JP5904103B2 - Stator manufacturing method, stator, and manufacturing apparatus thereof - Google Patents

Description

  The present invention relates to a technique for manufacturing a stator using a segment coil, and more particularly to a technique for processing an end portion of a segment coil after the segment coil is inserted into a slot of the stator.

  In recent years, there have been an increasing number of cases in which a driving motor is mounted on an automobile. A drive motor mounted on a vehicle is required to be space-saving because the mounting space is limited. In addition, higher output is required to improve the driving performance of automobiles. In particular, hybrid vehicles must be equipped with both an engine and a drive motor in the engine room, and space constraints are severe. For this reason, further miniaturization of the motor is required. In addition, it is desirable that a motor used in a general machine be reduced in size and output.

  Patent Document 1 discloses a technique related to a stator manufacturing method. The end of the segment coil inserted into the stator core is expanded in the radial direction of the stator core by inserting a wedge-shaped separation jig. As a method of spreading using this separation jig, (1) a method in which two segment coil ends adjacent to each other in the radial direction of the stator core are sequentially inserted into one set, and each time the insertion is performed, the separation jig is spread with the separation jig. (2) After inserting at once, a method of spreading the stepped segment coil end portion from the inner diameter side to the outer diameter direction using an expansion jig, (3) Called a taper cone from the radial direction of the stator core A method of spreading with a jig with a slope is disclosed.

JP 2012-175748 A

  However, the stator manufacturing method using the technique disclosed in Patent Document 1 is considered to have the following problems.

  The end of the segment coil needs to be finally welded to form the stator, but for end welding, it is better to improve the welding quality if the ends of the segment coil are separated from each other. Can be planned. However, in order to increase the expansion pitch for expanding the segment coils, it is necessary to increase the expansion amount, and it is desirable that it can be realized at a low cost in order to reduce the manufacturing cost. When the technique disclosed in Patent Document 1 is used, the method (1) of deforming one set at a time leaves a problem in that the cycle time becomes long and the cost is reduced. In the method of pressing the segment coil end from the inner diameter side to the outer shape side in (2), the difference in length between the segment coil ends must be large, and there is a shape limitation. In the method of expanding the segment coil end using the taper cone of (3), it is difficult to increase the expansion amount in relation to the taper angle.

  Therefore, in order to solve such a problem, the present invention has an object to provide a stator manufacturing method, a stator, and a manufacturing apparatus thereof that can expand the expansion pitch of segment coil ends at low cost. .

  In order to achieve the above object, a stator manufacturing method according to an aspect of the present invention has the following characteristics.

(1) In a stator manufacturing method of manufacturing a stator by bending a flat conductor to form a segment coil, and inserting the segment coil into a slot of the stator core, the segment inserted into the stator core In a slot that is housed in the slot by using a first pre-deformation blade that brings a first lead portion of a group of lead portions protruding from the end face of the stator core of the coil close to the axial direction of the stator core. A first expansion step of decentering the lead wire portion in the radial direction of the stator core and forming a gap portion between the first lead portion and another adjacent lead portion; and from the axial direction of the stator core A first deforming blade and a second deforming blade provided adjacent to the first deforming blade and having a different length from the first deforming blade are inserted into the lead portion group; The first deforming blade forms a first shift portion that is eccentric in the radial direction of the stator core from the in-slot conductor portion housed in the slot in the second lead portion of the lead portion group, A second expansion step of forming a second shift portion that is eccentric in the radial direction of the stator core from the in-slot conductor portion in the first lead portion by inserting a second deforming blade into the gap portion; It is characterized by having.

  According to the above aspect (1), the gap portion is formed between the first lead portion and another adjacent lead portion using the first preliminary deformation blade in the first expansion step. Then, in the second expansion step, the first shift blade is used to form the first shift portion on the second lead portion, the second deformation blade is inserted into the gap portion, and the second lead portion is added to the first lead portion. Forming. When a deformed blade whose tip is formed in a wedge shape is inserted to form a shift portion in the lead portion, if a gap portion is formed in advance, it is possible to prevent a situation where the deformed blade rides on the lead portion. . Here, the lead portion refers to a portion of the segment coil inserted into the stator core slot that protrudes from the end surface of the stator core. The lead portion group indicates the entire lead portion. The shift portion refers to a portion of the lead portion that is eccentric in the radial direction of the stator core by the deforming blade, that is, a portion that is bent at a predetermined angle with respect to the axial direction of the stator core.

  After the second expansion step, the stator is manufactured through a twisting step of bending the end portions of the segment coils in the circumferential direction of the stator core and a welding step of welding the end portions of the segment coils. As shown in the problem, it is desirable that the first pair of end portions of the segment coil to be welded in the welding process and the adjacent second pair are sufficiently separated from each other. A first shift portion and a second shift portion for realizing this interval. In order to widen this interval, it is necessary to increase the angle formed with the axis of the stator core of the shift portion. However, as the lead portion is expanded in the radial direction of the stator core, the position control of the tip portion of the segment coil becomes more difficult. Therefore, the second deforming blade inserted next to the first deforming blade inserted first is the segment. There is an increased risk of interference with the coil tip.

  However, the risk of interference between the second deformable blade and the tip portion of the segment coil can be suppressed by forming the gap portion with the first preliminary deformable blade as in the present invention. As a result, it is possible to improve the quality of the stator and contribute to reducing the cost required for manufacturing the stator.

(2) In the stator manufacturing method according to (1), the first deforming blade deforms the second lead portion to form the first shift portion that is eccentric to the outer peripheral side of the stator core. The second deforming blade is shorter than the first deforming blade and deforms the first lead portion located on the outer peripheral side of the stator core from the second lead portion, so that the stator core The second shift portion that is eccentric to the outer peripheral side is formed.

  According to the above aspect (2), the first shift portion and the second shift portion in which the first lead portion and the second lead portion are eccentric to the outer peripheral side of the stator core by the first deforming blade and the second deforming blade, respectively. A shift portion is formed. As a result, a stator having a lead portion expanded on the outer peripheral side of the stator core is formed. By setting the length of the second deforming blade to be shorter than that of the first deforming blade, even if the first deforming blade and the second deforming blade are moved at the same time, they can be inserted into the lead portion with a time difference. Since the gap portion is formed at this time, the risk that the second deforming blade interferes with the tip portion of the segment coil is reduced. Since the rotor is arranged on the inner peripheral side, it is more reasonable to expand the lead portion on the outer peripheral side in order to maintain the stator and the rotor while maintaining a narrow clearance. It is possible to take a margin for expansion of the lead subgroup.

(3) In the stator manufacturing method according to (2), in the first expansion step, the lead portion group is supported by inner diameter support means for supporting the lead portion group from the inner peripheral side of the stator core. The first preliminary deformation blade is inserted into the lead portion group to deform the first lead portion to form the gap portion, and the stator of the lead portion group is formed from the outer peripheral side of the stator core. In a second pressurizing step, the lead portion group is pressed by the root pressurizing means that pressurizes the root portion close to the core end surface, and in the second expansion step, the lead portion group is supported by the inner diameter support means, The first deforming blade and the second deforming blade are inserted into the lead portion group to form the first shift portion and the second shift portion, and the root pressing means is used to form the root portion of the lead portion group. Pressurize the part and fix it Outside 径加 pressure means from the outer circumferential side of the core to support the distal portion of the lead subgroup, it is molded under pressure from the outside in the radial direction of the stator core, characterized by.

  According to the aspect described in (3) above, in the first expansion step, the lead portion group is supported by the inner diameter support means, so that the lead portion is prevented from spreading inside the stator, and the lead portion is By suppressing the root of the group, it is possible to obtain an effect of further widening the gap portion. Further, in the second expansion step, the lead portion group is supported by the inner diameter support means to prevent the lead portion from spreading inside the stator, and the root pressurizing means is used to hold the root of the lead portion group and increase the outer diameter. By pressurizing the lead portion group from the outside of the stator with the pressure means, the tip of the lead portion can be formed to be substantially parallel to the axis of the stator core.

  By forming the lead part in this way, it becomes possible to bend the lead part in an appropriate direction in the subsequent twisting process, which contributes to reducing welding defects in the welding process provided thereafter. Is possible. As a result, it is possible to contribute to a reduction in manufacturing cost in manufacturing the stator.

  In order to achieve the above object, the stator according to one aspect of the present invention has the following characteristics.

(4) The stator is manufactured by using the stator manufacturing method according to any one of (1) to (3).

  According to the aspect described in (4) above, since the stator is manufactured using the stator manufacturing method described in (1) to (3), the yield is improved and the quality is improved in manufacturing the stator. As a result, cost reduction can be realized.

  In order to achieve the above object, a stator manufacturing apparatus according to an aspect of the present invention has the following characteristics.

(5) In a stator manufacturing apparatus for expanding a pitch between lead portions protruding from an end face of the stator core of a stator component in which a segment coil formed by bending a rectangular conductor is inserted into the stator core A first pre-deformation mechanism portion including a first pre-deformation blade that is inserted into the lead portion group to form a gap portion, which is used in the first expansion step, and a first insert that is inserted into the lead portion group, which is used in the second expansion step. It is characterized by comprising a deformation mechanism comprising: a deformation blade; and a second deformation blade that is shorter than the first deformation blade and is inserted into the gap portion.

  According to the aspect described in (5) above, a gap portion is formed between the first lead portion and another adjacent lead portion using the first preliminary deformation blade in the first expansion step, and in the second expansion step. A first shift portion can be formed in the second lead portion using the first deforming blade, and the first lead portion can be formed by inserting the second deforming blade into the gap portion. In other words, by using the stator manufacturing apparatus of the present invention, the gap portion is first formed by the first preliminary deformation blade at the time of stator manufacture, so that the risk of interference between the second deformation blade and the tip portion of the segment coil is increased. Can be suppressed. As a result, it is possible to improve the quality of the stator, and it is possible to provide a stator manufacturing apparatus capable of realizing a reduction in cost required for manufacturing the stator.

(6) In the stator manufacturing apparatus according to (5), an inner diameter support means for supporting the lead portion group from an inner peripheral side of the stator core and the first preliminary deformation blade are provided in the preliminary deformation mechanism portion. After inserting, a root pressurizing unit that pressurizes a root portion near the end surface of the stator core of the lead portion group from the outer peripheral side of the stator core, and the inner diameter support means in the deformation mechanism unit, After inserting the first deforming blade and the second deforming blade, the root pressing means that presses the root portion of the lead portion group close to the stator core end surface from the outer peripheral side of the stator core, and the root pressing And an outer diameter pressurizing means for supporting a tip side portion of the lead portion group from an outer peripheral side of the stator core after pressurizing a root portion of the lead portion group by means.

  According to the aspect described in (6) above, in the first expansion step, the lead portion group is supported by the inner diameter support means, so that the lead portion is prevented from spreading inside the stator, and the lead portion is By suppressing the root of the group, it is possible to obtain an effect of further widening the gap portion. Further, in the second expansion step, the lead portion group is supported by the inner diameter support means to prevent the lead portion from spreading inside the stator, and the root pressurizing means is used to hold the root of the lead portion group and increase the outer diameter. By pressing the lead portion from the outside of the stator with the pressure means, the tip of the lead portion can be molded so as to be substantially parallel to the axis of the stator core. That is, the stator manufacturing apparatus of the present invention can contribute to the reduction of the manufacturing cost in the manufacture of the stator.

It is a perspective view of the stator of this embodiment. It is an expansion perspective view by the side of a coil end partial lead of a stator of this embodiment. It is a perspective view at the time of inserting a segment in a stator of this embodiment. It is a top view of the segment of this embodiment. It is a conceptual diagram which shows the outline of the assembly process of the stator of this embodiment. (A) It is a perspective view of a stator core. (B) It is the perspective view which equipped the stator core with the insulator. (C) It is a perspective view of a segment. (D) It is sectional drawing which shows a mode that the segment was inserted in the stator core. (E) It is sectional drawing which shows a mode that the segment was welded. It is a flowchart of the assembly process of a stator of this embodiment. It is an expanded sectional view of the slot part of the state of this embodiment in the state where the conductor part in a slot entered into the slot of the stator core. It is sectional drawing which shows a mode that the segment coil was inserted in the stator core of this embodiment. It is sectional drawing which shows a mode that the segment coil is preliminarily expanded of this embodiment. It is the elements on larger scale which show a mode that the front-end | tip of the 1st preliminary | backup expansion blade of this embodiment was inserted in the lead part group. It is the elements on larger scale which show a mode that the front-end | tip of the 2nd preliminary | backup expansion blade of this embodiment was inserted in the lead part group. It is a front-end | tip enlarged view of the lead | read | reed part group in which this preliminary expansion was performed of this embodiment. It is sectional drawing which shows a mode that a lead part group expands at the 2nd expansion process of this embodiment. It is sectional drawing which shows a mode that the 2nd expansion processing apparatus was used for the lead part group at the 2nd expansion process of this embodiment. It is a tip enlarged view of a lead portion group of the 2nd expansion process of this embodiment. It is sectional drawing of the stator of this embodiment. It is a side view which shows the mode of the expansion process of the lead front-end | tip part prepared for the comparison.

  First, an embodiment of the present invention will be described with reference to the drawings. In addition, the detailed part of drawing used is simplified for convenience of explanation.

  In FIG. 1, the perspective view of the stator 10 of this embodiment is shown. FIG. 2 shows an enlarged perspective view of the stator 10 on the coil end partial lead side. The stator 10 includes a stator core 20 and a segment coil SC. A stator core 20 formed by laminating electromagnetic steel plates having a substantially cylindrical shape is provided with a slot 12 between adjacent teeth 11 formed so as to protrude to the inner peripheral side. The number of prepared teeth 11 is 48, and the number of slots 12 is the same. Three ribs 21 and bolt holes 22 are provided on the outer peripheral side of the stator core 20. And a motor cover etc. can be attached etc. using the volt | bolt hole 22. FIG. An insulator 25 having insulation properties shown in FIG. 2 is inserted into the slot 12. The insulator 25 ensures insulation between the segment coil SC and the stator core 20.

  FIG. 3 shows a perspective view of the stator core 20 in which the segment Sg is inserted and then expanded. FIG. 4 shows a plan view of the segment Sg. A segment Sg is formed by edgewise bending the flat rectangular conductor D into a substantially U shape. The segment Sg is roughly divided into three parts. The in-slot conductor portion Sgb inserted into the slot 12 of the stator core 20, the lead portion Sga protruding from the end face of the stator core 20 toward the lead side of the stator 10, and the anti-lead portion Sgc. For convenience, the lead portion Sga is referred to as a lead portion SgaA and a lead portion SgaB separately. Further, the in-slot conductor portion Sgb is referred to as an in-slot conductor portion SgbA and an in-slot conductor portion SgbB. The anti-lead portion Sgc is composed of a crank portion Sge, a hypotenuse portion SgdA, and a hypotenuse portion SgdB. The tips of the lead portion SgaA and the lead portion SgaB are peeled to be provided with a peeling portion Sgi which will be described later.

  In FIG. 5, the outline of the assembly process of the stator 10 is shown. FIG. 5A shows a perspective view of the stator core 20. FIG. 5B shows a perspective view in which the stator core 20 is provided with an insulator 25. FIG. 5C shows a perspective view of the segment Sg. FIG. 5D is a cross-sectional view showing a state where the segment Sg is inserted into the stator core 20. FIG. 5E shows a cross-sectional view of the segment Sg welded. Note that the perspective view shown in FIG. 5 is simplified in shape for explanation. First, the segment Sg shown in FIG. 5 (c) is inserted into the slot 12 formed in the stator core 20 shown in FIG. 5 (a) with the insulator 25 inserted as shown in FIG. 5 (b). To do.

  As a result, the state shown in FIG. That is, the segment Sg partially protrudes from the end of the stator core 20, and the lead portion SgaA and the lead portion SgaB protrude. Then, the stator 10 is formed by twisting the lead portion SgaA and the lead portion SgaB and welding the tips to form the welded portion Sgf as shown in FIG. In addition, although the formation process of the stator 10 is notionally demonstrated in FIG. 5, in the actual assembly | attachment process, the alignment process which arrange | positions the segment Sg in a ring shape is required.

  FIG. 6 shows a flowchart of the assembly process of the stator 10. In S <b> 1, “straight conductor straightening and cutting” is performed. Since the flat conductor D is wound around a bobbin (not shown), the flat conductor D is unwound and trimmed to a required length. In S2, “segment formation” is performed. The flat conductor D is edgewise bent, and a crank portion Sge is created using a die (not shown) to obtain a substantially U-shaped segment Sg. In S3, “segment alignment” is performed. The segment Sg is arranged in a cylindrical shape by combining the crank portions Sge of the segment Sg so that eight in-slot conductors SgbA or eight in-slot conductors SgbB can be accommodated in the slot 12 of the stator core 20 to form a segment coil SC. To do.

  In S4, “insulator insertion” is performed. Each slot 12 is provided with an insulator 25 in the slot 12 of the stator core 20 in order to insulate the stator core 20 from the segment coil SC. In this step, the insulator 25 is inserted into the slot 12. In S5, “segment coil insertion” is performed. Strictly speaking, this is a step of bringing the segment coil SC close to the stator core 20 and inserting the lead portion Sga into the slot 12 provided with the insulator 25.

  In S6, “wedge insertion” is performed. FIG. 7 shows an enlarged cross-sectional view of a portion of the slot 12 in a state where the in-slot conductor portion Sgb enters the slot 12 of the stator core 20. The wedge paper 13 is inserted into the innermost peripheral side of the stator core 20 in a state where eight in-slot conductor portions Sgb of the segment Sg are inserted into the slot 12. The wedge paper 13 is held by being stretched by a convex portion 11 a provided at the tip of the tooth 11 so as to project into the slot 12. In S7, “extended after lead portion” is performed. This is a step of forming the shift portion Sf in the lead portion Sga by a method described later.

  In S8, “twist formation” is performed. The lead portion Sga of the segment coil SC inserted into the stator core 20 is twisted in the radial direction of the stator core 20 and deformed into a shape in which adjacent coils are connected. As shown in FIG. 2, the lead portions Sga are twisted in different directions in the lead portions Sga adjacent in the radial direction. In S9, “Tig welding” is performed. As shown in FIG. 5E, the welded portion Sgf is formed by welding adjacent lead portions Sga to each other. In S10, “coil end portion insulation processing” is performed. This is a step of applying an insulating coating to the welded portion Sgf, and the insulating coating is performed using a resin in powder coating. Further, by impregnating the segment coil SC with varnish, the segment coil SC is fixed so that the segment coil SC does not move with respect to the stator 10 due to vibration transmitted from the vehicle body or the like when the stator 10 is operated.

  Next, a description will be given of the first extension step in the lead portion post-extension step which is S7 in FIG. FIG. 8 is a cross-sectional view showing a state where the segment coil is inserted into the stator core. First, inserting the segment coil SC into the stator core 20 results in the lead portion Sga projecting from the end face of the stator core 20. The lead portion Sga includes, from the inner peripheral side, the first lead portion Sga1, the second lead portion Sga2, the third lead portion Sga3, the fourth lead portion Sga4, the fifth lead portion Sga5, the sixth lead portion Sga6, and the seventh lead portion. Sga7 and the eighth lead portion Sga8. The length from the end face 20a of the stator core 20 is set to be increased in order from the first lead portion Sga1 to the eighth lead portion Sga8 in order. The first lead portion Sga1 to the eighth lead portion Sga8 are collectively referred to as a lead portion Sga group for convenience.

  The first expansion processing device 100 includes an inner diameter support means 50, a root pressurization means 60, and a preliminary expansion blade 70. The first expansion processing device 100 is used in the first expansion step shown in S7 of FIG. The inner diameter support means 50 is disposed on the inner diameter side of the segment coil SC and has a propulsion mechanism that can advance and retract toward the outer periphery side of the stator core 20. The inner diameter support means 50 shown in FIG. 8 shows a state positioned at the forward end. The inner diameter support means 50 can support the inner peripheral side of the lead portion group, that is, one side of the first lead portion Sga1. The root pressing means 60 has a function of pressing the position on the root side of the lead portion group, that is, the position near the end face 20 a of the stator core 20.

  The spare expansion blade 70 includes a first spare expansion blade 71 and a second spare expansion blade 72. The tips of the first preliminary expansion blade 71 and the second preliminary expansion blade 72 are formed in a wedge shape. 8 and FIG. 9, FIG. 10, and FIG. 11, which will be described later, the first preliminary expansion blade 71 and the second preliminary expansion blade 72 in FIG. is there. The preliminary expansion blade 70 is provided with a propulsion mechanism (not shown) so as to be able to advance and retreat in the axial direction of the stator core 20. The first preliminary expansion blade 71 and the second preliminary expansion blade 72 are configured to move simultaneously.

  FIG. 9 is a sectional view showing a state where the segment coil SC is preliminarily expanded. In the first expansion process, preliminary expansion is performed using the first expansion processing apparatus 100. Specifically, as shown in FIG. 9, by moving the spare expansion blade 70 toward the lead portion Sga group of the segment coil SC, the first spare expansion blade 71 is moved to the fourth lead portion Sga4 and the fifth lead portion. The second preliminary extension blade 72 is inserted between the sixth lead portion Sga6 and the seventh lead portion Sga7. After the first pre-expansion blade 71 and the second pre-expansion blade 72 are inserted into the lead portion Sga group, the pressure is applied from the outer peripheral side of the lead portion Sga group by the basic pressure means 60.

  FIG. 10 shows a partially enlarged view in which the tip of the first preliminary expansion blade 71 is inserted into the lead portion Sga group. FIG. 11 is a partial enlarged view in which the tip of the second preliminary expansion blade 72 is inserted into the lead portion Sga group. FIG. 12 shows an enlarged view of the tip of the lead portion Sga group that has been subjected to preliminary expansion. The chamfered portion Sgj is disposed so that the first lead portion Sga1 and the second lead portion Sga2 are back to back. Similarly, the chamfered portion Sgj is paired so that the third lead portion Sga3 and the fourth lead portion Sga4, the fifth lead portion Sga5 and the sixth lead portion Sga6, and the seventh lead portion Sga7 and the eighth lead portion Sga8 are paired. They are arranged so that they are back to back.

  On the other hand, the second lead portion Sga2 and the third lead portion Sga3 are arranged so that the chamfered portions Sgj face each other. Similarly, the fourth lead portion Sga4 and the fifth lead portion Sga5 are arranged so that the chamfered portions Sgj of the sixth lead portion Sga6 and the seventh lead portion Sga7 face each other. Therefore, the first preliminary expansion blade 71 is close to the lead portion Sga group, and the tip of the first preliminary expansion blade 71 is inserted between the fourth lead portion Sga4 and the fifth lead portion Sga5. At this time, since the tip of the first preliminary expansion blade 71 is formed in a wedge shape, the chamfered portion Sgj of the peeling portion Sgi formed at the tip of the lead portion Sga can be captured. Then, the root pressing means 60 holds down the root portion of the lead portion Sga group of the segment coil SC.

  As a result, as shown in FIG. 12, a first gap portion x1 is formed in the segment coil SC between the fourth lead portion Sga4 and the fifth lead portion Sga5. Further, the second gap portion x2 is formed between the sixth lead portion Sga6 and the seventh lead portion Sga7.

  Next, a description will be given of the second expansion step in the step of expanding the lead portion Sga group, which is S7 in FIG. FIG. 13 is a sectional view showing how the lead portion Sga group is expanded in the second expansion step. FIG. 14 is a cross-sectional view showing a state in which the second expansion processing device 110 is used for the lead portion Sga group in the second expansion step. The second expansion processing device 110 includes an inner diameter support means 50, a root pressurization means 60, an additional expansion blade 80, and an outer diameter pressurization means 90. The inner diameter support means 50 and the root pressurizing means 60 are the same as those provided in the first expansion processing apparatus 100, and thus description thereof is omitted.

  The additional expansion blade 80 includes a first expansion blade 81, a second expansion blade 82, and a third expansion blade 83. The first expansion blade 81 to the third expansion blade 83 have a wedge-shaped tip, similar to the first preliminary expansion blade 71 and the second preliminary expansion blade 72. The additional expansion blade 80 is provided with a propulsion mechanism (not shown) so as to be able to advance and retreat in the axial direction of the stator core 20. The first expansion blade 81, the second expansion blade 82, and the third expansion blade 83 are configured to move simultaneously. The outer diameter pressurizing means 90 has a function of pressing from the outer diameter direction of the lead portion Sga group, that is, from the side surface of the eighth lead portion Sga8. Note that the first and second expansion blades 81, 82, and 83 of FIGS. 13 and 14 and FIG. 15 described later are provided with dot hatching for the purpose of explanation.

  In the second expansion step, as in the first expansion step, the inner diameter support means 50 first supports the inner diameter side of the lead portion Sga group, and the additional expansion blade 80 is directed from the axial direction of the stator core 20 toward the lead portion Sga group. Close. FIG. 15 is an enlarged view of the tip of the lead portion Sga group in the second expansion process. After the first expansion blade 81 is inserted between the second lead portion Sga2 and the third lead portion Sga3, the second expansion blade 82 is inserted into the first gap portion x1, and the third expansion blade 83 is inserted into the second gap portion x2. Insert into.

  As a result, as shown in FIG. 14, the second expansion blade 82 is inserted between the fourth lead portion Sga4 and the fifth lead portion Sga5, and the third expansion blade is interposed between the sixth lead portion Sga6 and the seventh lead portion Sga7. 83 is inserted. Then, pressure is applied from the outer diameter side of the lead portion Sga group by the basic pressure means 60, and further, pressure is applied from the outer diameter side of the lead portion Sga group by the outer diameter pressure means 90, thereby forming the tip portion of the lead portion Sga. I do. Thus, the post-expansion process of the segment coil SC inserted in the stator core 20 is completed.

  FIG. 16 shows a cross-sectional view of the stator. The stator 10 is expanded after the lead portion in a state where the segment coil SC is inserted into the stator core 20 shown in FIG. 8, and is formed into the shape of the lead portion Sga as shown in FIG. The lead portion Sga of the segment coil SC has a first lead portion Sga1 and a second lead portion Sga2 that are parallel to the axis of the stator core 20. On the other hand, a first shift portion inner side Sf11 is formed in the third lead portion Sga3, and a first shift portion outer side Sf12 is formed in the fourth lead portion Sga4. The first shift portion inner side Sf11 and the first shift portion outer side Sf12 are formed on the first expansion blade 81 as the first shift portion Sf1.

  A second shift portion inner side Sf21 is formed in the fifth lead portion Sga5, and a second shift portion outer side Sf22 is formed in the sixth lead portion Sga6. The second shift portion inner side Sf21 and the second shift portion outer side Sf22 are formed on the second expansion blade 82 as the second shift portion Sf2. A third shift portion inner side Sf31 is formed in the seventh lead portion Sga7, and a third shift portion outer side Sf32 is formed in the eighth lead portion Sga8. The third shift portion inner side Sf31 and the third shift portion outer side Sf32 are formed on the third expansion blade 83 as the third shift portion Sf3. Each of the first shift portion Sf <b> 1 to the third shift portion Sf <b> 3 is formed along the wedge-shaped portion at the tip of the additional expansion blade 80. That is, it is formed as a side having a predetermined angle with respect to the axial direction of the stator core 20.

  Since the stator 10 of this embodiment is manufactured with the said structure, there exists an effect | action and effect which are demonstrated below.

  First, an advantage is that the extended pitch of the lead portion Sga can be increased. This is because the flat coil conductor D is bent to form the segment coil SC, and the segment coil SC is inserted into the slot 12 of the stator core 20 to manufacture the stator 10. The fourth lead portion Sga4 of the group of lead portions Sga protruding from the end face of the stator core 20 of the segment coil SC inserted into the stator core 20 is connected to the first preliminary expansion blade 71 from the axial direction of the stator core 20. And the first gap portion x1 between the fourth lead portion Sga4 and the fifth lead portion Sga5 adjacent to the fourth lead portion Sga4. Form.

  In the second expansion step, the first expansion blade 81 and the second expansion blade 82 that is provided adjacent to the first expansion blade 81 from the axial direction of the stator core 20 and has a different length from the first expansion blade 81 are provided. The first extension blade 81 causes the third lead portion Sga3 of the lead portions Sga to be displaced in the radial direction of the stator core 20 from the in-slot conductor portion Sgb accommodated in the slot 12 by being brought close to the lead portion Sga group. The first shift portion inner side Sf11 is formed, the first lead portion outer portion Sf12 is formed in the fourth lead portion Sga4, and the second expansion blade 82 is inserted into the first gap portion x1, thereby the fifth lead portion Sga5. A second shift portion inner side Sf21 that is eccentric in the radial direction of the stator core 20 from the in-slot conductor portion Sgb is formed, and the sixth lead portion Sga6 has a second shift portion inside. Shifting portion outer Sf22 is formed.

  FIG. 17 is a side view showing the state of the lead tip extension process prepared for comparison. In FIG. 16, the lead portion Sga group is expanded by the additional expansion blade 80 used in the second expansion process without performing the first expansion process. When the first extension blade 81 is inserted between the second lead portion Sga2 and the third lead portion Sga3, the third lead portion Sga3 to the eighth lead portion Sga8 are pushed and moved to the outer peripheral side of the stator core 20. To do. As a result, the tip of the fifth lead portion Sga5 interferes with the second expansion blade 82 as shown in the portion A of FIG. This interference is more likely to occur as the expansion width of the lead portion Sga group is increased with the additional expansion blade 80, and can be solved even if the shapes of the second expansion blade 82 and the third expansion blade 83 are adjusted. difficult.

  The heights of the first extension blade 81, the second extension blade 82, and the third extension blade 83 cannot be changed in order to ensure the quality of the lead portion Sga group after the extension processing. Therefore, the width that can be expanded is inevitably determined. However, as in the present invention, by dividing into two steps of the first expansion step and the second expansion step, the first gap portion x1 and the second gap portion x2 are formed, and the second expansion blade 82 and the third expansion blade 83 are formed. Can be prevented from interfering with the fifth lead portion Sga5, the seventh lead portion Sga7, or other lead portions Sga. Therefore, the expansion pitch of the lead portion Sga group can be further increased in the post-expansion process of the stator 10.

  Moreover, the point which can manufacture the stator 10 more cheaply is mentioned as an effect. This is because the interference between the additional expansion blade 80 and the lead portion Sga as shown in FIG. 16 can be prevented, so that the yield can be improved. In the post-expansion process, two processes of the first expansion process and the second expansion process are required, so that the lead time of the manufacturing process of the stator 10 becomes longer than it ends in one process. However, the yield can be improved, and as a result, the manufacturing cost can be reduced.

  Moreover, it is easy to ensure an expansion space by expanding to the outer peripheral side of the stator 10. This is because the first expansion blade 81 deforms the third lead portion Sga3 to form the first shift portion Sf1, and the second expansion blade 82 is shorter than the first expansion blade 81 and fixed more than the third lead portion Sga3. The fifth lead portion Sga5 located on the outer peripheral side of the child core 20 is deformed to form the second shift portion Sf2. Thereby, the stator 10 in which the lead portion Sga is expanded is formed on the outer peripheral side of the stator core 20. By setting the length of the second expansion blade 82 shorter than the first expansion blade 81 and the third expansion blade 83 shorter than the second expansion blade 82, even if the additional expansion blade 80 is moved at a time, it leads with a time difference. Can be inserted into the partial Sga group.

  At this time, since the first gap portion x1 and the second gap portion x2 are first formed in the first extension step, the second extension blade 82 and the third extension blade 83 interfere with the tip portion of the segment coil SC. Risk is reduced. A rotor (not shown) is disposed on the inner peripheral side of the stator 10 to form a motor (not shown). And in order to improve the performance of a motor, it is necessary to hold | maintain the stator 10 and a rotor, maintaining a narrow clearance. For this reason, it is more rational to expand the lead portion Sga group on the outer peripheral side of the stator 10, and it is possible to take a further margin for expansion of the lead portion Sga group.

  The lead portion Sga is twisted and Tig welded in a subsequent process. Thereafter, powder coating is performed to insulate the coil end portion. Therefore, the second lead portion Sga2 and the third lead portion Sga3, the fourth lead portion Sga4 and the fifth lead portion Sga5, and the sixth lead portion Sga6 and the seventh lead portion Sga7 are spaced apart from each other. desirable. When twisting, it becomes easy to hold the tip with a jig, and when Tig welding is performed, a reduction in welding defects can be expected. In the coil end portion insulation treatment, it can be expected that the powder can easily enter the coil end and the insulation can be easily secured.

  Further, by using the additional expansion blade 80 and the outer diameter pressurizing means 90, the tip of the lead portion Sga can be formed substantially parallel to the axis of the stator core 20. In the first expansion step of the stator 10, the lead portion Sga group is supported by the inner diameter support means 50 that supports the lead portion Sga group from the inner peripheral side of the stator core 20, and the first preliminary expansion blade 71 is moved to the fifth. The first gap portion x1 is formed close to the lead portion Sga5, and the lead portion Sga group is formed by the root pressing means 60 that supports the root portion near the end surface 20a of the lead portion Sga from the outer peripheral side of the stator core 20. Press to mold.

  In the second expansion step, the inner diameter support means 50 supports the lead portion Sga group, and the first expansion blade 81 to the third expansion blade 83 are inserted into the lead portion Sga group, and the first shift portions Sf1 to Sf1 to Sf1. The third shift portion Sf3 is formed, the root pressurizing means 60 pressurizes the root portion of the lead portion Sga group, and the outer diameter is increased to support the tip side portion of the lead portion Sga group from the outer peripheral side of the stator core 20. The pressure means 90 presses and molds the stator core 20 from the outside in the radial direction. Preliminary expansion is performed by the preliminary expansion blade 70 in the first expansion step, the first gap portion x1 and the second gap portion x2 are formed, and expansion is performed using the additional expansion blade 80 in the second expansion step. Smooth expansion is realized.

  Further, by supporting the inner diameter side of the lead portion Sga group by the inner diameter support means 50 and pressing the additional expansion blade 80 from the outer diameter side by the basic pressure means 60 and the outer diameter pressure means 90, The tip of the lead portion Sga is formed substantially parallel to the axis of the stator core 20. As a result, the tips of the lead portions Sga are substantially parallel to the axis of the stator core 20, so that when Tig welding is performed, weldability is improved and welding defects can be expected to be reduced.

  Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented. For example, although the number of in-slot conductors Sgb inserted into the slots 12 of the stator core 20 is eight, the present invention can be applied even if this number is increased or decreased.

  Further, after the lead portion extension, the first extension step and the second extension step are performed in two steps, but the first processing step, which is a preliminary extension step, is further subdivided according to the number of segments Sg inserted into the slot 12. Does not prevent However, considering the reduction of the lead time in the manufacture of the stator 10, it is desirable to suppress the increase in the number of processes as much as possible. Further, in the first expansion process and the second expansion process, the lead portion Sga is only shown for one row for convenience of explanation, but it is processed at once for 48 slots or divided into a plurality of times. Not disturb.

  Further, the first preliminary expansion blade 71 and the second preliminary expansion blade 72 of the preliminary expansion blade 70 are configured to move simultaneously by one propulsion mechanism, but the positions of the first preliminary expansion blade 71 and the second preliminary expansion blade 72 are the same. If accuracy can be secured, it will not prevent you from moving forward and backward separately. Similarly, the first expansion blade 81, the second expansion blade 82, and the third expansion blade 83 of the additional expansion blade 80 may be configured to advance and retract separately. Although it is desirable that the number of propulsion mechanisms is small, there is an advantage that the blades can be propelled at different timings as necessary, so that it is preferable to use them according to the design concept.

DESCRIPTION OF SYMBOLS 10 Stator 11 Teeth 12 Slot 20 Stator core 20a End surface 25 Insulator 30 External connection terminal 31 Terminal block D Rectangular conductor SC Segment coil Sf Shift part Sg Segment Sga Lead part Sgb In-slot lead part Sgc Anti-lead part Sge Crank part Sgf Welding Part Sgi peeling part

Claims (5)

In a stator manufacturing method of bending a flat conductor to form a segment coil, inserting the segment coil into a slot of a stator core, and manufacturing a stator,
Using a first pre-deformation blade for bringing the first lead portion of the group of lead portions protruding from the end face of the stator core of the segment coil inserted into the stator core closer from the axial direction of the stator core And a first expansion step in which a gap portion is formed between the first lead portion and another adjacent lead portion by decentering in a radial direction of the stator core from the in-slot conductor portion housed in the slot. When,
A first deforming blade from the axial direction of the stator core and a second deforming blade provided adjacent to the first deforming blade and having a different length from the first deforming blade, are inserted into the lead portion group;
The first deforming blade forms a first shift portion that is eccentric in the radial direction of the stator core from the in-slot conductor portion in the second lead portion of the lead portion group,
A second expansion step of forming a second shift portion that is eccentric in the radial direction of the stator core from the in-slot conductor portion in the first lead portion by inserting the second deforming blade into the gap portion. And having
The stator manufacturing method characterized by these. In the stator manufacturing method according to claim 1,
The first deformation blade deforms the second lead portion to form the first shift portion that is eccentric to the outer peripheral side of the stator core,
The second deforming blade is shorter than the first deforming blade and deforms the first lead portion located on the outer peripheral side of the stator core from the second lead portion, so that the outer peripheral side of the stator core. Forming the second shift portion eccentric to
The stator manufacturing method characterized by these. In the stator manufacturing method according to claim 2,
In the first expansion step,
In the inner diameter support means for supporting the lead portion group from the inner peripheral side of the stator core, the lead portion group is supported,
Inserting the first preliminary deformation blade into the lead portion group to deform the first lead portion to form the gap portion;
In the basic pressurizing means for pressurizing the root portion close to the stator core end face of the lead portion group from the outer peripheral side of the stator core, the lead portion group is pressed and molded,
In the second expansion step,
The inner diameter support means supports the lead portion group,
Inserting the first deformation blade and the second deformation blade into the lead portion group to form the first shift portion and the second shift portion;
The root pressurizing means pressurizes the root portion of the lead portion group,
In the outer diameter pressurizing means for supporting the distal end side portion of the lead portion group from the outer peripheral side of the stator core, molding is performed by pressing from the radially outer side of the stator core,
The stator manufacturing method characterized by these. In the stator manufacturing apparatus that expands the pitch between the lead portions protruding from the end face of the stator core of the stator component in which the segment coil formed by bending a flat conductor is inserted into the stator core,
A pre-deformation mechanism portion comprising a first pre-deformation blade that is inserted into the lead portion group and forms a gap portion, which is used in the first expansion step;
A deformation mechanism unit including a first deformation blade to be inserted into the lead portion group and a second deformation blade having a shorter length than the first deformation blade and inserted into the gap portion, which is used in the second expansion step; Providing,
The stator manufacturing apparatus characterized by this . In the stator manufacturing apparatus according to claim 4,
An inner diameter support means for supporting the lead portion group from the inner peripheral side of the stator core and the lead portion group from the outer peripheral side of the stator core after inserting the first preliminary deformation blade into the preliminary deformation mechanism portion. A base pressurizing means for pressurizing a base portion close to the end face of the stator core,
After inserting the inner diameter support means, the first deformation blade, and the second deformation blade into the deformation mechanism portion, a root portion close to the stator core end surface of the lead portion group from the outer peripheral side of the stator core is formed. Root pressing means for pressing, and after pressing the root portion of the lead portion group by the root pressing means, an outer diameter pressing for supporting the tip side portion of the lead portion group from the outer peripheral side of the stator core Providing means,
The stator manufacturing apparatus characterized by this.

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