacturing a stator coil according to any one of means 2 to 4 , the temporary winding step may wind up all the built-in bodies around the outer peripheral surface of the first core member.

手段５によれば、本巻き取り体における最内周部位にも、仮巻き取り工程において巻き取り癖が形成されることになる。これにより、本巻き取り体における内周側のコイルのスプリングバックが、本巻き取り体の最外周側への影響を小さくできる。つまり、本巻き取り体の形状を確実に維持できる。 According to the means 5 , a winding rod is also formed in the innermost peripheral part of the main winding body in the temporary winding process. Thereby, the spring back of the coil of the inner peripheral side in this winding body can make the influence on the outermost peripheral side of this winding body small. That is, the shape of this winding body can be maintained reliably.

（手段６）手段１〜５の何れかの固定子コイルの製造方法において、前記本巻き取り体は、前記第二芯部材の外周面に複数周巻き取られており、前記第一芯部材の外径は、前記本巻き取り体の最外周部位の内径より小さい径に設定されているとよい。 (Means 6 ) In the method of manufacturing a stator coil according to any one of means 1 to 5 , the main winding body is wound a plurality of times around the outer peripheral surface of the second core member. The outer diameter is preferably set to be smaller than the inner diameter of the outermost peripheral portion of the main winding body.

手段６によれば、仮巻き取り体の最内周部位の曲率半径が、本巻き取り体の最外周部位の曲率半径より小さくなる。従って、本巻き取り体の最外周部位が、径方向外方へのスプリングバックが生じることを抑制できる。 According to the means 6 , the radius of curvature of the innermost peripheral portion of the temporary winding body is smaller than the radius of curvature of the outermost peripheral portion of the main winding body. Therefore, it can suppress that the outermost peripheral part of this winding body produces the spring back to radial direction outward.

（手段７）手段６の固定子コイルの製造方法において、前記第二芯部材の外径は、前記第一芯部材の外径と同一に設定されているとよい。 (Means 7 ) In the stator coil manufacturing method of means 6 , the outer diameter of the second core member may be set to be the same as the outer diameter of the first core member.

手段７によれば、第一芯部材と第二芯部材と同一のものを利用できる。従って、製造装置の部品種点数を削減できる。 According to the means 7 , the same thing as a 1st core member and a 2nd core member can be utilized. Accordingly, it is possible to reduce the number of parts of the manufacturing apparatus.

（手段８）手段１〜７の何れかの固定子コイルの製造方法において、前記仮巻き取り工程は、押圧部材により、前記第一芯部材の外周面に巻き取られた前記仮巻き取り体のコイルエンド部の外周側から径方向内方に向かって押圧するようにしてもよい。 (Means 8 ) In the method of manufacturing a stator coil according to any one of means 1 to 7 , the temporary winding step is performed by the pressing member of the temporary winding body wound around the outer peripheral surface of the first core member. You may make it press toward the radial inside from the outer peripheral side of a coil end part.

手段８によれば、仮巻き取り工程において、仮巻き取り体に形成する巻き取り癖を、より効果的につけることができる。 According to the means 8 , in the temporary winding process, the winding rod formed on the temporary winding body can be more effectively applied.

以下、本発明の固定子コイルの製造方法を具体化した実施形態について図面を参照しつつ説明する。   DESCRIPTION OF EMBODIMENTS Hereinafter, an embodiment embodying a method for manufacturing a stator coil of the present invention will be described with reference to the drawings.

＜第一実施形態＞
まず、本実施形態の固定子コイルの製造方法により得られた固定子コイルを用いた回転電機１の構成について説明する。 <First embodiment>
First, the structure of the rotary electric machine 1 using the stator coil obtained by the stator coil manufacturing method of the present embodiment will be described.

この回転電機１は、図１に示されるように、略有底筒状の一対のハウジング部材１００、１０１が開口部同士で接合されてなるハウジング１０と、ハウジング１０に軸受け１１０、１１１を介して回転自在に支承された回転軸２０と、回転軸２０に固定された回転子２と、ハウジング１０の内部で回転子２を包囲する位置でハウジング１０に固定された固定子３と、を備えている。   As shown in FIG. 1, the rotating electrical machine 1 includes a housing 10 in which a pair of substantially bottomed cylindrical housing members 100 and 101 are joined at openings, and the housing 10 via bearings 110 and 111. A rotating shaft 20 rotatably supported, a rotor 2 fixed to the rotating shaft 20, and a stator 3 fixed to the housing 10 at a position surrounding the rotor 2 inside the housing 10. Yes.

回転子２は、永久磁石により周方向に交互に異なる磁極を、固定子３の内周側と向き合う外周側に複数形成している。回転子２の磁極の数は、回転電機により異なるため限定されるものではない。本実施形態では、８極（Ｎ極：４、Ｓ極：４）の回転子が用いられている。   The rotor 2 is formed with a plurality of magnetic poles that are alternately different in the circumferential direction by permanent magnets on the outer peripheral side facing the inner peripheral side of the stator 3. The number of magnetic poles of the rotor 2 is not limited because it varies depending on the rotating electric machine. In this embodiment, an 8-pole rotor (N pole: 4, S pole: 4) is used.

固定子３は、図２に示されるように、固定子コア３０と、複数の各相巻線から形成された三相の固定子コイル４と、固定子コア３０と固定子コイル４との間に配された絶縁紙５と、を備えた構成を有している。   As shown in FIG. 2, the stator 3 includes a stator core 30, a three-phase stator coil 4 formed of a plurality of phase windings, and between the stator core 30 and the stator coil 4. And an insulating paper 5 disposed on the surface.

固定子コア３０は、図３に示されるように、内周側に開口部を有する複数のスロット３１が形成された円環状を呈している。複数のスロット３１は、その深さ方向が径方向と一致するように形成されている。固定子コア３０に形成されたスロット３１の数は、回転子２の磁極数に対し、固定子コイル４の一相あたり２個の割合で形成されている。本実施形態では、８×３×２＝４８より、スロット数は４８個とされている。   As shown in FIG. 3, the stator core 30 has an annular shape in which a plurality of slots 31 having openings on the inner peripheral side are formed. The plurality of slots 31 are formed such that the depth direction thereof coincides with the radial direction. The number of slots 31 formed in the stator core 30 is formed at a ratio of two per one phase of the stator coil 4 with respect to the number of magnetic poles of the rotor 2. In this embodiment, since 8 × 3 × 2 = 48, the number of slots is 48.

固定子コア３０は、図４に示される分割コア３２を所定の数（本実施形態では、２４個）だけ周方向に連結して形成されている。分割コア３２は、一つのスロット３１を区画するとともに、周方向で隣接する分割コア３２との間で一つのスロット３１を区画する形状を呈している。具体的には、分割コア３２は、径方向内方に伸びる一対のティース部３２０と、ティース部３２０を径方向外方で連結するバックコア部３２１とを有している。   The stator core 30 is formed by connecting a predetermined number (24 in this embodiment) of the split cores 32 shown in FIG. 4 in the circumferential direction. The split core 32 has a shape in which one slot 31 is defined and one slot 31 is defined between the adjacent split cores 32 in the circumferential direction. Specifically, the split core 32 has a pair of teeth portions 320 that extend radially inward and a back core portion 321 that connects the teeth portions 320 radially outward.

固定子コア３０を構成する分割コア３２は、０．３ｍｍの厚さの電磁鋼坂４１０枚を積層させて形成されている。なお、積層された電磁鋼板の間には、絶縁薄膜が配置されている。固定子コア３０を構成する分割コア３２は、この電磁鋼板の積層体からだけでなく、従来公知の金属薄板及び絶縁薄膜を用いて形成してもよい。   The split core 32 constituting the stator core 30 is formed by laminating 410 electromagnetic steel hills having a thickness of 0.3 mm. An insulating thin film is disposed between the laminated electrical steel sheets. The split core 32 constituting the stator core 30 may be formed not only from the laminated body of electromagnetic steel sheets but also using a conventionally known metal thin plate and insulating thin film.

固定子コイル４は、複数の巻線４０を所定の巻回方法で巻回してなる。固定子コイル４を構成する巻線４０は、図５（Ａ）に示されるように、銅製の導体４１と、導体４１の外周を覆い導体４１を絶縁する内層４２０及び外層４２１からなる絶縁被膜４２とから形成されている。内層４２０及び外層４２１を合わせた絶縁被膜４２の厚みは、１００μｍ〜２００μｍの間に設定されている。このように、内層４２０及び外層４２１からなる絶縁被膜４２の厚みが厚いので、巻線４０同士を絶縁するために巻線４０同士の間に絶縁紙等を挟み込む必要がなくなっているが、巻線４０同士の間あるいは図２に示されるように固定子コア３０と固定子コイル４０との間に絶縁紙を配設してもよい。   The stator coil 4 is formed by winding a plurality of windings 40 by a predetermined winding method. As shown in FIG. 5A, the winding 40 constituting the stator coil 4 includes a copper conductor 41 and an insulating coating 42 made of an inner layer 420 and an outer layer 421 covering the outer periphery of the conductor 41 and insulating the conductor 41. And is formed from. The thickness of the insulating coating 42 including the inner layer 420 and the outer layer 421 is set between 100 μm and 200 μm. Thus, since the thickness of the insulating coating 42 composed of the inner layer 420 and the outer layer 421 is thick, it is not necessary to sandwich insulating paper or the like between the windings 40 in order to insulate the windings 40 from each other. Insulating paper may be disposed between the 40 or between the stator core 30 and the stator coil 40 as shown in FIG.

さらに、固定子コイル４の巻線４０は、図５（Ｂ）に示されるように、内層４２０及び外層４２１からなる絶縁被膜４２の外周をエポキシ樹脂等からなる融着材４８で被覆して形成してもよい。この場合、回転電機１に発生する熱により融着材４８が絶縁被膜４２よりも早く溶融するので、同じスロット３１に設置されている複数の巻線４０同士が融着材４８同士により熱接着する。その結果、同じスロット３１に設置されている複数の巻線４０が一体化し巻線４０同士が鋼体化することで、スロット３１内の巻線４０の機械的強度が向上する。   Further, as shown in FIG. 5B, the winding 40 of the stator coil 4 is formed by covering the outer periphery of the insulating coating 42 made of the inner layer 420 and the outer layer 421 with a fusion material 48 made of epoxy resin or the like. May be. In this case, the fusion material 48 is melted faster than the insulating coating 42 by the heat generated in the rotating electrical machine 1, so that the plurality of windings 40 installed in the same slot 31 are thermally bonded by the fusion material 48. . As a result, the plurality of windings 40 installed in the same slot 31 are integrated to form a steel body between the windings 40, so that the mechanical strength of the winding 40 in the slot 31 is improved.

固定子コイル４は、図６に示されるように、それぞれが２本の三相巻線（Ｕ１、Ｕ２、Ｖ１、Ｖ２、Ｗ１、Ｗ２）により形成されている。   As shown in FIG. 6, each of the stator coils 4 is formed by two three-phase windings (U1, U2, V1, V2, W1, W2).

固定子コイル４は、図７に示されるように、複数の巻線４０を所定の形状に巻回してなる。固定子コイル４を構成する巻線４０は、固定子コア３０の内周側で周方向に沿って波巻きされる形状で成形されている。   As shown in FIG. 7, the stator coil 4 is formed by winding a plurality of windings 40 into a predetermined shape. The winding 40 constituting the stator coil 4 is formed in a shape that is wave-wound along the circumferential direction on the inner peripheral side of the stator core 30.

固定子コイル４を構成する巻線４０は、固定子コア３０のスロット３１に収容される直線状のスロット収容部）４３と、隣り合ったスロット収容部４３同士を連結するコイルエンド部（「ターン部」とも称する）４４と、を備えている。スロット収容部４３は、所定のスロット数（本実施形態では、３相×２個＝６個）ごとのスロット３１に収容されている。ターン部４４は、固定子コア３０の軸方向の端面から突出して形成されている。   The winding 40 constituting the stator coil 4 includes a linear slot accommodating portion 43 accommodated in the slot 31 of the stator core 30 and a coil end portion (“turn”) that connects the adjacent slot accommodating portions 43 to each other. 44). The slot accommodating portions 43 are accommodated in the slots 31 for each predetermined number of slots (in this embodiment, 3 phases × 2 = 6). The turn portion 44 is formed so as to protrude from the end surface of the stator core 30 in the axial direction.

固定子コイル４は、複数の巻線４０の両端を固定子コア３０の軸方向の端面から突出させ、かつ複数の巻線４０を周方向に沿って波状に巻装した状態で形成されている。固定子コイル４の１相は、第１の巻線部４０ａと第２の巻線部４０ｂとの端部同士を溶接により接合して形成されている。すなわち、２本の電気導体線から成形した２つの成形体の端部同士を接合して形成された一つの組体から固定子コイル４の１相が形成されている。第１の巻線部４０ａのスロット収容部４３と第２の巻線部４０ｂのスロット収容部４３とは、同一スロット３１に収容される。このとき、第一の巻線部４０ａのスロット収容部４３と、第二の巻線部４０ｂのスロット収容部４３とは、スロット３１の深さ方向（径方向）で交互に位置するように設置されている。そして、第１の巻線部４０ａと第２の巻線部４０ｂとの接合部４５は、第１の巻線部４０ａと第２の巻線部４０ｂの巻装される方向が反転するスロット収容部４３よりなる折り返し部４６に形成されている。   The stator coil 4 is formed in a state in which both ends of the plurality of windings 40 protrude from the axial end face of the stator core 30 and the plurality of windings 40 are wound in a wave shape along the circumferential direction. . One phase of the stator coil 4 is formed by welding the ends of the first winding portion 40a and the second winding portion 40b together by welding. That is, one phase of the stator coil 4 is formed from one assembly formed by joining the ends of two molded bodies formed from two electric conductor wires. The slot accommodating portion 43 of the first winding portion 40a and the slot accommodating portion 43 of the second winding portion 40b are accommodated in the same slot 31. At this time, the slot accommodating portion 43 of the first winding portion 40a and the slot accommodating portion 43 of the second winding portion 40b are installed so as to be alternately positioned in the depth direction (radial direction) of the slot 31. Has been. And the joint part 45 of the 1st coil | winding part 40a and the 2nd coil | winding part 40b is the slot accommodation in which the winding direction of the 1st coil | winding part 40a and the 2nd coil | winding part 40b reverses. A folded portion 46 formed by the portion 43 is formed.

固定子コイル４の展開図、すなわち巻回される前の組み込み体４７の平面図が図８に示されるように、固定子コイル４は、互いに巻装方向が異なる第１の巻線部４０ａと第２の巻線部４０ｂとからなる組体を６組有し、６組の組体を用いて、３相（Ｕ，Ｖ，Ｗ）×２個（倍スロット）のコイルとされている。各組体において、第１の巻線部４０ａの中性点側（又は相端子側）の端部と反対側の端部と、第２の巻線部４０ｂの相端子側（又は中性点側）の端部と反対側の端部とが、折り返し部４６よりなるスロット収容部４３を介して接続されている。各相の巻線４０の結線方法は同様である。   As shown in FIG. 8 which is a development view of the stator coil 4, that is, a plan view of the assembled body 47 before being wound, the stator coil 4 includes the first winding portion 40a having different winding directions. Six sets of the second winding portion 40b are formed, and six sets of sets are used to form a three-phase (U, V, W) × 2 (double slot) coil. In each assembly, the end on the opposite side to the end on the neutral point side (or phase terminal side) of the first winding portion 40a, and the phase terminal side (or neutral point) of the second winding portion 40b Side end) and the opposite end are connected via a slot accommodating portion 43 formed of a folded portion 46. The method of connecting the windings 40 of each phase is the same.

以下、第一実施形態の固定子コイル４の製造方法について説明する。すなわち、固定子コイル４は、以下のようにして製造される。なお、以下の説明において、径方向は芯部材又は巻き取り体の径方向を意味し、周方向は芯部材又は巻き取り体の周方向を意味する。   Hereinafter, the manufacturing method of the stator coil 4 of 1st embodiment is demonstrated. That is, the stator coil 4 is manufactured as follows. In the following description, the radial direction means the radial direction of the core member or the wound body, and the circumferential direction means the circumferential direction of the core member or the wound body.

＜成形工程＞
まず、１２本の電気導体線から１２個の成形体を成形する。ここで成形する各成形体は、互いに平行に延びて成形体の長手方向に並列した複数の直状部（スロット収容部）４３１と、隣り合う直状部４３１同士を直状部４３１の一端側と他端側とで交互に連結する複数のターン部（コイルエンド部）４４１とを有する。 <Molding process>
First, 12 molded bodies are formed from 12 electric conductor wires. Each molded body to be molded here includes a plurality of straight portions (slot accommodating portions) 431 extending in parallel with each other and arranged in parallel in the longitudinal direction of the molded body, and adjacent straight portions 431 are connected to one end side of the straight portion 431. And a plurality of turn portions (coil end portions) 441 that are alternately connected on the other end side.

＜組み込み工程＞
１２個の成形体を組み込むことにより、組み込み体４７を形成する。この組み込み体４７においては、６組の組体が組み込み体４７の長手方向に並列している。各組体は、第１の巻線部４０ａとなる第１線部と、第２の巻線部４０ｂとなる第２線部とからなる。なお、第１線部が１個の成形体よりなり、第２線部も１個の成形体よりなる。各組体における第１線部の端部と第２線部の端部とが溶接接合されて接合部４５とされている。なお、１２個の成形体を組み込んでから、各組体における第１線部の端部と第２線部の端部とを接合してもよいし、第１線部の端部と第２線部の端部とを接合して６組の組体を形成してから、この６組の組体を組み込んでもよい。 <Incorporation process>
The built-in body 47 is formed by incorporating 12 molded bodies. In this built-in body 47, six sets of bodies are arranged in parallel in the longitudinal direction of the built-in body 47. Each assembly includes a first line portion that becomes the first winding portion 40a and a second line portion that becomes the second winding portion 40b. In addition, the 1st line part consists of one molded object, and the 2nd line part also consists of one molded object. The end portion of the first line portion and the end portion of the second line portion in each assembly are welded to form a joint portion 45. In addition, after assembling the twelve molded bodies, the end portion of the first line portion and the end portion of the second line portion in each assembly may be joined, or the end portion of the first line portion and the second portion. After joining the ends of the line portions to form six sets of assemblies, these six sets of assemblies may be incorporated.

組み込み体４７における各組体は、第１線部における複数の直状部４３１と第２線部における複数の直状部４３１とがそれぞれ重ね合わされて形成された複数の直状重ね合わせ部４７１を組み込み体４７の長手方向に有する。このように、組み込み体４７は、複数の成形体を組み込むことで帯状に形成されている。   Each assembly in the built-in body 47 includes a plurality of straight overlapping portions 471 formed by overlapping a plurality of straight portions 431 in the first line portion and a plurality of straight portions 431 in the second line portion. It is in the longitudinal direction of the built-in body 47. Thus, the built-in body 47 is formed in a belt shape by incorporating a plurality of molded bodies.

＜仮巻き取り工程＞
仮巻き取り工程について、図９（Ａ）（Ｂ）を参照して説明する。図９（Ａ）に示すように、帯状の組み込み体４７の長手方向の一端、具体的には組み込み体４７のうち端部が延出している側（折り返し部４６と反対側）から、第一芯部材５０の外周面に巻き取る。そして、図９（Ｂ）に示すように、全ての組み込み体４７を第一芯部材５０の外周面に巻き取って、仮巻き取り体５１を形成する。ここで、第一芯部材５０の外周面のうち組み込み体４７を巻き取る部位の軸方向断面形状は、半径Ｒの円形をなしている。つまり、仮巻き取り体５１は円筒状となり、仮巻き取り体５１の内径はＲとなる。そして、第一芯部材５０は、後述する本巻き取り工程において用いる第二芯部材６０と同一のものを用いている。つまり、第一芯部材５０の外径は、第二芯部材６０の外径と同一の半径Ｒとしている。また、本実施形態においては、仮巻き取り体５１は、４周巻回されている。従って、第一芯部材５０の外径は、後述する本巻き取り体６１の最外周部位の内径より小さい径に設定されている。なお、仮巻き取り体５１においては、折り返し部４６が最外周に位置している。 <Temporary winding process>
A temporary winding process is demonstrated with reference to FIG. 9 (A) (B). As shown in FIG. 9A, from the end in the longitudinal direction of the band-shaped built-in body 47, specifically, from the side where the end of the built-in body 47 extends (the side opposite to the folded portion 46), the first The core member 50 is wound around the outer peripheral surface. Then, as shown in FIG. 9B, all the built-in bodies 47 are wound around the outer peripheral surface of the first core member 50 to form a temporary winding body 51. Here, the axial cross-sectional shape of the portion of the outer peripheral surface of the first core member 50 where the built-in body 47 is wound has a circular shape with a radius R. That is, the temporary winding body 51 is cylindrical, and the inner diameter of the temporary winding body 51 is R. And the 1st core member 50 uses the same thing as the 2nd core member 60 used in the final winding process mentioned later. That is, the outer diameter of the first core member 50 is the same radius R as the outer diameter of the second core member 60. Moreover, in this embodiment, the temporary winding body 51 is wound 4 times. Accordingly, the outer diameter of the first core member 50 is set to be smaller than the inner diameter of the outermost peripheral portion of the main winding body 61 described later. In addition, in the temporary winding body 51, the folding | returning part 46 is located in the outermost periphery.

そして、図９（Ｂ）に示すように、組み込み体４７を第一芯部材５０の外周面に巻き取った状態において、３つのチャック（押圧部材）５２により、仮巻き取り体５１のうち両端のコイルエンド部に相当する部位の外周側から、径方向内方に向かって押圧される。これにより、仮巻き取り体５１のコイルエンド部に、第一芯部材５０の外周面に倣って巻き取り癖が付けられる。   Then, as shown in FIG. 9B, in the state where the built-in body 47 is wound around the outer peripheral surface of the first core member 50, the three chucks (pressing members) 52 are used to fix both ends of the temporary winding body 51. It is pressed radially inward from the outer peripheral side of the portion corresponding to the coil end portion. Thereby, a winding rod is attached to the coil end portion of the temporary winding body 51 along the outer peripheral surface of the first core member 50.

＜本巻き取り工程＞
仮巻き取り工程の後に、本巻き取り工程を行う。本巻き取り工程について、図９（Ｃ）（Ｄ）を参照して説明する。図９（Ｃ）に示すように、第一芯部材５０に巻回されている仮巻き取り体５１を、第二芯部材６０の外周面に巻き取る。具体的には、帯状の組み込み体４７の長手方向の他端、具体的には仮巻き取り体５１のうち最外周に位置する折り返し部４６側から、第二芯部材６０の外周面に巻き取る。そして、図９（Ｄ）に示すように、全ての仮巻き取り体５１を第二芯部材６０の外周面に巻き取って、図７に示す本巻き取り体６１（固定子コイル４に相当する。）を形成する。ここで、第二芯部材６０の外周面のうち組み込み体４７を巻き取る部位の軸方向断面形状は、第一芯部材６０の外周面と同一の半径Ｒの円形をなしている。つまり、仮巻き取り体５１は円筒状となり、仮巻き取り体５１の内径はＲとなる。本実施形態においては、本巻き取り体６１は、４周巻回されている。なお、本巻き取り体６１においては、折り返し部４６が最内周に位置し、組み込み体４７のうち端部が延出している側が最外周に位置する。 <Main winding process>
After the temporary winding process, the main winding process is performed. The main winding process will be described with reference to FIGS. As shown in FIG. 9C, the temporary winding body 51 wound around the first core member 50 is wound around the outer peripheral surface of the second core member 60. Specifically, the belt-shaped built-in body 47 is wound around the outer peripheral surface of the second core member 60 from the other end in the longitudinal direction, specifically, from the side of the folded portion 46 located on the outermost periphery of the temporary winding body 51. . 9D, all the temporary winding bodies 51 are wound around the outer peripheral surface of the second core member 60 and correspond to the main winding body 61 (corresponding to the stator coil 4) shown in FIG. .). Here, of the outer peripheral surface of the second core member 60, the axial cross-sectional shape of the portion where the built-in body 47 is wound is a circle having the same radius R as the outer peripheral surface of the first core member 60. That is, the temporary winding body 51 is cylindrical, and the inner diameter of the temporary winding body 51 is R. In the present embodiment, the main winding body 61 is wound four times. In addition, in this winding body 61, the folding | returning part 46 is located in an innermost periphery, and the side in which the edge part has extended among the built-in bodies 47 is located in an outermost periphery.

このとき、本巻き取り体６１は、一つの組体における複数の直状重ね合わせ部４７１が径方向に巻数分だけ積層されて形成された複数の直状積層部６１１を本巻き取り体６１の周方向に有する。各直状積層部６１１においては、巻数の２倍の数の直状部４３１が重ね合わされて径方向（放射方向）に一列に並んでいる。このとき、各直状積層部６１１は、本巻き取り体６１の周方向で小間隔を隔てた状態で位置している。   At this time, the main winding body 61 includes a plurality of straight laminated portions 611 formed by laminating a plurality of straight overlapping portions 471 in one assembly by the number of turns in the radial direction. Have in the circumferential direction. In each of the straight stacked portions 611, the number of the straight portions 431 that is twice the number of turns is overlapped and aligned in a row in the radial direction (radial direction). At this time, the respective straight laminated portions 611 are located in a state of being spaced apart in the circumferential direction of the main winding body 61.

こうして得られた本巻き取り体６１に対して、径方向外方から分割コア３２のティース部３２０を隣り合う直状積層部６１１同士の間の隙間に挿入し、隣り合う分割コア３２同士を連結して固定子３とする。   With respect to the main winding body 61 obtained in this way, the teeth 320 of the split core 32 is inserted into the gap between the adjacent straight laminated portions 611 from the outside in the radial direction, and the adjacent split cores 32 are connected to each other. Thus, the stator 3 is obtained.

以上説明したように、固定子コイル４を製造することにより、以下の効果を奏する。上記の製造方法は、固定子コイル４を最終的な形状とするための本巻き取り工程の前に、仮巻き取り工程を行っている。つまり、帯状の組み込み体４７に対してまず仮巻き取り工程を行うことで、仮巻き取り工程により得られた仮巻き取り体５１は、ほぼ平面状である帯状の組み込み体４７を、ある程度の湾曲した形状とすることができる。すなわち、コイルエンド部４４に相当する部位に巻き取り癖をつけることができる。従って、この状態から、本巻き取り工程を行って本巻き取り体６１を形成することで、本巻き取り体６１の最外周端部にコイルエンド部４４によるスプリングバックが生じることを抑制できる。その結果、接着剤を塗布することなく、本巻き取り体６１（固定子コイル４に相当）の形状を維持することができる。   As described above, the following effects are produced by manufacturing the stator coil 4. In the above manufacturing method, the temporary winding process is performed before the main winding process for making the stator coil 4 into a final shape. In other words, by first performing a temporary winding process on the band-shaped built-in body 47, the temporary winding body 51 obtained by the temporary winding process causes the band-shaped built-in body 47 to be curved to a certain extent. The shape can be made. That is, a winding hook can be attached to a portion corresponding to the coil end portion 44. Therefore, from this state, by performing the main winding process to form the main winding body 61, it is possible to suppress the occurrence of springback due to the coil end portion 44 at the outermost peripheral end portion of the main winding body 61. As a result, the shape of the main winding body 61 (corresponding to the stator coil 4) can be maintained without applying an adhesive.

また、仮巻き取り工程では、組み込み体４７の全てを第一芯部材５０の外周面に巻き取るようにしている。すなわち、仮巻き取り工程では、組み込み体４７の少なくとも長手方向の一端部（折り返し部４６と反対側）を、第一芯部材５０の外周面に巻き取っている。ここで、仮巻き取り工程において少なくとも巻き取られる当該長手方向の一端部（折り返し部４６と反対側部分）が、本巻き取り工程において最外周端部となる。つまり、仮巻き取り工程にて確実に巻き取り癖のつけられる当該長手方向の一端部が、本巻き取り工程にて最外周端部となるため、最外周端部のスプリングバックを確実に抑制できる。   Further, in the temporary winding process, all the built-in body 47 is wound on the outer peripheral surface of the first core member 50. In other words, in the temporary winding process, at least one end portion of the built-in body 47 in the longitudinal direction (the side opposite to the folded portion 46) is wound around the outer peripheral surface of the first core member 50. Here, at least one end portion in the longitudinal direction (a portion on the side opposite to the folded-back portion 46) wound in the temporary winding step becomes the outermost peripheral end portion in the main winding step. That is, since the one end portion in the longitudinal direction to which the winding rod is reliably attached in the temporary winding step becomes the outermost peripheral end portion in the final winding step, the springback at the outermost peripheral end portion can be reliably suppressed. .

さらに、仮巻き取り工程で組み込み体４７の全てを第一芯部材５０の外周面に巻き取るということは、仮巻き取り工程は、少なくとも本巻き取り体６１における最外周全周に相当する部位を、第一芯部材５０の外周面に巻き取ることになる。ここで、本巻き取り体６１が複数周巻き取られる場合に、最外周以外の部位に対しては、当該部位の外周側部分のコイルによる形状規制力が生じる。従って、本巻き取り体６１の最外周以外の部位は、最外周部位に比べて、比較的スプリングバックが小さい。これに対して、本巻き取り体６１の最外周部位は、その外周側には何も存在しないため、他の部材による形状規制力が働かない。そのため、本巻き取り体６１の最外周部位は、スプリングバックにより目的の位置にコイルを位置決めすることができないおそれがある。そこで、少なくとも、本巻き取り体における最外周全周に相当する部位を、仮巻き取り工程にて巻き取ることで、本巻き取り体６１の最外周全周に相当する部位に巻き取り癖をつけることができる。従って、本巻き取り体６１の最外周全周に亘って、スプリングバックが生じることを抑制できる。   Furthermore, winding all of the built-in body 47 around the outer peripheral surface of the first core member 50 in the temporary winding process means that the temporary winding process includes at least a portion corresponding to the entire outer circumference of the main winding body 61. The first core member 50 is wound around the outer peripheral surface. Here, when the main winding body 61 is wound a plurality of times, a shape regulating force is generated by a coil on an outer peripheral side portion of the portion other than the outermost periphery. Accordingly, the portion other than the outermost periphery of the winding body 61 has a relatively small spring back compared to the outermost periphery. On the other hand, since the outermost peripheral portion of the winding body 61 does not exist on the outer peripheral side, the shape regulating force by other members does not work. Therefore, the outermost peripheral part of the main winding body 61 may not be able to position the coil at a target position due to the spring back. Therefore, at least a portion corresponding to the entire outermost circumference of the main winding body is wound in the temporary winding process, so that a winding rod is attached to a portion corresponding to the entire outermost periphery of the main winding body 61. be able to. Therefore, it is possible to suppress the occurrence of spring back over the entire outermost circumference of the winding body 61.

さらに、仮巻き取り工程で組み込み体４７の全てを第一芯部材５０の外周面に巻き取るということは、仮巻き取り工程では、第一芯部材５０の外周面に組み込み体４７を複数周巻き取ることになる。このように、仮巻き取り工程において、複数周巻き取ることで、仮巻き取り体５１のうち最内周部位に対しては、その外周側部分のコイルによる形状規制力が生じる。従って、仮巻き取り体５１のうち最内周部位には、巻き取り癖が確実に形成される。ここで、仮巻き取り体５１のうち最内周部位は、本巻き取り体６１の最外周側に相当するため、本巻き取り体６１の最外周部位のスプリングバックを確実に抑制できる。   Furthermore, winding all of the assembled body 47 around the outer peripheral surface of the first core member 50 in the temporary winding process means that the embedded body 47 is wound around the outer peripheral surface of the first core member 50 in the temporary winding process. Will take. In this way, in the temporary winding process, a shape regulating force is generated by the coil on the outer peripheral side portion of the temporary winding body 51 with respect to the innermost peripheral portion by winding a plurality of times. Therefore, a winding rod is reliably formed in the innermost peripheral portion of the temporary winding body 51. Here, since the innermost peripheral portion of the temporary winding body 51 corresponds to the outermost peripheral side of the main winding body 61, the spring back of the outermost peripheral portion of the main winding body 61 can be reliably suppressed.

さらに、仮巻き取り工程で組み込み体４７の全てを第一芯部材５０の外周面に巻き取ることで、本巻き取り体６１における最内周部位にも、仮巻き取り工程において巻き取り癖が形成されることになる。これにより、本巻き取り体６１における内周側のコイルのスプリングバックが、本巻き取り体６１の最外周側への影響を小さくできる。つまり、本巻き取り体６１の形状を確実に維持できる。   Further, by winding all of the built-in body 47 on the outer peripheral surface of the first core member 50 in the temporary winding process, a winding rod is also formed in the innermost peripheral portion of the main winding body 61 in the temporary winding process. Will be. Thereby, the spring back of the coil on the inner peripheral side of the main winding body 61 can reduce the influence on the outermost peripheral side of the main winding body 61. That is, the shape of the main winding body 61 can be reliably maintained.

また、第一芯部材５０の外径と第二芯部材６０の外径とは同一である。第一芯部材５０の外径は、本巻き取り体６１の最外周部位の内径より小さい径に設定されていることになる。これにより、仮巻き取り体５１の最内周部位の曲率半径が、本巻き取り体６１の最外周部位の曲率半径より小さくなる。従って、本巻き取り体６１の最外周部位が、径方向外方へのスプリングバックが生じることを抑制できる。さらに、第一、第二芯部材５０、６０を同一とすることで、両者を同一のものを用いることができる。従って、製造装置の部品種点数を削減できる。   Further, the outer diameter of the first core member 50 and the outer diameter of the second core member 60 are the same. The outer diameter of the first core member 50 is set to be smaller than the inner diameter of the outermost peripheral portion of the main winding body 61. Thereby, the curvature radius of the innermost peripheral part of the temporary winding body 51 becomes smaller than the curvature radius of the outermost peripheral part of the main winding body 61. Therefore, it is possible to suppress the outermost peripheral portion of the winding body 61 from causing springback outward in the radial direction. Furthermore, by making the first and second core members 50 and 60 the same, the same can be used for both. Accordingly, it is possible to reduce the number of parts of the manufacturing apparatus.

さらに、仮巻き取り工程において、チャック（押圧部材）５２により、第一芯部材５０の外周面に巻き取られた仮巻き取り体５１のコイルエンド部４４の外周側から径方向内方に向かって押圧するようにしている。これにより、仮巻き取り工程において、仮巻き取り体５１に形成する巻き取り癖を、より効果的につけることができる。   Furthermore, in the temporary winding process, the chuck (pressing member) 52 is directed radially inward from the outer peripheral side of the coil end portion 44 of the temporary winding body 51 wound around the outer peripheral surface of the first core member 50. I try to press it. Thereby, in a temporary winding process, the winding rod formed in the temporary winding body 51 can be attached more effectively.

＜その他＞
上記実施形態において、第一芯部材５０と第二芯部材６０とは、同一のものとしたが、これに限られるものではない。ただし、第一芯部材５０の外径が、本巻き取り体６１の最外周部位の内径より小さい径に設定されているとよい。 <Others>
In the said embodiment, although the 1st core member 50 and the 2nd core member 60 were made the same, it is not restricted to this. However, the outer diameter of the first core member 50 is preferably set to a diameter smaller than the inner diameter of the outermost peripheral portion of the main winding body 61.

さらに、仮巻き取り工程において、組み込み体４７の全てを第一芯部材５０の外周面に巻き取るようにしたが、これに限られるものではない。他に、組み込み体４７の長手方向の一端部（折り返し部４６と反対側）のみを第一芯部材５０の外周面に巻き取るようにしてもよい。また、仮巻き取り工程において、本巻き取り体６１における最外周全周に相当する部位のみを、第一芯部材５０の外周面に巻き取るようにしてもよい。また、仮巻き取り工程において、第一芯部材５０の外周面に組み込み体４７全てではなく、その一部を複数周巻き取るようにしてもよい。これらの場合には、それぞれによる効果を奏する。   Furthermore, in the provisional winding process, all of the built-in body 47 is wound around the outer peripheral surface of the first core member 50. However, the present invention is not limited to this. In addition, only one end portion in the longitudinal direction of the built-in body 47 (the side opposite to the folded portion 46) may be wound around the outer peripheral surface of the first core member 50. In the temporary winding process, only the portion corresponding to the entire outer periphery of the main winding body 61 may be wound on the outer peripheral surface of the first core member 50. In addition, in the temporary winding process, a part of the built-in body 47 may be wound around the outer peripheral surface of the first core member 50 instead of the entire periphery. In these cases, there is an effect by each.

また、仮巻き取り工程において、チャック５２の代わりに、ホースバンドなどを利用することもできる。もちろん、仮巻き取り工程において、チャック５２などの押圧部材を用いないことも可能である。第一芯部材５０の外径と第二芯部材６０の外径との関係、巻線４０の曲げ剛性などにより、仮巻き取り工程における巻き取り癖の付き具合によって適宜調整する。   Further, in the temporary winding process, a hose band or the like can be used instead of the chuck 52. Of course, it is possible not to use a pressing member such as the chuck 52 in the temporary winding process. Depending on the relationship between the outer diameter of the first core member 50 and the outer diameter of the second core member 60, the bending rigidity of the winding 40, and the like, it is adjusted as appropriate according to the degree of the winding rod in the temporary winding process.

回転電機の構成を模式的に示す軸方向断面図である。It is an axial direction sectional view showing typically the composition of a rotary electric machine. 固定子の平面図である。It is a top view of a stator. 固定子コアの平面図である。It is a top view of a stator core. 分割積層コアの平面図である。It is a top view of a division | segmentation laminated core. 固定子コイルを構成する巻線の断面図である。It is sectional drawing of the coil | winding which comprises a stator coil. 固定子コイルの結線を示す図である。It is a figure which shows the connection of a stator coil. 固定子コイルとなる巻き取り体の斜視図である。It is a perspective view of the winding body used as a stator coil. 固定子コイルの展開図であり、組み込み体の平面図である。It is an expanded view of a stator coil, and is a top view of a built-in body. 仮巻き取り工程および本巻き取り工程の状態遷移図である。It is a state transition diagram of a temporary winding process and a main winding process.

符号の説明Explanation of symbols

１：回転電機
３：固定子、 ３０：固定子コア、 ３１ａ、３１ｂ：スロット
４：固定子コイル、 ４３：スロット収容部、 ４４：コイルエンド部（ターン部）
４７：組み込み体
５０：第一芯部材、 ５１：仮巻き取り体、 ５２：チャック
６０：第二芯部材、 ６１：本巻き取り体 1: rotating electrical machine 3: stator, 30: stator core, 31a, 31b: slot 4: stator coil, 43: slot accommodating part, 44: coil end part (turn part)
47: Built-in body 50: First core member 51: Temporary winding body 52: Chuck 60: Second core member 61: Main winding body

Claims (8)

固定子コアのスロットに収容されるスロット収容部、および、隣り合った前記スロット収容部を連結し前記固定子コアの両端面からそれぞれ突出するコイルエンド部を備える固定子コイルの製造方法であって、
電気導体線から複数の成形体を成形する成形工程と、
複数の前記成形体を組み込んで帯状の組み込み体を形成する組み込み工程と、
前記組み込み体を帯状の前記組み込み体の長手方向の一端から第一芯部材の外周面に巻き取って仮巻き取り体を形成する仮巻き取り工程と、
前記仮巻き取り体を前記組み込み体の長手方向の他端から第二芯部材の外周面に巻き取って、前記固定子コイルである本巻き取り体を形成する本巻き取り工程と、
を備えることを特徴とする固定子コイルの製造方法。 A stator coil manufacturing method comprising: a slot accommodating portion that is accommodated in a slot of a stator core; and a coil end portion that connects the adjacent slot accommodating portions and projects from both end faces of the stator core. ,
A molding step of molding a plurality of molded bodies from electrical conductor wires;
An assembling step of incorporating a plurality of the molded bodies to form a strip-shaped assembling body;
A temporary winding step of winding the built-in body from one end in the longitudinal direction of the belt-shaped built-in body onto the outer peripheral surface of the first core member to form a temporary wound body;
A main winding step of winding the temporary winding body from the other end in the longitudinal direction of the built-in body onto the outer peripheral surface of the second core member to form a main winding body that is the stator coil;
The manufacturing method of the stator coil characterized by the above-mentioned. 前記仮巻き取り工程は、前記組み込み体の少なくとも前記長手方向の一端部を、前記第一芯部材の外周面に巻き取る請求項１に記載の固定子コイルの製造方法。 The method of manufacturing a stator coil according to claim 1 , wherein the temporary winding step winds at least one end portion in the longitudinal direction of the built-in body around the outer peripheral surface of the first core member. 前記本巻き取り体は、前記第二芯部材の外周面に複数周巻き取られており、
前記仮巻き取り工程は、少なくとも前記本巻き取り体における最外周全周に相当する部位を、前記第一芯部材の外周面に巻き取る請求項２に記載の固定子コイルの製造方法。 The main winding body is wound around the outer peripheral surface of the second core member a plurality of times,
The method of manufacturing a stator coil according to claim 2 , wherein the temporary winding step winds at least a portion corresponding to the entire outer periphery of the main winding body around the outer peripheral surface of the first core member. 前記仮巻き取り工程は、前記第一芯部材の外周面に前記組み込み体を複数周巻き取る請求項２または３に記載の固定子コイルの製造方法。 The said temporary winding process is a manufacturing method of the stator coil of Claim 2 or 3 which winds up the said integration body several times around the outer peripheral surface of said 1st core member. 前記仮巻き取り工程は、前記組み込み体全てを前記第一芯部材の外周面に巻き取る請求項２〜４の何れか一項に記載の固定子コイルの製造方法。 The said temporary winding process is a manufacturing method of the stator coil as described in any one of Claims 2-4 which winds up all the said integration bodies on the outer peripheral surface of said 1st core member. 前記本巻き取り体は、前記第二芯部材の外周面に複数周巻き取られており、
前記第一芯部材の外径は、前記本巻き取り体の最外周部位の内径より小さい径に設定されている請求項１〜５の何れか一項に記載の固定子コイルの製造方法。 The main winding body is wound around the outer peripheral surface of the second core member a plurality of times,
The method for manufacturing a stator coil according to any one of claims 1 to 5 , wherein an outer diameter of the first core member is set to be smaller than an inner diameter of an outermost peripheral portion of the main winding body. 前記第二芯部材の外径は、前記第一芯部材の外径と同一に設定されている請求項６に記載の固定子コイルの製造方法。 The method for manufacturing a stator coil according to claim 6 , wherein an outer diameter of the second core member is set to be the same as an outer diameter of the first core member. 前記仮巻き取り工程は、押圧部材により、前記第一芯部材の外周面に巻き取られた前記仮巻き取り体のコイルエンド部の外周側から径方向内方に向かって押圧する請求項１〜７の何れか一項に記載の固定子コイルの製造方法。 The said temporary winding process presses radially inward from the outer peripheral side of the coil end part of the said temporary winding body wound up by the outer peripheral surface of said 1st core member with a press member . The method for manufacturing a stator coil according to claim 7 .
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