JP5533474B2 - Stator for rotating electric machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a stator of a rotating electrical machine used as an electric motor or a generator in a vehicle, for example, and a method for manufacturing the same.

  Conventionally, as a stator of a rotating electric machine used in a vehicle, an annular stator core having a plurality of slots in the circumferential direction and a wire wound around the stator core, a part of which is formed in the slot There is known one provided with a stator winding that is installed in a state where a plurality of wires are stacked. Various proposals have been made for a rotating electrical machine including such a stator in order to prevent the stator core and the wire from moving relatively due to vibration during operation.

  For example, Patent Document 1 discloses a technique for impregnating the inside of the slot and drying and hardening it by immersing the entire stator in an impregnation tank for the purpose of fixing the wire and the core so as not to move relatively. Yes.

JP 2006-262541 A

  However, in the case of the above-mentioned Patent Document 1, since it is necessary to remove the impregnating material adhering to unnecessary places such as the outer periphery of the stator core, the material cost and the man-hour are increased and the cost is increased.

  Therefore, in order to tightly fix the wire and the stator core in the slot, it is conceivable that the impregnating material is dropped from the slot opening side on the inner peripheral side of the stator. However, in that case, the impregnating material does not always reliably penetrate and fix the wire and the stator core in the innermost part (outermost layer) of the slot. On the other hand, there are a plurality of wire rods that are at the back of the slot, which are terminal wires, that is, output wires, neutral point joining wires, and the like. Since these terminal wires are exposed to a larger vibration environment than the other layers of wires integrated with the stator core, it is necessary to ensure the fixation with the stator core.

  The present invention has been made in view of the above circumstances, and a rotating electrical machine capable of realizing cost reduction by suppressing the application of impregnating material to unnecessary portions while allowing the wire material to be a terminal wire to be securely fixed. It is a problem to be solved to provide a stator and a manufacturing method thereof.

The invention according to claim 1, which has been made to solve the above problems, includes an annular stator core having a plurality of slots in the circumferential direction, and a plurality of wires wound around the slots of the stator core. A stator winding that is formed and includes a stator winding in which a terminal wire serving as an output line or a neutral point joining line is present in the outermost layer of the wire that is arranged in the core radial direction in the slot. The wire rod is a rectangular wire having a rectangular cross-section in a direction perpendicular to the extending direction, and at least the wire rod serving as the terminal wire among the wire rods installed in the slot is bent into a U-shape. Other than the wire rod fixed to the stator core by the fixing material sheet disposed between the stator core and the stator core along the three outer surfaces of the slot accommodating portion of the wire rod. Less of wire Also the innermost layer of the wire is characterized in that it is fixed to the stator core by impregnation material dropped on the slot opening from the inner peripheral side of the stator core.

  According to the first aspect of the present invention, at least the wire used as the terminal wire among the wires installed in the slot is fixed to the stator core (slot peripheral wall surface) by the fixing material sheet disposed between the stator core. ), The wire that becomes a terminal wire that is easily affected by vibration due to coupling with other wire, that is, the portion that cannot be reliably fixed by liquid impregnation, can be securely fixed to the stator core. Further, the creepage distance between the wire and the stator core can be sufficiently maintained.

  According to the present invention, among the wires other than the wires fixed by the fixing material sheet, at least the innermost layer of the wires is fixed by the impregnating material dropped into the slot opening from the inner peripheral side of the stator core. As a result, it is possible to reliably fix the wire in the innermost layer of the slot, that is, the wire that may interfere with the rotor, while suppressing the application of the impregnating material to unnecessary portions.

  Furthermore, according to the configuration of the present invention, the amount of the fixing material sheet can be minimized by using the fixing material sheet and the liquid impregnation together. In comparison, cost can be reduced.

  In the present invention, a thermoplastic resin or a thermosetting resin can be employed as the fixing material for forming the fixing material sheet. Examples of the thermoplastic resin include PET, PPS, PEN, and the like. Examples of the thermosetting resin include epoxy and polyester. These fixing materials preferably have thermal expansibility. Since the fixing material is thermally expanded, a gap between the facing surfaces of the wire and the stator core in the slot can be filled, so that a fixing failure between the wire and the stator core can be avoided. As the fixing material having thermal expansibility, for example, a thermoplastic resin such as acrylic mixed with gas encapsulated beads can be suitably used. The fixing material sheet may have an insulating material layer in an intermediate portion in the thickness direction. Moreover, as an impregnating material, an epoxy resin, a polyester resin, an acrylic resin, or the like can be suitably used.

The invention according to claim 2, wherein the wire is characterized by being arranged a row in the core radially in front Symbol the slot.

  According to the second aspect of the present invention, the rectangular wires are arranged in a row in the slot, so that the three surfaces of the outermost rectangular wires that are the terminal wires are evenly fixed with the fixing material sheet. be able to. Therefore, the outermost layer wire (square wire) that becomes the terminal wire can be reliably fixed by the stator core.

  The invention according to claim 3 is characterized in that an insulating sheet is disposed between the wire core fixed by the impregnating material in the slot and the stator core.

  According to the invention described in claim 3, since the insulating sheet is disposed between the wire core fixed by the impregnating material in the slot and the stator core, the wire material is also fixed at the fixing portion by liquid impregnation. The creepage distance in the stator core can be kept sufficiently.

  The invention according to claim 4 is characterized in that the insulating sheet used for the wire rod other than the wire rod used for the wire rod used as the terminal wire and the wire rod used for the fixing material sheet. It is characterized by being arranged in combination.

  According to the invention described in claim 4, between the stator core and the stator windings installed in a state in which a plurality of stator cores are arranged in the slot, the fixing material sheet used for the required fixing portion, and the others By combining with the insulating sheet used in this part, the usage amount of the fixing material sheet can be minimized, and the cost can be reduced.

  The invention according to claim 5 is characterized in that the insulating sheet is used for the wire on the inner diameter side in the slot.

  According to the fifth aspect of the present invention, the insulating sheet is used for the wire on the inner diameter side in the slot, so that when the slot accommodating portion of the wire is inserted into the slot of the stator core, the winding of the fixing material sheet is performed. It is possible to prevent breakage due to intrusion and to suppress the occurrence of poor fixing of the wire.

  The invention according to claim 6 is characterized in that the fixing material sheet is arranged in a state in which both end portions protrude outward from both axial end surfaces of the stator core.

  According to the sixth aspect of the present invention, the gap between the wire disposed in the outermost layer in the slot and the peripheral wall surface of the slot is filled, and the impregnating material leaks to the end surface of the stator core where the impregnating material cannot be adhered. That can be suppressed.

  According to the seventh aspect of the present invention, a cylindrical stator winding is produced by using a plurality of wires so that the slot accommodating portions of the plurality of wires accommodated in the same slot of the stator core are aligned in the core radial direction. A stator winding manufacturing step, and a fixing material sheet for at least the wire that becomes a terminal wire among the plurality of slot accommodating portions arranged in the core radial direction, or a predetermined portion of a corresponding peripheral wall surface of the slot A fixing material sheet arranging step, an assembling step of assembling the stator winding and the stator core so that the slot accommodating portion is accommodated in the predetermined slot, and the fixing material sheet. An adhering material sheet adhering step for adhering at least the slot accommodating portion of the wire to be a terminal wire to the peripheral wall surface of the slot; and an impregnation material is dropped from the inner peripheral side of the stator core to the slot opening. And, characterized by having a a impregnant fixing step of fixing the slot circumferential wall by the wire other than the wire that is fixed by the adhesive sheet wherein the impregnant.

  According to the seventh aspect of the present invention, there is provided a stator for a rotating electrical machine capable of realizing cost reduction by suppressing application of an impregnating material to an unnecessary portion while ensuring that a wire serving as a terminal wire can be firmly fixed. It can be manufactured easily.

  According to an eighth aspect of the present invention, an insulating sheet is provided between the wire other than the wire fixed by the fixing material sheet in the slot and the peripheral wall surface of the slot before or after the fixing material sheet arranging step. It has the insulating sheet arrangement | positioning process to arrange | position, It is characterized by the above-mentioned.

  According to the invention described in claim 8, by performing the insulating sheet arrangement step, the creepage distance between the wire and the stator core is sufficiently maintained not only at the fixing portion by the fixing material sheet but also at the fixing portion by liquid impregnation. It is possible to manufacture a stator that can be used.

1 is an overall perspective view of a stator of a rotating electrical machine according to an embodiment. It is a side view of the stator of the rotary electric machine which concerns on embodiment. It is a fragmentary perspective view which expands and shows the terminal line part of the stator which concerns on embodiment. It is a fragmentary perspective view which expands and shows a part of stator which concerns on embodiment. It is a top view of the stator core used in embodiment. It is a top view of the division | segmentation core used in embodiment. 1 is an overall perspective view of a stator winding according to an embodiment. It is a front view which shows the coil end of the stator winding | coil used in embodiment. It is a front view which shows the whole shape of the wire used in embodiment. (A) is sectional drawing of the wire used in embodiment, (B) is sectional drawing of the wire which concerns on other embodiment. It is a perspective view which shows the shape of the turn part of the wire used in embodiment. It is explanatory drawing which shows typically the adhering state of the wire installed in the slot in embodiment. It is a fragmentary sectional view of the adhering material sheet used in the embodiment. It is a connection diagram of a stator winding used in the embodiment. It is explanatory drawing explaining the manufacturing method of the stator which concerns on embodiment, Comprising: (A) And (B) is explanatory drawing of a fixing material sheet arrangement | positioning process, (C) is explanatory drawing of an assembly | attachment process. It is explanatory drawing which shows typically the use condition of the adhesive material sheet which concerns on other embodiment. It is explanatory drawing which shows the impregnating material adhering process of the manufacturing method of the stator which concerns on embodiment.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a stator for a rotating electrical machine according to the present invention will be specifically described with reference to FIGS. It should be noted that the present invention should not be construed as being limited to the following embodiments, and it is a matter of course that the technical idea of the present invention may be realized by a combination of other known techniques.

  FIG. 1 is a perspective view showing an appearance of a stator 10 of a rotating electrical machine according to the embodiment, and FIG. 2 is a side view of the stator 10. FIG. 3 is an enlarged partial perspective view showing the terminal line portion of the stator 10. FIG. 4 is an enlarged partial perspective view showing a part of the stator 10.

  The stator 10 shown in FIGS. 1 and 2 is used, for example, in a rotating electric machine as a motor generator that also serves as a motor and a generator of a vehicle. Of course, the rotating electrical machine may be an electric motor or a generator mounted on a vehicle.

  The stator 10 rotatably accommodates a rotor (not shown) on the inner peripheral side. The rotor is formed with a plurality of magnetic poles having different magnetism alternately in the circumferential direction by a permanent magnet on the outer peripheral side facing the inner peripheral side of the stator 10. The number of magnetic poles of the rotor is not limited because it varies depending on the rotating electrical machine, and in this embodiment, an 8-pole (N pole: 4, S pole: 4) rotor is used.

  The stator 10 of the present embodiment includes a stator core 20 and a three-phase stator winding 40 formed from a plurality of wires 30. As shown in FIG. 4, the stator core 20 is formed with a plurality of sets of slots in the circumferential direction on the inner circumferential side of the stator core 20, with a pair of slots 21 a and 21 b adjacent in the circumferential direction along the axial direction. ing. The stator winding 40 is a three-phase winding, and stator windings for each phase are installed in a pair of slots 21a and 21b adjacent in the circumferential direction. Then, stator windings of different phases are installed in three sets of slots 21a and 21b adjacent in the circumferential direction with the slots 21a and 21b as a set.

  As shown in FIG. 5, the stator core 20 has an annular shape in which a plurality of slots 21 are formed on the inner periphery. The plurality of slots 21 are formed such that the depth direction thereof coincides with the radial direction. The number of slots 21 formed in the stator core 20 is formed at a ratio of two per one phase of the stator winding 40 with respect to the number of magnetic poles of the rotor. In this embodiment, since 8 × 3 × 2 = 48, the number of slots is 48.

  The stator core 20 is formed in an annular shape by connecting a predetermined number (24 in this embodiment) of the split cores 22 shown in FIG. 6 in the circumferential direction. These divided cores 22 are fixed by an outer cylinder 27 fitted on the outer periphery in a state of being connected in an annular shape. The divided core 22 has a shape that divides one slot 21 and divides one slot 21 between adjacent divided cores 22 in the circumferential direction. Specifically, the split core 22 has a pair of teeth portions 23 that extend radially inward, and a back core portion 24 that connects the teeth portions 23 radially outward.

  The split core 22 constituting the stator core 20 is formed by laminating a plurality of electromagnetic steel plates. An insulating thin film is disposed between the laminated electrical steel sheets. The split core 22 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.

  As shown in FIG. 7, the stator winding 40 is formed in a cylindrical shape by a plurality of wires 30, and a straight portion 41 accommodated in the slot 21 of the stator core 20 and both ends of the straight portion 41. The coil end 42 is disposed outside the slot 21. On the end face of one coil end 42, the output wire (U, V, W) and the neutral point (U, V, W) protrude in the axial direction, and the end of the wire rod 30 protruding from the inner diameter side has an outer diameter. A crossover 70 connected to the end of the wire 30 protruding from the side is provided.

  In order to form the stator winding 40, first, a plurality of wire rods 30 (12 in this embodiment) formed into a waveform as shown in FIG. 9 are prepared, and are knitted or stacked by a predetermined method. The wire rod assembly is formed. Next, the stator winding 40 is formed by winding the wire assembly in a spiral shape. As shown in FIG. 9, the wire 30 of the stator winding 40 has a plurality of turn portions 32 formed at a predetermined pitch, and has a length of about 1 m.

  As shown in FIG. 10A, the wire rod 30 is a rectangular wire whose cross-sectional shape in a direction perpendicular to the extending direction is a rectangular wire, and covers the outer periphery of the copper conductor 37 and the conductor 37 to insulate the conductor 37. And an insulating coating 38 made of an outer layer 38b. The inner layer 38a covers the outer periphery of the conductor 37, and the outer layer 38b covers the outer periphery of the inner layer 38a. The thickness of the insulating coating 38 including the inner layer 38a and the outer layer 38b is set to a value between 100 μm and 200 μm.

  The outer layer 38b is formed of an insulating material, and the inner layer 38a is formed of an insulating material such as a thermoplastic resin having a glass transition temperature higher than that of the outer layer 38b or polyamideimide having no glass transition temperature. Thereby, the outer layer 38b of the insulating coating 38 is crystallized faster than the inner layer 38a by the heat generated in the rotating electrical machine, so that the surface hardness of the outer layer 38b is increased and the wire rod 30 is hardly damaged. For this reason, the insulation of the wire 30 which processed the step part in the turn part 32 is securable.

  As shown in FIG. 10B, the wire 30 may be one in which the outer periphery of the insulating coating 38 made of the inner layer 38a and the outer layer 38b is covered with a fusion material 39 made of epoxy resin or the like. In this wire 30, the fusion material 39 is melted faster than the insulating coating 38 due to the heat generated in the rotating electrical machine, so that the plurality of wires 30 installed in the same slot 21 are thermally bonded together by the fusion material 39. To do. As a result, the plurality of wire rods 30 installed in the same slot 31 are integrated and the wire rods 30 are made into a steel body, so that the mechanical strength of the wire rod 30 in the slot 21 is improved.

  4 and 8, when the wire 30 is wound around the stator core 20, the slot accommodating portion 31 installed in the slots 21a and 21b of the stator core 20, and the slots 21a and 21b. Projecting out of the stator core 20, and having a turn portion 32 connecting the slot accommodating portions 31 installed in different slots in the circumferential direction, and being wound around the stator core 20. Thus, the stator winding 40 is formed. The turn portions 32 are located on both sides of the stator core 20 in the axial direction. In this case, the connection part of the slot accommodating part 31 and the turn part 32 is bent at a substantially right angle.

  As shown in FIG. 11, a crank portion 33 without twisting is formed at a substantially central portion of the turn portion 32. The crank portion 33 is formed in a crank shape along the end surface 20 a of the stator core 20. The shift amount of the crank portion 33 due to the crank shape is substantially the width of the wire 30. Thereby, the turn parts 32 of the wire 30 adjacent to each other in the radial direction can be densely wound. As a result, since the radial width of the coil end is reduced, the stator winding 40 is prevented from projecting radially outward.

  In addition, the end portions 20a on both axial sides of the stator core 20 face the slots where the wire rods 30 are installed across the projecting portions of the turn portion 32 projecting out of the stator core 20 from the slots 21a and 21b. A step portion 34 is formed along. Thereby, the wire 30 is installed across the interval between the protruding portions of the turn portion 32 of the wire rod 30 protruding from the slots 21a and 21b, in other words, the length of the bottom of the triangular portion formed by the turn portion 32. It is narrower than the interval between slots. As a result, the height h of the coil end is lowered.

  Further, d1 ≦ d2 is satisfied, where d1 is the length of the step portion 34 along the end surface 20a of the stator core 20 and d2 is the interval between slots adjacent in the circumferential direction. Thereby, it can prevent that the step part 34 of the wire 30 interferes with the wire 30 which protrudes from the slot adjacent to the circumferential direction. Thereby, in order to avoid that the wire rods 30 protruding from the slots adjacent in the circumferential direction interfere with each other, the height of the coil end is increased or the radial width of the coil end is increased. Can be prevented. As a result, the height of the coil end is reduced. Furthermore, since the radial width of the coil end is reduced, the stator winding 40 is prevented from projecting radially outward.

  Furthermore, two step portions 35 are formed on the wire 30 between the crank portion 33 at the substantially central portion of the turn portion 32 and the step portions 34 formed at both ends (projections) of the turn portion 32. ing. That is, one crank portion 33 and a total of six step portions 34 and 35 are formed on the turn portion 32 of the wire 30 on the side of one axial end face 20 a of the stator core 20. Thereby, the height h of the turn part 32 becomes lower than the height of the triangular turn part not forming the step part. Similar to the step portion 34 and the crank portion 33, the step portion 35 is formed to extend in parallel along the end surface 20 a of the stator core 20. Therefore, both sides of the turn portion 32 of the wire 30 are formed stepwise with the crank portion 33 interposed therebetween.

  As shown in FIG. 12, the slot accommodating portion 31 of the wire 30 is accommodated inside each slot 21 of the stator core 20. That is, in each slot 21, twelve wire rods 30 and 30 a (slot housing portions 31 and 31 a) are installed in a row in the radial direction of the stator core 20. FIG. 12 shows an enlarged view of the split core 22 of the slot 21 in which the wire 30a (slot accommodating portion 31a) serving as a terminal wire (for example, the output line U) is present in the outermost layer of the 12 wires 30 arranged in the slot 21. It is a thing. In FIG. 12, in order to facilitate understanding of the structure in the slot 21, eight wire rods 30 (slot housing portions 31) in the middle of the 12 wire rods 30 (slot housing portions 31). And only four wire rods 30 and 30a (slot housing portions 31 and 31a) are schematically shown. Further, the members arranged in the slot 21 are provided with cross-sectional hatching.

  The slot accommodating portions 31 and 31a of the wire rods 30 and 30a installed in the slot 21 are supported by the impregnating material 50, the fixing material sheet 55, and the insulating sheet 60. The adhering material sheet 55 is located on the outermost layer of the twelve wire rods 30 and 30a (slot housing portions 31 and 31a) installed in the slot 21 and is a terminal wire and the peripheral wall surface of the stator core 20 The wire 30 a is fixed to the slot peripheral wall surface 25 by the fixing material sheet 55.

  As shown in FIG. 13, the fixing material sheet 55 includes an insulating material layer 55a made of a film such as PET, PPS, PEN and the like and a fixing material made of a foamed thermoplastic resin and laminated on both surfaces of the insulating material layer 55a. It has a three-layer structure composed of layers 55b and 55c. The adhering material layers 55b and 55c are made by mixing beads filled with gas into a resin to give foaming properties. The fixing material sheet 55 is bent into a U-shape and disposed between the opposing surfaces of the wire 30a (slot accommodating portion 31a) and the slot peripheral wall surface 25, and then the fixing material sheet 55 is heated to expand. It is made to harden in the state where it was made to stand. In this case, since the wire 30a serving as the terminal wire is a square wire, its three surfaces are opposed to the slot peripheral wall surface 25, so that the entire region of the three surfaces is fixed to the fixing material layer 55b or 55c. Thereby, the fixing strength is sufficiently ensured.

  The impregnating material 50 and the insulating sheet 60 are located between the 11 wire rods 30 (slot accommodating portions 31) other than the wire rod 30a fixed by the fixing material sheet 55 and the slot peripheral wall surface 25, and both It arrange | positions so that the space between opposing surfaces may be filled. For this reason, the 11 wire rods 30 (slot housing portions 31) are fixedly supported on the slot peripheral wall surface 25 by the impregnating material 50. In the slot 21, the impregnating material 51 integrated with the impregnating material 50 is also filled between the adjacent wire materials 30 and 30 a (slot housing portions 31 and 31 a). For this reason, the twelve wire rods 30 and 30 a (slot accommodating portions 31 and 31 a) accommodated in the slot 21 are fixed and integrated with each other by the impregnating material 51. The impregnating materials 50 and 51 are solidified liquid impregnating materials dropped from the inner peripheral side of the stator core 20 into the slot openings.

  As shown in FIG. 14, each of the stator windings 40 is formed by two three-phase windings (U1, U2, V1, V2, W1, W2). The wire 30 constituting the stator winding 40 is formed in a shape that is wave-wound along the circumferential direction on the inner peripheral side of the stator core 20. The slot accommodating portions 31 of the wire rod 30 are accommodated in the slots 21 for each predetermined number of slots (for example, three phases × 2 = 6), and the turn portions 32 are formed from both end surfaces 20a of the stator core 20 in the axial direction. Each protrudes. A coil end 42 of the stator winding 40 is formed by the turn portions 32 projecting from both axial end surfaces 20a of the stator core 20 (see FIG. 2).

  The stator winding 40 is formed by winding a plurality of wires 30 in a wavy shape along the circumferential direction with one end protruding from the axial end surface 20a of the stator core 20 on the outermost peripheral side of the slot 21. It is formed in the state. The other ends of the plurality of wire rods 30 protrude from the axial end surface 20 a of the stator core 20 in the same direction as the one end on the innermost peripheral side of the slot 31. Two wires 30 are wound around the same slot 21. Although depending on the winding method, the two slot accommodating portions 31 accommodated in the same slot 21 are installed such that the positions in the depth direction of the slots 21 adjacent in the circumferential direction are alternately or at the same position. ing.

  In the stator winding 40, the ends of the windings of the same phase (U1 and U2, V1 and V2, W1 and W2) are joined at the connection portion. The connecting portion is formed so as to protrude from the end surface of the turn portion 32 protruding from the stator core 20.

  The stator winding 40 is formed by winding a plurality of wire rods 30 in a wavy shape along the circumferential direction with one end protruding from the axial end surface 20a of the stator core 20. The wire 30 of the stator winding 40 is wound from the radially outer side toward the radially inner side. The end of the wire 30 protrudes from the end surface of the stator winding 40 on the innermost peripheral surface side.

  The stator 10 of the present embodiment configured as described above includes a stator winding manufacturing process, a fixing material sheet arranging process, an insulating sheet arranging process, and a set in which the stator winding 40 and the stator core 20 are assembled. It manufactures by performing an attaching process, an adhering material sheet adhering process, and an impregnating material adhering process in order.

  First, in the stator winding manufacturing process, twelve wire rods 30 formed into a waveform shown in FIG. 7 are knitted by a predetermined method to form a strip-like wire rod assembly. And the cylindrical stator coil | winding 40 shown in FIG. 7 is produced by winding the wire integrated body in a spiral shape. In this case, the stator winding 40 is formed in a state in which the slot accommodating portions 31 and 31a of the twelve wire rods 30 and 30a to be accommodated in the same slot 21 of the stator core 20 are aligned in the radial direction.

  In the next fixing material sheet arranging step, as shown in FIGS. 15A and 15B, the fixing material sheet 55 bent in a U-shape is accommodated in the slots of the twelve wire rods 30 and 30a arranged in the radial direction. It arrange | positions along 3 surfaces of the outer periphery of the slot accommodating part 31a of the wire 30a which is located in the outermost layer and becomes a terminal wire among the parts 31 and 31a.

  In addition, as shown in FIG. 16, the both ends of the fixing material sheet 55 may be disposed in a state of protruding outward from the axial end surfaces 20 a of the stator core 20. In this way, the gap between the wire 30 installed in the outermost layer in the slot 21 and the peripheral wall surface 25 of the slot is filled, and the impregnating material is applied to the end surface 20a of the stator core 20 where the impregnating material 50 cannot be attached. 50 can be prevented from leaking.

  Next, the two insulating sheets 60 are arranged along both side surfaces of the slot accommodating portions 31 of the remaining eleven wires 30 of the twelve wire rods 30 and 30a aligned in the radial direction. Arrange and perform insulating sheet arrangement process. In addition, you may perform this insulating sheet arrangement | positioning process before the adhering material sheet arrangement | positioning process. Further, the fixing material sheet 55 and the insulating sheet 60 may be arranged along the slot peripheral wall surface 24 instead of being arranged around the slot accommodating portions 31 and 31a of the twelve wires 30 and 30a. .

  In the next assembling step, as shown in FIG. 12, the twelve slot accommodating portions 31, 31 a arranged in the radial direction are accommodated in the predetermined slots 21 of the stator core 20, and the stator winding is performed. The wire 40 and the stator core 20 are assembled. Accordingly, the fixing material sheet 55 and the insulating sheet 60 are located between the twelve slot accommodating portions 31 and 31a and the slot peripheral wall surface 25 arranged in the radial direction.

  In the next fixing step, the fixing material sheet 55 is first heated and expanded. Accordingly, the gap formed between the slot accommodating portion 31a and the slot peripheral wall surface 25 is filled with the fixing material sheet 55, and is cured in a state where the gap is eliminated. As a result, the slot accommodating portion 31 a of the wire 30 a serving as the terminal wire is firmly fixed to the slot peripheral wall surface 25 via the fixing material sheet 55.

  In the next impregnating material fixing step, the stator core 20 is held by a holding portion of a rotating device (not shown) such that its axis is oriented in the horizontal direction. Then, while rotating the stator core 20 about the axis by the rotating device, the slot of the stator core 20 from the impregnating material discharge port of the nozzle 53 disposed on the inner peripheral side of the stator core 20 as shown in FIG. A liquid impregnating material 50 is dropped toward the opening. At this time, the impregnating material 50 that has entered the slot 21 penetrates into the radially outward depth of the slot 31 due to the action of centrifugal force accompanying the rotation of the stator core 20. As a result, the impregnating material 50 has a gap between the 11 wire rods 30 (slot housing portion 31) on the inner diameter side in the slot 21 and the slot peripheral wall surface 25, and the adjacent wire rods 30 and 30a (slot housing portion 31). , 31a) penetrates into the gaps between them. Thereafter, the impregnating material 50 that has penetrated into the slot 21 is solidified, whereby the eleven wire rods 30 (slot accommodating portions 31) that are integrally fixed in the slot 21 are fixed to the slot peripheral wall surface 25.

  After assembling and fixing the stator winding 40 and the stator core 20 as described above, necessary processing such as connection work of the wire rods 30 and 30a constituting the stator winding 40 is performed. Thus, the stator 10 shown in FIGS. 1 and 2 is completed.

  As described above, according to the stator 10 of the rotating electrical machine of the present embodiment, at least the wire 30 a serving as a terminal wire among the wires 30 installed in the slot 21 is disposed between the stator core 20. The wire rods 30 other than the wire rod 30a fixed to the slot peripheral wall surface 25 by the fixing material sheet 55 and fixed by the fixing material sheet 55 are impregnated by the impregnating material 50 dropped from the inner peripheral side of the stator core 20 into the slot opening. It is fixed. Therefore, it is possible to reliably fix the wire 30a serving as the terminal wire, and it is possible to reduce the cost by suppressing the application of the impregnating material 50 to unnecessary portions. Furthermore, since the usage amount of the fixing material sheet 55 can be suppressed to a necessary minimum by using the fixing material sheet 55 and the liquid impregnation in combination, the cost is lower than the case where the fixing material sheet 55 is used in all the slots 21. Down is possible.

  In the present embodiment, the wire rods 30 and 30 a are rectangular wires having a rectangular cross-sectional shape in a direction perpendicular to the extending direction, and are arranged in a row in the core radial direction in the slot 21. Thereby, the three surfaces of the outermost layer wire 30a serving as the terminal wire can be evenly fixed by the fixing material sheet 55, so that the outermost layer wire 30a serving as the terminal wire is attached to the slot peripheral wall surface 25 of the stator core 20. , It can be more securely fixed.

  In the present embodiment, since the insulating sheet is disposed between the wire 30 fixed by the impregnating material 50 in the slot 21 and the slot peripheral wall surface 25 of the stator core 20, the fixing portion by liquid impregnation is provided. The creepage distance between the wire 30 and the stator core 20 can be sufficiently maintained.

  In the present embodiment, the fixing material sheet 55 used for the wire rod 30a serving as the terminal wire and the insulating sheet 60 used for the wire rod 30 other than the wire rod 30a used for the fixing material sheet 55 are combined and arranged. It is installed. Therefore, between the stator core 20 and a plurality of wires 30 and 30a (slot accommodating portions 31 and 31a) installed in a state of being aligned in the slot 21, a fixing material sheet 55 used for a required fixing portion, By combining the insulating sheet 60 used for other parts, the amount of the fixing material sheet 55 used can be minimized, so that the cost can be reduced.

  In the present embodiment, the insulating sheet 60 is used for the wire 30 on the inner diameter side in the slot 21. Thereby, when the slot accommodating parts 31 and 31a of the wire rods 30 and 30a are inserted into the slots 21 of the stator core 20, damage due to the winding of the fixing material sheet 55 can be prevented, and occurrence of poor fixing of the wire rod 30 can be suppressed. .

  Then, according to the method for manufacturing the stator 10 of the present embodiment, the stator winding manufacturing process, the fixing material sheet arranging process, the insulating sheet arranging process, the stator winding 40 and the stator core 20 are assembled. Since the attaching step, the adhering material sheet adhering step, and the impregnating material adhering step are sequentially performed, the impregnating material can be applied to unnecessary portions while ensuring that the wire rod 30a serving as the terminal wire can be securely fixed. It is possible to easily manufacture the stator 10 of the rotating electrical machine that can realize cost reduction by suppressing the above.

  In addition, since the insulating sheet arranging step is included, the stator 10 capable of maintaining a sufficient creepage distance between the wire 30 and the stator core 20 not only at the fixing portion by the fixing material sheet 55 but also at the fixing portion by liquid impregnation is manufactured. It becomes possible to do.

  DESCRIPTION OF SYMBOLS 10 ... Stator 20 ... Stator core 20a ... Core end surface 21, 21a, 21b ... Slot 22 ... Divided core 23 ... Teeth part 24 ... Back core part 25 ... Slot peripheral wall surface 27 ... Outer cylinder 30 ... Wire material 30a ... With terminal wire Wire rod 31 ... Slot accommodating portion 32 ... Turn portion 33 ... Crank portion 34, 35 ... Step portion 37 ... Conductor portion 38 ... Insulating coating 38a ... Inner layer 38b ... Outer layer 39 ... Fusing material 40 ... Stator winding 41 ... Straight portion 42 ... Coil end 50, 51 ... Impregnation material 55 ... Adhesive material sheet 55a ... Insulating material layer 55b, 55c ... Adhesive material layer 60 ... Insulating sheet 70 ... Crossing part

Claims (8)

An annular stator core having a plurality of slots in the circumferential direction, and a plurality of wires wound around the slots of the stator core, and a plurality of the wires arranged in the core radial direction in the slots In a stator of a rotating electrical machine having a stator winding having a terminal line that becomes an output line or a neutral point joining line in the outermost layer,
The wire is a rectangular wire whose cross-sectional shape in a direction perpendicular to the stretching direction is rectangular,
Of the wires installed in the slot, at least the wire that becomes the terminal wire is bent into a U-shape and arranged between the stator core along the three outer surfaces of the slot accommodating portion of the wire. Fixed to the stator core by the provided fixing material sheet,
Among the wires other than the wire fixed by the fixing material sheet, at least the innermost layer of the wire is fixed to the stator core by the impregnating material dropped from the inner peripheral side of the stator core to the slot opening. A stator for a rotating electrical machine. In claim 1,
The wire is a stator of a rotary electric machine, characterized in that it is arranged before Symbol a line in the core radially in the slot. In claim 1 or 2,
A stator for a rotating electrical machine, wherein an insulating sheet is disposed between the wire material fixed by the impregnating material in the slot and the stator core. In claim 3,
The fixing material sheet used for at least the wire used as the terminal wire and the insulating sheet used for the wire other than the wire used for the fixing material sheet are disposed in combination. A stator of a rotating electric machine characterized by In claim 3 or 4,
The stator for a rotating electrical machine, wherein the insulating sheet is used for the wire on the inner diameter side in the slot. In any one of Claims 1-5,
The stator of a rotating electrical machine, wherein the fixing material sheet is disposed in a state in which both end portions protrude outward from both axial end surfaces of the stator core. A method for manufacturing a stator of a rotating electrical machine according to any one of claims 1 to 6,
A stator winding production step of producing a cylindrical stator winding such that a plurality of the wire accommodating portions accommodated in the same slot of the stator core are aligned in the core radial direction by a plurality of wires;
An adhering material sheet arranging step of arranging an adhering material sheet to at least a portion of the slot accommodating portions arranged in the core radial direction as a terminal wire, or to a predetermined portion of a corresponding slot peripheral wall;
An assembly step of assembling the stator winding and the stator core such that the slot accommodating portion is accommodated in the predetermined slot;
An adhering material sheet adhering step for adhering the slot accommodating portion of the wire that becomes at least a terminal wire to the peripheral wall surface of the slot via the adhering material sheet;
An impregnating material fixing step in which an impregnating material is dropped from the inner peripheral side of the stator core into the slot opening, and the wire material other than the wire material fixed by the fixing material sheet is fixed to the slot peripheral wall surface by the impregnating material; ,
The manufacturing method of the stator of the rotary electric machine characterized by having. In claim 7,
Before or after the fixing material sheet arranging step, the insulating sheet arranging step of arranging an insulating sheet between the wire material other than the wire material fixed by the fixing material sheet in the slot and the peripheral wall surface of the slot. A method of manufacturing a stator of a rotating electric machine, characterized in that

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