JP6804415B2 - Manufacture method of stator, manufacturing method of rotary electric machine - Google Patents

Manufacture method of stator, manufacturing method of rotary electric machine Download PDF

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JP6804415B2
JP6804415B2 JP2017179033A JP2017179033A JP6804415B2 JP 6804415 B2 JP6804415 B2 JP 6804415B2 JP 2017179033 A JP2017179033 A JP 2017179033A JP 2017179033 A JP2017179033 A JP 2017179033A JP 6804415 B2 JP6804415 B2 JP 6804415B2
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stator
welding
electric machine
rotary electric
manufacturing
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JP2019054693A (en
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松延 豊
豊 松延
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Hitachi Astemo Ltd
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Hitachi Automotive Systems Ltd
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Description

本発明は、固定子の製造方法、および回転電機の製造方法関する。 The present invention relates to a method of manufacturing a stator, and relates to a method of manufacturing a rotary electric machine.

昨今の地球温暖化に関連して、回転電機は小型高出力が求められている。このような回転電機として、たとえば内周側に開口する多数のスロットを備える固定子鉄心を有し、各スロットに複数の略U字形状のセグメント導体を挿入する事で占積率を向上させて性能を向上させたものが知られている。
特許文献1には、コアの異なる各スロットにそれぞれ挿通された多数の導体セグメントの端部を一対ずつ溶融接合して接合端部を形成することにより巻線を構成する導体セグメント接合型の回転電機の製造方法において、前記接合端部は、前記導体セグメント対の端部の溶融部を前記コアの周方向一方側に付勢しつつ固化することにより、前記接合端部を周方向一方側に偏って膨設された形状に形成することを特徴とする導体セグメント接合型の回転電機の製造方法が開示されている。
In connection with the recent global warming, rotary electric machines are required to have a small size and high output. As such a rotary electric machine, for example, it has a stator core provided with a large number of slots open on the inner peripheral side, and the space factor is improved by inserting a plurality of substantially U-shaped segment conductors into each slot. Those with improved performance are known.
In Patent Document 1, a conductor segment joint type rotary electric machine that constitutes a winding by melt-joining a pair of ends of a large number of conductor segments inserted into each slot having different cores to form a joint end. In the manufacturing method of, the joint end portion is solidified while urging the molten portion of the end portion of the conductor segment pair to one side in the circumferential direction of the core, so that the joint end portion is biased to one side in the circumferential direction. A method for manufacturing a conductor segment joint type rotary electric machine, which is characterized in that it is formed into an inflated shape, is disclosed.

特許第3769990号Patent No. 3769990

特許文献1に記載されている発明では、太いコイルを用いる場合に固定子の変形を抑制できない。 In the invention described in Patent Document 1, deformation of the stator cannot be suppressed when a thick coil is used.

本発明の第1の態様による固定子の製造方法は、複数のスロットが円周上に設けられる固定子鉄心と、前記複数のスロットのそれぞれに挿入されるセグメント導体と、前記複数のスロットのそれぞれにおいて前記セグメント導体同士を溶接して構成される固定子コイルとを備える固定子の製造方法であって、前記セグメント導体同士を溶接する順番は、前記円周上の少なくとも一か所で不連続である。
本発明の第2の態様による回転電機の製造方法は、固定子を備える回転電機の製造方法であって、前記固定子は、複数のスロットが円周上に設けられる固定子鉄心と、前記複数のスロットのそれぞれに挿入されるセグメント導体と、前記複数のスロットのそれぞれにおいて前記セグメント導体同士を溶接して構成される固定子コイルとを備え、前記セグメント導体同士を溶接する順番は、前記円周上の少なくとも一か所で不連続である
The method for manufacturing a stator according to the first aspect of the present invention includes a stator core in which a plurality of slots are provided on the circumference, a segment conductor inserted into each of the plurality of slots, and each of the plurality of slots. In the method for manufacturing a stator including a stator coil formed by welding the segment conductors to each other, the order in which the segment conductors are welded is discontinuous at at least one place on the circumference. is there.
The method for manufacturing a rotary electric machine according to the second aspect of the present invention is a method for manufacturing a rotary electric machine including a stator, wherein the stator includes a stator core in which a plurality of slots are provided on the circumference and the plurality of stators. A segment conductor inserted into each of the slots and a stator coil formed by welding the segment conductors to each other in each of the plurality of slots are provided, and the order of welding the segment conductors is the circumference. Discontinuous in at least one of the above .

本発明によれば、太いコイルを用いる場合でも固定子の変形を抑制できる。 According to the present invention, deformation of the stator can be suppressed even when a thick coil is used.

回転電機10を搭載する車両500の構成図Configuration diagram of vehicle 500 equipped with rotary electric machine 10 回転電機10の断面図Sectional view of rotary electric machine 10 固定子20の外観図External view of stator 20 固定子コイル60の巻線方法を示す図。図4(a)はセグメント導体28を示す図、図4(b)はセグメント導体28同士の接続を示す図、図4(c)はスロット21Sに4本のセグメント導体28が挿入された例を示す図The figure which shows the winding method of the stator coil 60. FIG. 4A is a diagram showing segment conductors 28, FIG. 4B is a diagram showing connections between segment conductors 28, and FIG. 4C is an example in which four segment conductors 28 are inserted into slots 21S. Figure shown 一相分のコイル40を示す図The figure which shows the coil 40 for one phase 本実施の形態における溶接の順番を示す図The figure which shows the order of welding in this embodiment 比較例における溶接の順番を示す図The figure which shows the welding order in the comparative example 本実施の形態および比較例において溶接部28Eの固定子コイル60の中心からの距離を示す概念図Conceptual diagram showing the distance from the center of the stator coil 60 of the welded portion 28E in the present embodiment and the comparative example.

―実施の形態―
以下、図1〜図8を参照して、本発明にかかる回転電機の実施の形態を説明する。
-Embodiment-
Hereinafter, embodiments of the rotary electric machine according to the present invention will be described with reference to FIGS. 1 to 8.

(全体構成)
図1は、本発明にかかる回転電機10を搭載する車両500の構成図である。車両500は、ハイブリッド自動車であり、エンジン501、回転電機10、変速機502、前輪503、後輪504、電力変換装置505、およびバッテリ506を備える。エンジン501および回転電機10が発生する動力は、変速機502により変速され、前輪503に伝達される。後輪504は、後輪504側に配置された回転電機10と後輪504が機械的に接続されて、動力が伝達される。回転電機10は、車両500の走行状態に応じて、駆動力の発生と、車両500の減速時のエネルギーを電気エネルギーとして回収する発電力の発生とを切り換える。
(overall structure)
FIG. 1 is a configuration diagram of a vehicle 500 equipped with the rotary electric machine 10 according to the present invention. The vehicle 500 is a hybrid vehicle and includes an engine 501, a rotary electric machine 10, a transmission 502, a front wheel 503, a rear wheel 504, a power conversion device 505, and a battery 506. The power generated by the engine 501 and the rotary electric machine 10 is changed by the transmission 502 and transmitted to the front wheels 503. In the rear wheel 504, power is transmitted by mechanically connecting the rotary electric machine 10 arranged on the rear wheel 504 side and the rear wheel 504. The rotary electric machine 10 switches between the generation of the driving force and the generation of the power generation that recovers the energy at the time of deceleration of the vehicle 500 as electric energy according to the traveling state of the vehicle 500.

回転電機10の駆動および発電動作は、車両500の運転状況にあわせて、トルクおよび回転数が最適になるように電力変換装置505により制御される。回転電機10の駆動に必要な電力は、電力変換装置505を介してバッテリ506から供給される。また、回転電機10が発電動作を行う場合は、電力変換装置505を介してバッテリ506に電気エネルギーが充電される。以下、回転電機10の構成および製造方法を説明する。 The drive and power generation operation of the rotary electric machine 10 is controlled by the power conversion device 505 so that the torque and the rotation speed are optimized according to the operating condition of the vehicle 500. The electric power required to drive the rotary electric machine 10 is supplied from the battery 506 via the power conversion device 505. Further, when the rotary electric machine 10 performs the power generation operation, the battery 506 is charged with electric energy via the power conversion device 505. Hereinafter, the configuration and manufacturing method of the rotary electric machine 10 will be described.

(定義)
本実施の形態では、回転電機10の回転軸に沿った方向を「軸方向」と呼び、回転電機10の回転方向に沿った方向を「周方向」と呼ぶ。また回転電機10の回転軸を中心としたときの動径方向(半径方向)を「径方向」と呼ぶ。回転電機10の径方向内側(内径側)を「内周側」と呼び、その逆方向である径方向外側(外径側)を「外周側」と呼ぶ。
(Definition)
In the present embodiment, the direction along the rotation axis of the rotary electric machine 10 is referred to as "axial direction", and the direction along the rotation direction of the rotary electric machine 10 is referred to as "circumferential direction". Further, the radial direction (radial direction) when the rotary electric machine 10 is centered on the rotation axis is called "diameter direction". The radial inner side (inner diameter side) of the rotary electric machine 10 is called the "inner peripheral side", and the radial outer side (outer diameter side) in the opposite direction is called the "outer peripheral side".

(回転電機10の構成)
図2は回転電機10の断面図である。回転電機10は、ハウジング50と、固定子20と、回転子11とを備える。固定子20は、固定子鉄心21と、固定子コイル60とを備える。ハウジング50の内周側には、固定子20が固定される。固定子20の内周側には、回転子11が回転可能に支持される。ハウジング50は、炭素鋼など鉄系材料の切削により、または、鋳鋼やアルミニウム合金の鋳造により、または、プレス加工によって円筒状に成形される。ハウジング50は、回転電機10の外被を構成する。ハウジング50は、枠体またはフレームとも称される。
(Structure of rotary electric machine 10)
FIG. 2 is a cross-sectional view of the rotary electric machine 10. The rotary electric machine 10 includes a housing 50, a stator 20, and a rotor 11. The stator 20 includes a stator core 21 and a stator coil 60. A stator 20 is fixed to the inner peripheral side of the housing 50. The rotor 11 is rotatably supported on the inner peripheral side of the stator 20. The housing 50 is formed into a cylindrical shape by cutting an iron-based material such as carbon steel, casting a cast steel or an aluminum alloy, or by pressing. The housing 50 constitutes the outer cover of the rotary electric machine 10. The housing 50 is also referred to as a frame or frame.

ハウジング50の外周側には、液冷ジャケット130が固定される。液冷ジャケット130の内周壁とハウジング50の外周壁とで、油などの液状の冷媒RFの冷媒通路153が構成され、この冷媒通路153は液漏れしないように形成される。液冷ジャケット130は、軸受144,145を収納しており、液冷ジャケット130は軸受ブラケットとも称される。なお直接液体冷却の場合は、冷媒RFは冷媒通路153を通り、冷媒出口154,155から固定子20へ向けて流出し、固定子20を冷却する。冷媒RFは、冷媒貯蔵空間150に貯蔵される。 A liquid-cooled jacket 130 is fixed to the outer peripheral side of the housing 50. The inner peripheral wall of the liquid-cooled jacket 130 and the outer peripheral wall of the housing 50 form a refrigerant passage 153 for a liquid refrigerant RF such as oil, and the refrigerant passage 153 is formed so as not to leak. The liquid-cooled jacket 130 houses bearings 144 and 145, and the liquid-cooled jacket 130 is also referred to as a bearing bracket. In the case of direct liquid cooling, the refrigerant RF passes through the refrigerant passage 153 and flows out from the refrigerant outlets 154 and 155 toward the stator 20 to cool the stator 20. The refrigerant RF is stored in the refrigerant storage space 150.

固定子20は、固定子鉄心21と、固定子コイル60とから構成される。固定子鉄心21は、珪素鋼板の薄板を積層したものである。固定子コイル60は、固定子鉄心21の内周部に多数個設けられているスロット21Sに巻回され、ワニス等で固定される。固定子コイル60からの発熱は固定子鉄心21を介して液冷ジャケット130に伝熱され、液冷ジャケット130内を流通する冷媒RFにより放熱される。 The stator 20 is composed of a stator core 21 and a stator coil 60. The stator core 21 is a laminate of thin silicon steel plates. The stator coil 60 is wound around a large number of slots 21S provided on the inner peripheral portion of the stator core 21 and fixed with a varnish or the like. The heat generated from the stator coil 60 is transferred to the liquid-cooled jacket 130 via the stator core 21, and is dissipated by the refrigerant RF circulating in the liquid-cooled jacket 130.

回転子11は、回転子鉄心12と、回転軸13とから構成される。回転子鉄心12は、珪素鋼板の薄板を積層したものである。回転軸13は、回転子鉄心12の中心に固定される。回転軸13は、液冷ジャケット130に取り付けられた軸受144,145により回転自在に保持され、固定子20内の所定の位置で、固定子20に対向した位置で回転する。また回転子11には、永久磁石18と不図示のエンドリングとが設けられる。 The rotor 11 is composed of a rotor core 12 and a rotating shaft 13. The rotor core 12 is formed by laminating thin plates of silicon steel plates. The rotating shaft 13 is fixed to the center of the rotor core 12. The rotating shaft 13 is rotatably held by bearings 144 and 145 attached to the liquid-cooled jacket 130, and rotates at a predetermined position in the stator 20 and at a position facing the stator 20. Further, the rotor 11 is provided with a permanent magnet 18 and an endling (not shown).

回転電機10の組立は、予め、固定子20をハウジング50の内側に挿入してハウジング50の内周壁に取付けておき、その後、固定子20内に回転子11を挿入する。次に、回転軸13に軸受144,145が嵌合するようにして液冷ジャケット130に組み付ける。符号61および62については後述する。 To assemble the rotary electric machine 10, the stator 20 is inserted inside the housing 50 and attached to the inner peripheral wall of the housing 50 in advance, and then the rotor 11 is inserted into the stator 20. Next, the bearings 144 and 145 are fitted to the rotating shaft 13 and assembled to the liquid cooling jacket 130. Reference numerals 61 and 62 will be described later.

(固定子20)
図3は、固定子20の外観図である。以下では固定子20の構成を説明する。固定子鉄心21には、U相、V相、W相の三相の固定子巻線40が分布巻きで捲回される。固定子鉄心21の内周には、その中心軸に平行に延在する例えば72個のスロット21Sが、周方向に等間隔に形成される。すなわちU相、V相、W相の三相の固定子巻線40は、絶縁紙200で絶縁されつつスロット21S内に挿入される。固定子巻線40には、断面が略矩形形状の導体、たとえば銅線が使用される。固定子巻線40の断面は、たとえば短辺と長辺がそれぞれ2mmと3mmの略矩形形状であり容易には変形されない。固定子巻線40の断面が略矩形形状なので、スロット21S内の占積率が向上され、回転電機10の効率が向上する。
(Stator 20)
FIG. 3 is an external view of the stator 20. The configuration of the stator 20 will be described below. A three-phase stator winding 40 of U phase, V phase, and W phase is wound around the stator core 21 in a distributed winding manner. On the inner circumference of the stator core 21, for example, 72 slots 21S extending parallel to the central axis thereof are formed at equal intervals in the circumferential direction. That is, the three-phase stator windings 40 of the U phase, the V phase, and the W phase are inserted into the slot 21S while being insulated by the insulating paper 200. For the stator winding 40, a conductor having a substantially rectangular cross section, for example, a copper wire is used. The cross section of the stator winding 40 has a substantially rectangular shape with short and long sides of 2 mm and 3 mm, respectively, and is not easily deformed. Since the cross section of the stator winding 40 has a substantially rectangular shape, the space factor in the slot 21S is improved, and the efficiency of the rotary electric machine 10 is improved.

絶縁紙200が各スロット21Sに配設され、固定子鉄心21と固定子コイル60との電気的絶縁を確実にしている。絶縁紙200は、銅線を包装するようにB字形状や、S字形状に成形される。なお、図3に示す回転電機100は例えば三相交流を二系統備えた2Yモータであり、U相、V相、W相の巻線が計6個設けられる。図3に示すように、固定子コイル60における一方のコイルエンド61には、UVW三相それぞれ二系統の入出力用コイル導体42U、42V、42Wが各相2系統の6つのコイル巻き初め端部から6本引き出されている。また、各相2系統の6つのコイル巻き終わり端部から中性点結線用導体41(図5参照)が6本引き出されている。 Insulating paper 200 is arranged in each slot 21S to ensure electrical insulation between the stator core 21 and the stator coil 60. The insulating paper 200 is formed into a B-shape or an S-shape so as to wrap a copper wire. The rotary electric machine 100 shown in FIG. 3 is, for example, a 2Y motor provided with two systems of three-phase alternating current, and is provided with a total of six U-phase, V-phase, and W-phase windings. As shown in FIG. 3, one coil end 61 of the stator coil 60 has two UVW three-phase input / output coil conductors 42U, 42V, and 42W at the beginning and end of six coil windings of each phase. 6 are pulled out from. Further, six conductors 41 for neutral point connection (see FIG. 5) are drawn out from the end ends of the six coils of the two systems of each phase.

(固定子コイル60の巻線方法)
図4は、固定子コイル60の巻線方法を示す図である。なお前述のとおり回転電機10は三相の固定子巻線が設けられているが、図4においては、理解を容易にするために、一相の一系統のみの固定子巻線40を示し、固定子鉄心21や絶縁紙200を省略して示している。
(Wounding method of stator coil 60)
FIG. 4 is a diagram showing a winding method of the stator coil 60. As described above, the rotary electric machine 10 is provided with a three-phase stator winding, but in FIG. 4, for the sake of easy understanding, a stator winding 40 having only one phase and one system is shown. The stator core 21 and the insulating paper 200 are omitted.

固定子コイル60の巻線方法は、まず、断面が略矩形の銅線を図4(a)に示す略U字形状のセグメント導体28に成型し、そのセグメント導体28の先端部28Eを軸方向からスロット21Sに挿入する。セグメント導体28はスロット21Sよりも長いので、挿入した先端部28Eはスロット21Sを貫通する。次に先端部28E付近を捻る捻り加工を行い、図4(b)に示すように導体斜行部28Dを形成する。なお実際には捻り加工を施すと図3に示すような形状となるが、図4(b)では捻りの影響を排除して図示している。導体斜行部28Dの形成が完了すると、所定の数だけ離れたスロット21Sに挿入された他のセグメント導体28と導体端部28Eにおいて溶接により接続する。なお図4(b)では図示の都合により隣接するスロット21Sに挿入されたセグメント導体28同士を溶接しているように図示しているが、実際には所定のセグメント数だけ離れているセグメント導体28同士が溶接される。 In the winding method of the stator coil 60, first, a copper wire having a substantially rectangular cross section is molded into a substantially U-shaped segment conductor 28 shown in FIG. 4A, and the tip portion 28E of the segment conductor 28 is axially oriented. Is inserted into the slot 21S. Since the segment conductor 28 is longer than the slot 21S, the inserted tip 28E penetrates the slot 21S. Next, a twisting process is performed in the vicinity of the tip portion 28E to form the conductor skew portion 28D as shown in FIG. 4 (b). Actually, when the twisting process is performed, the shape is as shown in FIG. 3, but in FIG. 4B, the influence of the twisting is excluded. When the formation of the conductor skew portion 28D is completed, the conductor end portion 28E is connected by welding to another segment conductor 28 inserted into the slots 21S separated by a predetermined number. Note that FIG. 4B shows that the segment conductors 28 inserted into the adjacent slots 21S are welded to each other for convenience of illustration, but the segment conductors 28 are actually separated by a predetermined number of segments. They are welded together.

溶接が完了すると、セグメント導体28には、スロット21Sに挿入されている部位である導体直線部28Sと、接続相手のセグメント導体の導体端部28Eへ向かって傾斜する部位である導体斜行部28Dと、屈曲部28Kとが形成される。Nを正の整数とすると、それぞれのスロット21Sには2N本のセグメント導体28が挿入される。図4(c)は、Nが2の場合、すなわち1つのスロット21Sに、28R1〜28R4の4本のセグメント導体28が挿入された例を示す図である。セグメント導体28は断面が略矩形の導体のため、スロット内の占積率を向上させることができ、回転電機10の効率が向上する。 When the welding is completed, the segment conductor 28 has a conductor straight portion 28S, which is a portion inserted into the slot 21S, and a conductor skew portion 28D, which is a portion inclined toward the conductor end portion 28E of the segment conductor to be connected. And the bent portion 28K are formed. Assuming that N is a positive integer, 2N segment conductors 28 are inserted into each slot 21S. FIG. 4C is a diagram showing an example in which N is 2, that is, four segment conductors 28 of 28R1 to 28R4 are inserted into one slot 21S. Since the segment conductor 28 is a conductor having a substantially rectangular cross section, the space factor in the slot can be improved, and the efficiency of the rotary electric machine 10 is improved.

図5は、図4(b)の接続作業をセグメント導体28が環状となるまで繰り返し、一相分、たとえばU相の固定子コイル60を形成した図である。一相分の固定子コイル60は導体端部28Eが軸方向のある一方に集まるように構成され、導体端部28Eの集まる溶接側コイルエンド62と、反溶接側コイルエンド61とを形成する。セグメント導体28は両端の溶接部28Eが隣接するセグメント導体28に溶接されると、環状である固定子コイル60の一部、すなわち円弧を形成する。しかしセグメント導体28の形状が所定の円弧形状とは異なる場合や、溶接された際の隣接するセグメント導体28との位置や姿勢の関係が理想的な状態と異なる場合は、溶接されたセグメント導体28には残留応力が生じる。さらにセグメント導体28には、溶接による温度変化などを原因とする残留応力が生じる。 FIG. 5 is a diagram in which the connection operation of FIG. 4B is repeated until the segment conductor 28 becomes annular to form a stator coil 60 for one phase, for example, a U phase. The stator coil 60 for one phase is configured so that the conductor end 28E gathers on one side in the axial direction, and forms a welding side coil end 62 where the conductor end 28E gathers and an anti-welding side coil end 61. When the welded portions 28E at both ends are welded to the adjacent segment conductor 28, the segment conductor 28 forms a part of an annular stator coil 60, that is, an arc. However, if the shape of the segment conductor 28 is different from the predetermined arc shape, or if the position and orientation relationship with the adjacent segment conductor 28 when welded is different from the ideal state, the welded segment conductor 28 Residual stress is generated in. Further, residual stress is generated in the segment conductor 28 due to a temperature change due to welding or the like.

仮に固定子巻線40が細く剛性が弱ければ、残留応力を受けたセグメント導体28が局所的に変形し、セグメント導体28自体の位置ずれは生じにくい。しかし本実施の形態における固定子コイル60は断面が大きく剛性が高いので、残留応力が生じても局所的な変形は起こりにくく残留応力によりセグメント導体28の位置がずれる。この位置のずれが溶接により接続された隣接するセグメント導体28に影響し、特段の工夫を行わない場合は位置のずれが累積してしまう。そのため本実施の形態では、後述するように溶接の順番を工夫してこの問題を解決している。 If the stator winding 40 is thin and has low rigidity, the segment conductor 28 subjected to residual stress is locally deformed, and the position of the segment conductor 28 itself is unlikely to shift. However, since the stator coil 60 in the present embodiment has a large cross section and high rigidity, local deformation is unlikely to occur even if residual stress occurs, and the position of the segment conductor 28 shifts due to the residual stress. This misalignment affects the adjacent segment conductors 28 connected by welding, and the misalignment accumulates unless special measures are taken. Therefore, in the present embodiment, this problem is solved by devising the welding order as described later.

(溶接の順番)
図6は本実施の形態における溶接の順番を示す図である。図6は72個のスロット21Sを有するコイル40の平面図に相当する。図6における丸囲みの数字は溶接を実行する順番を示す。図6における丸囲みの数字の脇に記載した序数は、図示上部を1番とし時計回りにそれぞれのスロット21Sに割り当てたスロット番号である。以下ではスロット番号を固定子コイル60の円周上の位置とも呼ぶ。ただしここでは、スロット番号1番から溶接を開始し、溶接の順番は対角とする。具体的には図6に示すように、本実施の形態ではスロット番号1番、スロット番号37番、スロット番号19番、スロット番号55番、スロット番号10番・・という順番で溶接を行う。
(Welding order)
FIG. 6 is a diagram showing the order of welding in the present embodiment. FIG. 6 corresponds to a plan view of the coil 40 having 72 slots 21S. The circled numbers in FIG. 6 indicate the order in which welding is performed. The ordinal numbers shown next to the circled numbers in FIG. 6 are slot numbers assigned to each slot 21S clockwise with the upper part of the drawing as number 1. Hereinafter, the slot number is also referred to as a position on the circumference of the stator coil 60. However, here, welding is started from slot number 1, and the welding order is diagonal. Specifically, as shown in FIG. 6, in the present embodiment, welding is performed in the order of slot number 1, slot number 37, slot number 19, slot number 55, slot number 10 ...

すなわち溶接を行う位置は、溶接位置が可能な限り全周にわたって均等に分布するように決定される。これにより、図6に示すように全ての溶接個所において次の溶接個所とスロット21Sが隣接しない。換言すると、ある溶接個所と次の溶接個所は少なくとも2つのスロット21S以上離れる。なお図6では図示の都合により10番目〜71番目の溶接個所を省略しているが、溶接を行うスロット番号を改めて最初から記載すると以下のとおりである。ただしここでは序数の数字部分のみを記載する。 That is, the welding positions are determined so that the welding positions are evenly distributed over the entire circumference as much as possible. As a result, as shown in FIG. 6, the next welded portion and the slot 21S are not adjacent to each other at all the welded portions. In other words, one weld and the next weld are separated by at least two slots 21S or more. In FIG. 6, the 10th to 71st welding points are omitted for convenience of illustration, but the slot numbers for welding are described from the beginning as follows. However, only the ordinal number part is described here.

1,37,19,55,10,46,28,64,5,41,23,59,14,50,32,68,3,39,21,57,12,48,30,66,7,43,25,61,16,52,34,70,2,38,20,56,11,47,29,65,8,44,26,62,17,53,35,71,4,40,22,58,13,49,31,67,6,42,24,60,15,51,33,69,9,45,27,63,18,54,36,72 1,37,19,55,10,46,28,64,5,41,23,59,14,50,32,68,3,39,21,57,12,48,30,66,7, 43, 25, 61, 16, 52, 34, 70, 2, 38, 20, 56, 11, 47, 29, 65, 8, 44, 26, 62, 17, 53, 35, 71, 4, 40, 22,58,13,49,31,67,6,42,24,60,15,51,33,69,9,45,27,63,18,54,36,72

また上記の数字の列から明らかなように、セグメント導体28同士を溶接する順番は、円周上の全てで不連続である。なおこの溶接の順番は、フランジのボルトの締め付け順番、いわゆる「回し締め」の順番として知られている。上述した順番で溶接することにより、固定子コイル60を構成するそれぞれのセグメント導体28に生じた残留応力が累積することを回避し、固定子コイル60の変形を低減することができる。 Further, as is clear from the above sequence of numbers, the order of welding the segment conductors 28 to each other is discontinuous on all sides of the circumference. The order of welding is known as the order of tightening the bolts of the flange, the so-called "turn tightening" order. By welding in the order described above, it is possible to prevent the residual stress generated in each of the segment conductors 28 constituting the stator coil 60 from accumulating and reduce the deformation of the stator coil 60.

(比較例)
図7は比較例における溶接の順番を示す図である。作業効率の観点から連続して溶接を行うことが一般的なので、この比較例では固定子コイル60の円周を順番に溶接する。すなわち図1に示すように、比較例ではスロット番号と溶接の順番とが一致する。換言すると、ある溶接個所に隣接するスロット21Sが次の溶接個所である。
(Comparison example)
FIG. 7 is a diagram showing the order of welding in the comparative example. Since it is common to perform continuous welding from the viewpoint of work efficiency, in this comparative example, the circumferences of the stator coil 60 are welded in order. That is, as shown in FIG. 1, in the comparative example, the slot numbers and the welding order match. In other words, the slot 21S adjacent to a certain weld point is the next weld point.

(効果)
図8は、本実施の形態および比較例において、それぞれの溶接部28Eの固定子コイル60の中心からの距離を示す概念図である。図8の横軸はスロット番号を示し、図8の縦軸は溶接部28Eの固定子コイル60の中心からの距離を示す。図8では、丸のプロットが本実施の形態を示し、三角のプロットが比較例を示す。スロット番号1番では、本実施の形態および比較例に固定子コイル60の中心からの距離に差はない。比較例では、隣接するセグメント導体28同士が順番に溶接されるので、位置のずれが累積する。そのため比較例ではスロット番号72番目とスロット番号1番の距離の差は大きく、固定子コイル60が大きなゆがみを有する。一方で本実施の形態によれば、対角線に溶接を行うので位置のずれが累積しにくく、固定子コイル60の全周にわたって回転軸からの距離が変動しにくい。
(effect)
FIG. 8 is a conceptual diagram showing the distance from the center of the stator coil 60 of each welded portion 28E in the present embodiment and the comparative example. The horizontal axis of FIG. 8 indicates the slot number, and the vertical axis of FIG. 8 indicates the distance from the center of the stator coil 60 of the welded portion 28E. In FIG. 8, a circle plot shows the present embodiment, and a triangle plot shows a comparative example. In slot number 1, there is no difference in the distance from the center of the stator coil 60 in the present embodiment and the comparative example. In the comparative example, the adjacent segment conductors 28 are welded to each other in order, so that the positional deviations accumulate. Therefore, in the comparative example, the difference in the distance between the slot number 72 and the slot number 1 is large, and the stator coil 60 has a large distortion. On the other hand, according to the present embodiment, since the welding is performed diagonally, the positional deviation is unlikely to accumulate, and the distance from the rotating shaft is unlikely to fluctuate over the entire circumference of the stator coil 60.

上述した実施の形態によれば、次の作用効果が得られる。
(1)複数のスロット21Sが円周上に設けられる固定子鉄心21と、複数のスロット21Sのそれぞれに挿入されるセグメント導体28と、複数のスロット21Sのそれぞれにおいてセグメント導体28同士を溶接して構成される固定子コイル60とを備える固定子20の製造方法は、セグメント導体28同士を溶接する順番は、円周上の少なくとも一か所で不連続である。上述した比較例のように、セグメント導体28同士を溶接する順番が円周上ですべて連続である場合は、位置のずれが累積して固定子コイル60が大きな歪を有する。しかし少なくとも一か所でセグメント導体28同士を溶接する順番を不連続にすることでずれの累積を低減して、太い固定子巻線40を用いる場合でも固定子20の変形を抑制することができる。このようにこの固定子20の製造方法によれば、断面が大きい矩形の固定子巻線40を用いる小型高出力の固定子20であって、溶接部の信頼性が優れた固定子を製造できる。
According to the above-described embodiment, the following effects can be obtained.
(1) A stator core 21 in which a plurality of slots 21S are provided on the circumference, a segment conductor 28 inserted into each of the plurality of slots 21S, and a segment conductor 28 are welded to each other in each of the plurality of slots 21S. In the method of manufacturing the stator 20 including the stator coil 60 to be configured, the order of welding the segment conductors 28 to each other is discontinuous at at least one place on the circumference. When the order of welding the segment conductors 28 to each other is continuous on the circumference as in the above-mentioned comparative example, the displacement of the positions is accumulated and the stator coil 60 has a large distortion. However, by discontinuing the order of welding the segment conductors 28 to each other at at least one place, the accumulation of deviations can be reduced, and the deformation of the stator 20 can be suppressed even when the thick stator winding 40 is used. .. As described above, according to the method for manufacturing the stator 20, it is possible to manufacture the stator 20 which is a small high-power stator using a rectangular stator winding 40 having a large cross section and has excellent reliability of the welded portion. ..

なお図4(b)に示したように導体端部28Eはスロット21Sの外部に存在するため溶接はスロット21Sの内部では行われない。しかしいずれの導体端部28Eの溶接を行うかは、セグメント導体28が挿入されているスロット21Sを基準として決定することができる。そのため本実施の形態における溶接は、複数のスロット21Sのそれぞれにおいてセグメント導体28同士を溶接している、と表現することができる。 As shown in FIG. 4B, since the conductor end 28E exists outside the slot 21S, welding is not performed inside the slot 21S. However, which conductor end 28E is to be welded can be determined with reference to the slot 21S in which the segment conductor 28 is inserted. Therefore, the welding in the present embodiment can be expressed as welding the segment conductors 28 to each other in each of the plurality of slots 21S.

(2)セグメント導体28同士を溶接する順番は、円周上の全てで不連続である。そのためセグメント導体28の位置ずれの累積を排除し、固定子20の変形を抑制することができる。 (2) The order of welding the segment conductors 28 to each other is discontinuous on all circumferences. Therefore, it is possible to eliminate the accumulation of misalignment of the segment conductor 28 and suppress the deformation of the stator 20.

(3)セグメント導体28同士を溶接する順番は、円周上のセグメント導体28同士の溶接位置が全周にわたって均等に分布するように決定される。そのため固定子20の変形をさらに抑制することができる。 (3) The order of welding the segment conductors 28 to each other is determined so that the welding positions of the segment conductors 28 on the circumference are evenly distributed over the entire circumference. Therefore, the deformation of the stator 20 can be further suppressed.

(4)固定子20は、上述した固定子20の製造方法によって製造される。そのため固定子20の変形が抑制される。 (4) The stator 20 is manufactured by the above-mentioned manufacturing method of the stator 20. Therefore, the deformation of the stator 20 is suppressed.

(5)回転電機10は、上述した固定子20の製造方法によって製造される固定子20を備える。そのため固定子20の変形が抑制されており、固定子20への回転子11の挿入が容易である。 (5) The rotary electric machine 10 includes a stator 20 manufactured by the above-described method for manufacturing a stator 20. Therefore, the deformation of the stator 20 is suppressed, and the rotor 11 can be easily inserted into the stator 20.

(変形例1)
上述した実施の形態において図6に示した溶接の順番は、円周上のセグメント導体28同士の溶接位置が全周にわたって均等に分布するように決定された。しかし溶接位置の分布の均等性は考慮せず、単に円周上の全てで溶接の順番が不連続となるように決定してもよい。さらに、円周上の全てで不連続であることは必須の条件ではなく、円周上の少なくとも一か所でセグメント導体28同士を溶接する順番が不連続であればよい。
(Modification example 1)
In the above-described embodiment, the welding order shown in FIG. 6 is determined so that the welding positions of the segment conductors 28 on the circumference are evenly distributed over the entire circumference. However, the uniformity of the distribution of welding positions may not be considered, and the welding order may be simply determined to be discontinuous on all sides of the circumference. Further, it is not an indispensable condition that the segment conductors 28 are discontinuous at all on the circumference, and the order of welding the segment conductors 28 to each other at at least one place on the circumference may be discontinuous.

(変形例2)
上述した実施の形態では、図5に示すように溶接部28Eはコイル導体42Uとは軸方向で反対側にのみ存在している。しかし、溶接部28Eがコイル導体42Uと軸方向で同じ側にのみ存在してもよいし、溶接部28Eが軸方向の両側に分布してもよい。
(Modification 2)
In the above-described embodiment, as shown in FIG. 5, the welded portion 28E exists only on the side opposite to the coil conductor 42U in the axial direction. However, the welded portion 28E may be present only on the same side in the axial direction as the coil conductor 42U, or the welded portion 28E may be distributed on both sides in the axial direction.

(変形例3)
回転電機10は、車両500に1つのみ備えられてもよい。また回転電機10は、内燃機関を備えない電気自動車に備えられてもよい。さらに回転電機10は、自動車以外に備えられてもよい。
(Modification 3)
Only one rotary electric machine 10 may be provided in the vehicle 500. Further, the rotary electric machine 10 may be provided in an electric vehicle that does not have an internal combustion engine. Further, the rotary electric machine 10 may be provided in addition to the automobile.

上記した実施例は本発明を分かりやすく説明するために詳細に説明したものであり、必ずしも説明した全ての構成を備えるものに限定されるものではない。また、ある実施例の構成の一部を他の実施例の構成に置き換えることが可能であり、また、ある実施例の構成に他の実施例の構成を加えることも可能である。また、各実施例の構成の一部について、他の構成の追加・削除・置換をすることが可能である。 The above-described embodiment has been described in detail in order to explain the present invention in an easy-to-understand manner, and is not necessarily limited to those having all the described configurations. Further, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Further, it is possible to add / delete / replace a part of the configuration of each embodiment with another configuration.

10…回転電機
11…回転子
20…固定子
21…固定子鉄心
28…セグメント導体
40…固定子巻線
40…コイル
41…中性点結線用導体
42U…入出力用コイル導体
42U…コイル導体
50…ハウジング
60…固定子コイル
100…回転電機
10 ... Rotating electric machine 11 ... Rotator 20 ... Stator 21 ... Stator iron core 28 ... Segment conductor 40 ... Stator winding 40 ... Coil 41 ... Neutral point connection conductor 42U ... Input / output coil conductor 42U ... Coil conductor 50 ... Housing 60 ... Stator coil 100 ... Rotating electric machine

Claims (4)

複数のスロットが円周上に設けられる固定子鉄心と、
前記複数のスロットのそれぞれに挿入されるセグメント導体と、
前記複数のスロットのそれぞれにおいて前記セグメント導体同士を溶接して構成される固定子コイルとを備える固定子の製造方法であって、
前記セグメント導体同士を溶接する順番は、前記円周上の少なくとも一か所で不連続である固定子の製造方法。
A stator core with multiple slots on the circumference and
A segment conductor inserted into each of the plurality of slots,
A method for manufacturing a stator including a stator coil formed by welding the segment conductors to each of the plurality of slots.
A method for manufacturing a stator in which the order of welding the segment conductors is discontinuous at at least one place on the circumference.
請求項1に記載の固定子の製造方法において、
前記セグメント導体同士を溶接する順番は、前記円周上の全てで不連続である固定子の製造方法。
In the method for manufacturing a stator according to claim 1,
The order in which the segment conductors are welded is a method for manufacturing a stator that is discontinuous all over the circumference.
請求項2に記載の固定子の製造方法において、
前記セグメント導体同士を溶接する順番は、前記円周上の前記セグメント導体同士の溶接位置が全周にわたって均等に分布するように決定される固定子の製造方法。
In the method for manufacturing a stator according to claim 2,
A method for manufacturing a stator in which the order of welding the segment conductors is determined so that the welding positions of the segment conductors on the circumference are evenly distributed over the entire circumference.
固定子を備える回転電機の製造方法であって、
前記固定子は、
複数のスロットが円周上に設けられる固定子鉄心と、
前記複数のスロットのそれぞれに挿入されるセグメント導体と、
前記複数のスロットのそれぞれにおいて前記セグメント導体同士を溶接して構成される固定子コイルとを備え、
前記セグメント導体同士を溶接する順番は、前記円周上の少なくとも一か所で不連続である回転電機の製造方法。
It is a manufacturing method of a rotary electric machine equipped with a stator.
The stator is
A stator core with multiple slots on the circumference and
A segment conductor inserted into each of the plurality of slots,
Each of the plurality of slots is provided with a stator coil formed by welding the segment conductors to each other.
A method for manufacturing a rotary electric machine in which the order of welding the segment conductors is discontinuous at at least one place on the circumference.
JP2017179033A 2017-09-19 2017-09-19 Manufacture method of stator, manufacturing method of rotary electric machine Active JP6804415B2 (en)

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