JP7087948B2 - How to manufacture the stator - Google Patents

Description

The present invention relates to a method for manufacturing a stator.

For example, the following Patent Document 1 (Japanese Unexamined Patent Publication No. 2013-90365) discloses a method for manufacturing a stator for a rotary electric machine. Hereinafter, the reference numerals shown in parentheses in the description of the background technique are those of Patent Document 1. In the method of Patent Document 1, the stator coil (14) is formed by using an expansion ring (22) as a regulating jig for regulating the position of the stator coil (14) wound around the tubular stator core (12). The stator coil (14) is positioned with respect to the stator core (12) by pressing it outward in the radial direction. Then, from the state where the stator coil (14) is positioned in this way, the stator coil (14) is impregnated with varnish to fix the stator core (12) and the stator coil (14) with the varnish. As a result, in Patent Document 1, in the finished product of the rotary electric machine, a sufficient radial distance between the stator core (12) and the rotor is secured, and an eddy current generated in the stator coil (14) due to the magnetic flux from the rotor is secured. The current is reduced to reduce the loss generated in the rotary electric machine.

By the way, in the method of Patent Document 1, since the varnish is impregnated in the entire stator coil (14) with the expansion ring (22) attached, the varnish also adheres to the expansion ring (22). Therefore, a mold release agent is applied to the surface of the expansion ring (22), but the expansion ring (22) cannot be easily removed from the stator coil (14) depending on the state of adhesion of the varnish. May be. In such a case, when the expansion ring (22) is removed from the stator coil (14), the stator coil (14) and the expansion ring (22) may be damaged. Further, there is also a problem that the expansion ring (22) to which the varnish is attached requires maintenance work to remove the varnish after removing the ring (22).

Japanese Unexamined Patent Publication No. 2013-90365

In view of the above situation, it is desired to realize a method for manufacturing a stator in which the varnish does not easily adhere to the regulating jig for regulating the position of the coil before being hardened with the varnish.

The method for manufacturing a stator according to the present disclosure is a method for manufacturing a stator including a core and a coil mounted on the core, the coil mounting step for mounting the coil on the core, and the core. In the jig mounting process of mounting the regulating jig for restricting the position of the coil to the core so that the coil is in an appropriate position, and the region of a part of the coil, the said in the regulating jig. After the coil mounting step and the jig mounting step, the region not facing the regulation surface that regulates the position of the coil is set as the target region, and after the coil mounting step, the coil is heated and the target region has a first thermosetting property. After the first fixing step of supplying the varnish and solidifying the target area with the first varnish, the jig removing step of removing the regulating jig from the core, and the jig removing step. After the step, the coil has a second fixing step of supplying a second varnish to a region other than the target region and solidifying the region with the second varnish.

According to this configuration, in the first fixing step, the target area of the coil that does not face the regulation surface of the regulation jig is hardened with the first varnish, so that the possibility that the first varnish adheres to the regulation jig is reduced. At the same time, the target area can be solidified with the first varnish. Here, in the first fixing step, since the first varnish is supplied to the target region while the coil is heated, the curing of the first varnish is started in a short time (for example, immediately after) after being supplied to the target region. be able to. As a result, the first varnish can be easily cured in or near the target region, and from this point as well, it is possible to reduce the possibility that the first varnish adheres to the regulating jig.

Then, by solidifying the target region of the coil with the first varnish in the first fixing step as described above, the relative movement of the conductor wires constituting the coil can be regulated. As a result, even after the regulation jig is removed in the jig removal process, the movement of the coil from the proper position with respect to the core is restricted, and the coil is in the proper position with respect to the core (or it). It is possible to maintain a close state). Then, the second fixing step can be continued in this state to appropriately manufacture the stator.

As described above, according to the above configuration, it is possible to reduce the possibility of varnish adhering to the regulating jig while allowing the regulating jig to perform the function of regulating the position of the coil. As a result, it is possible to prevent the regulation jig and the stator from being adhered by the varnish and making it difficult to remove the regulation jig from the stator, and it is also possible to reduce the labor of removing the varnish adhering to the regulation jig. Can be done.

Further features and advantages of the method of manufacturing the stator will be clarified from the following description of embodiments described with reference to the drawings.

Schematic diagram of a cross section along the axial direction of the stator according to the first embodiment. A partial axial view of the stator according to the first embodiment in a jig-mounted state. Partial axial orthogonal cross-sectional view of the stator according to the first embodiment in a jig-mounted state A flowchart showing a method of manufacturing a stator according to the first embodiment. Explanatory drawing which shows the specific example of the 1st fixing process which concerns on 1st Embodiment Explanatory drawing which shows specific example of 2nd fixing process which concerns on 1st Embodiment Explanatory drawing which shows the specific example of the 1st fixing process which concerns on 2nd Embodiment Explanatory drawing which shows specific example of 1st fixing process which concerns on other embodiment

1. 1. First Embodiment A method for manufacturing a stator according to the first embodiment will be described with reference to the drawings. The stator 1 manufactured by the manufacturing method of the present embodiment is used as an armature of a rotary electric machine, and in particular, an inner rotor in which a rotor as a field (not shown) is arranged radially inside the stator 1. Used for type rotary electric machines. In this specification, "rotary electric machine" is used as a concept including any of a motor (motor), a generator (generator), and, if necessary, a motor / generator that functions as both a motor and a generator. There is.

In the following description, unless otherwise specified, "axial direction L", "diameter direction R", and "circumferential direction C" refer to the cylindrical core inner peripheral surface 11F (see FIG. 3). It is defined based on the axis. Further, in the present specification, terms relating to dimensions, arrangement directions, arrangement positions, etc. of each member are used as a concept including a state having a difference due to an error (an error to an extent acceptable in manufacturing).

[Constituent configuration]
First, the configuration of the stator 1 manufactured by the manufacturing method of the present embodiment will be described with reference to FIGS. 1 to 3. Note that FIG. 1 shows a simple cross-sectional view of the entire stator 1, and FIGS. 2 and 3 show the stator 1 in a state where the regulation jig 2 is attached (jig attached state) during manufacturing. Shows a part of.

As shown in FIGS. 1 to 3, the stator 1 includes a stator core 11 and a stator coil 12 mounted on the stator core 11. In the present embodiment, the stator core 11 is formed in a cylindrical shape in which a plurality of slots 110 that open inside in the radial direction R are arranged in the circumferential direction C. That is, the stator core 11 has a slot 110 that opens to the inner peripheral surface 11F (see FIG. 3: hereinafter referred to as the core inner peripheral surface 11F). Further, the stator coil 12 is mounted on the stator core 11 by being housed in the slot 110 formed in the stator core 11. The stator coil 12 has a slot accommodating portion 120 arranged inside the slot 110, and a coil end portion 121 projecting outward from the slot 110 in the axial direction L. In this embodiment, the stator core 11 corresponds to the "core" and the stator coil 12 corresponds to the "coil".

[Stator core]
The stator core 11 is configured by laminating a plurality of magnetic steel sheets of magnetic material in the axial direction L, or is configured mainly of a green compact obtained by pressure-molding a powder of a magnetic material.

A plurality of slots 110 extending in the axial direction L and the radial direction R are dispersedly arranged in the circumferential direction C in the stator core 11. In the present embodiment, the plurality of slots 110 are adjacent to each other at regular intervals along the circumferential direction C. A teeth 111 is formed between two slots 110 adjacent to each other in the circumferential direction C. The teeth 111 are formed so as to project inward in the radial direction R from the annular yoke portion 112, and are arranged in a plurality of distributed directions along the circumferential direction C.

As shown in FIG. 3, the side surface portion 110A of the slot 110 is configured by the side surface of the teeth 111 in the circumferential direction C. Further, the slot 110 has a bottom surface portion 110B at the outer end portion in the radial direction R thereof. The bottom surface portion 110B of the slot 110 is formed so as to be a flat surface facing inward in the radial direction R, and is composed of an inner end portion in the radial direction R of the yoke portion 112. In the present embodiment, the slot 110 is configured as a so-called fully open slot formed so that the side surface portions 110A on both sides in the circumferential direction C are formed to be a continuous plane up to the core inner peripheral surface 11F of the stator core 11. Therefore, the inner end of the teeth 111 in the radial direction R is not formed with a protrusion that protrudes in the circumferential direction C as provided in the case of a semi-open slot, for example. In this example, the inner peripheral surface 11F of the core is a cylindrical virtual surface connecting the inner ends of the plurality of teeth 111 in the radial direction R.

As shown in FIGS. 2 and 3, in the present embodiment, the insulating sheet 13 is arranged in the slot 110. The insulating sheet 13 is a sheet-like member (insulating paper) formed by using a material having an electrically insulating property. The insulating sheet 13 is arranged inside the slot 110 between the stator core 11 and the slot accommodating portion 120, and electrically insulates the two. In the present embodiment, the insulating sheet 13 is arranged along the side surface portions 110A and the bottom surface portions 110B on both sides in the circumferential direction C in the slot 110.

[Stator coil]
The stator coil 12 is composed of a conductor wire W which is a linear conductor. The conductor wire W is formed by using a conductive material (for example, a metal such as copper or aluminum), and in this example, the shape of the orthogonal cross section orthogonal to the extending direction is configured as a so-called flat wire having a rectangular shape. ing. Regarding the cross-sectional shape of the conductor wire W, the “rectangular shape” includes a conductor wire W having a chamfered corner. In the illustrated example, the four corners are chamfered. The surface of the conductor wire W is covered with an insulating film made of a resin (for example, enamel or the like) except for a part of a connection portion with another conductor wire W.

As described above, the stator coil 12 has a slot accommodating portion 120 and a coil end portion 121. The stator coil 12 is partially inserted into the slot 110 and wound around the stator core 11. The portion of the stator coil 12 that is inserted into the slot 110 and is arranged inside the slot 110 is referred to as a slot accommodating portion 120. As shown in FIG. 3, a plurality of conductor wires W (six conductor wires W in the example shown in FIG. 3) arranged inside one slot 110 are accommodated in a slot arranged inside the slot 110. It constitutes a unit 120. Here, "plurality" of the conductor lines W means that the number of the conductor lines W is a plurality of cross sections orthogonal to the extending direction of the conductor lines W (here, an axis orthogonal cross section orthogonal to the axial direction L). Conductor wire W may form parts of one continuous conductor wire (conductor wire integrally formed in the extending direction seamlessly) different from each other in the extending direction. The same applies to the plurality of conductor wires W constituting the coil end portion 121. As described above, in the present specification, different portions in the extending direction of one continuous conductor wire may be distinguished from each other, and each of the portions may be referred to as a different conductor wire W.

Further, the stator coil 12 has a portion that partially protrudes outward in the axial direction L from the stator core 11 (in other words, a portion that protrudes outward in the axial direction L from the slot 110). The portion of the stator coil 12 is referred to as a coil end portion 121. The coil end portion 121 is composed of a set of a plurality of conductor wires W. The plurality of conductor wires W constituting the coil end portion 121 include a plurality of crossover portions 122. Each of the crossover portions 122 extends in the circumferential direction C so as to connect a pair of conductor wires W (conductor wires W constituting the slot accommodating portion 120) arranged in different slots 110. The conductor wire W constituting the crossover portion 122 and the conductor wire W constituting the slot accommodating portion 120 are integrally continuous.

[Regulatory jig]
The regulating jig 2 is a jig that regulates the position of the stator coil 12 so that the stator coil 12 is in an appropriate position with respect to the stator core 11. The regulating jig 2 is used when the stator 1 is manufactured. The regulating jig 2 regulates the position of the stator coil 12 so that the stator coil 12 is in the proper position with respect to the stator core 11 by restricting the movement of the stator coil 12 from the proper position. As shown in FIG. 3, the regulating jig 2 has a regulating surface 21A that regulates the position of the stator coil 12. The regulation surface 21A is arranged so as to face a part of the region (opposite region) of the stator coil 12. The regulation surface 21A is arranged so as to be in contact with the facing region, or is arranged with a gap from the facing region. Then, the regulation surface 21A restricts the movement of the facing region to the regulation surface 21A side from the position where the facing region contacts the regulation surface 21A. In the present embodiment, the regulating jig 2 faces the regulating surface 21A from the inside of the radial direction R with respect to the slot accommodating portion 120 so that the slot accommodating portion 120 is in an appropriate position in the radial direction R with respect to the stator core 11. It is configured to do. As shown in FIGS. 2 and 3, the regulating jig 2 restricts the slot accommodating portion 120 from moving inward in the radial direction R from an appropriate position while being mounted on the stator core 11. In the present embodiment, the regulating jig 2 is formed in a cylindrical shape, and a ridge portion 21 that protrudes outward in the radial direction R and extends along the axial direction L is formed on the outer peripheral surface thereof. The regulation surface 21A is formed by the outer end surface of the ridge portion 21 in the radial direction R.

The number of ridges 21 is the same as the number of slots 110, and the ridges 21 are arranged side by side in the circumferential direction C at intervals corresponding to the arrangement intervals of the plurality of slots 110 of the stator 1. Each of the ridges 21 has a width in the circumferential direction C that is less than the width in the circumferential direction C in the opening inside the radial direction R of the slot 110. The amount of protrusion of the ridge portion 21 to the outside in the radial direction is the innermost end surface (hereinafter, inner side) in the radial direction R of the slot accommodating portion 120 arranged in the slot 110 with respect to the core inner peripheral surface 11F of the stator core 11. It is set according to the specified position of the end face 120A). Specifically, the protrusion amount of the ridge portion 21 is set so that the distance in the radial direction R between the inner peripheral surface 11F of the core and the inner end surface 120A of the slot accommodating portion 120 is equal to or more than a predetermined set distance SD. Has been done. The "set distance SD" will be described later. In the present embodiment, when the distance R in the radial direction between the inner peripheral surface 11F of the core and the inner end surface 120A of the slot accommodating portion 120 is equal to or larger than the set distance SD, the slot accommodating portion 120 is in the radial direction R with respect to the stator core 11. It is in the proper position.

Further, the length of the ridge portion 21 in the axial direction L is set to be equal to or less than the length of the stator core 11 in the axial direction L. Then, in the state where the regulating jig 2 is mounted on the stator core 11, each of the plurality of ridges 21 is inserted from the inside of the radial direction R with respect to each of the corresponding slots 110, and is arranged inside the slot 110. It faces the inner end surface 120A of the slot accommodating portion 120. Therefore, the slot accommodating portion 120 is restricted from moving inward in the radial direction R from the position where the inner end surface 120A contacts the regulation surface 21A. As a result, the regulating jig 2 restricts the movement of the slot accommodating portion 120 inward in the radial direction R so that the position of the slot accommodating portion 120 arranged in the slot 110 in the radial direction R is within the specified range. do.

[Manufacturing method of stator]
Next, a method for manufacturing the stator according to the present embodiment will be described. As shown in FIG. 4, in the method of manufacturing the stator of the present embodiment, the coil mounting step S1, the jig mounting step S2, the first fixing step S3, the jig removing step S4, and the second fixing step S5 And, in order. In the first fixing step S3, the first varnish 31 is used, and in the second fixing step S5, the second varnish 32 is used.

The first varnish 31 is a thermosetting varnish 30 that is cured by heating. In the present embodiment, in the second fixing step S5, the thermosetting varnish 30 that is cured by heating is used as the second varnish 32. Further, in the present embodiment, the same type of varnish 30 is used in the first fixing step S3 and the second fixing step S5. That is, in the present embodiment, the first varnish 31 and the second varnish 32 are the same type of varnish 30. In the present specification, when it is not necessary to distinguish between the first varnish 31 and the second varnish 32, these may be collectively referred to as varnish 30. As these varnishes 30, various known varnishes such as those using a polyimide resin, a polyester resin, or an epoxy resin can be used. Hereinafter, each step executed by the method for manufacturing a stator according to the present embodiment will be described in detail.

[Coil mounting process]
The coil mounting step S1 is a step of mounting the stator coil 12 on the stator core 11. In the present embodiment, in the coil mounting step S1, the slot accommodating portion 120 is inserted into the slot 110 from the inside in the radial direction R. As shown in FIG. 3, in the present embodiment, a plurality of conductor wires W (six conductor wires W in this example) are arranged in the radial direction R inside the slot 110 by the coil mounting step S1. do. Here, the plurality of conductor wires W inside the slot 110 are in contact with each other in the radial direction R. The inner end surface 120A of the slot accommodating portion 120 described above is a surface facing the inside of the radial direction R in the conductor wire W arranged in the innermost direction of the radial direction R among the plurality of conductor wires W arranged inside the slot 110. Consists of. In this step, without being limited to the above configuration, a large number of conductor wires W having a cross section smaller than that of the illustrated example may be irregularly arranged inside the slot 110. Further, the number of conductor wires W arranged inside the slot 110 can be arbitrarily set.

Although detailed description will be omitted, in the present embodiment, the stator coil 12 is provided with a stator core so that the insulating sheet 13 is arranged between the slot accommodating portion 120 and the inner surface (side surface portion 110A and bottom surface portion 110B) of the slot 110. Attach to 11. Here, before the coil mounting step S1, a core preparation step of preparing the stator core 11 in which the insulating sheet 13 is arranged inside the slot 110 is executed.

[Jig mounting process]
The jig mounting step S2 is a step of mounting the regulation jig 2 on the stator core 11. In this embodiment, the jig mounting step S2 is executed after the coil mounting step S1. That is, in the jig mounting step S2, with the slot accommodating portion 120 arranged inside the slot 110, the restricting jig 2 so that the restricting surface 21A faces the slot accommodating portion 120 from the inside in the radial direction R. Is attached to the stator core 11. As shown in FIG. 3, in the present embodiment, in the jig mounting step S2, the plurality of ridges 21 of the regulating jig 2 are inserted into the corresponding slots 110, and the slot accommodating portions in each slot 110 are inserted. The regulation jig 2 is arranged so as to face the inner end surface 120A of the 120. In the present embodiment, as described above, in the coil mounting step S1, the slot accommodating portion 120 of the stator coil 12 is inserted into the slot 110 from the inside of the radial direction R, so that the slot accommodating portion 120 is springbacked. It may move inward in the radial direction R. Therefore, in the jig mounting step S2, the regulating jig 2 is mounted on the stator core 11 while pressing the slot accommodating portion 120 to the outside in the radial direction R. That is, in the present embodiment, the regulation surface 21A comes into contact with the slot accommodating portion 120 (inner end surface 120A) from the inside in the radial direction R, in other words, the regulation surface 21A is the slot accommodating portion 120 (inner end surface 120A). The regulating jig 2 is mounted on the stator core 11 so as to support from the inside in the radial direction R. Then, as described above, the protrusion amount of the ridge portion 21 of the regulation jig 2 is such that the distance R in the radial direction between the inner peripheral surface 11F of the core and the inner end surface 120A of the slot accommodating portion 120 is equal to or larger than the set distance SD. It is set. Therefore, when the regulating jig 2 is mounted on the stator core 11, the slot accommodating portion 120 is positioned at an appropriate position in the radial direction R with respect to the stator core 11 (in the present embodiment, the core inner peripheral surface 11F and the slot accommodating portion). The distance of the radial direction R from the inner end surface 120A of the 120 is equal to or larger than the predetermined set distance SD), and the slot accommodating portion 120 is restricted from moving in the radial direction R by the regulating jig 2. ..

Here, the "set distance SD" is set based on the eddy current generated in the slot accommodating portion 120 due to the change in the magnetic flux from the rotor (not shown). More specifically, if the allowable distance AD is the limit distance at which the loss due to the eddy current generated in the slot accommodating portion 120 can be suppressed to the allowable limit or less, the set distance SD is set to a value larger than the allowable distance AD. Is good. This "allowable distance AD" varies depending on the size of the rotary electric machine, the required performance, and the like, and is a distance determined based on an experiment or the like. In the present embodiment, the set distance SD and the allowable distance AD are defined with the core inner peripheral surface 11F as a base point. However, the present invention is not limited to this, and the base points of the set distance SD and the allowable distance AD can be arbitrarily set. For example, the set distance SD and the allowable distance AD may be defined with the axial center position of the cylindrical stator core 11 as a base point.

Although detailed description is omitted, a preheating step of preheating the stator 1 may be executed before the jig mounting step S2 (for example, between the coil mounting step S1 and the jig mounting step S2). .. Various methods can be used as the preheating method for the stator 1. For example, energization heating, induction heating (high frequency induction heating, electromagnetic induction heating), furnace heating, hot air heating, light heating, or the like can be used, and at least two of these may be used in combination.

[First fixing step]
In the first fixing step S3, after the coil mounting step S1 and the jig mounting step S2, the first varnish 31 is supplied to the target region NR in a state where the stator coil 12 is heated, and the target region NR is set by the first varnish 31. This is the process of hardening. Here, the target region NR is a region that is a part of the stator coil 12 and does not face the regulation surface 21A of the regulation jig 2. As described above, in the present embodiment, since the regulation jig 2 is arranged so that the regulation surface 21A contacts a part of the region of the stator coil 12, the region not facing the regulation surface 21A is the regulation surface. It coincides with the area not in contact with 21A. In the present embodiment, in the first fixing step S3, the region (non-opposing region) in the inner peripheral portion 121A of the coil end portion 121 that does not face the regulation surface 21A is set as the target region NR. Therefore, as shown in FIG. 5, in the first fixing step S3, the target region NR of the inner peripheral portion 121A of the coil end portion 121 that does not face the regulation surface 21A is solidified by the first varnish 31. Here, as shown in FIG. 2, the "inner peripheral portion 121A of the coil end portion 121" is a portion inside the radial direction R of the coil end portion 121 with respect to the intermediate portion of the thickness of the radial direction R. Further, the "target region NR" is a region of the coil end portion 121 that does not face the regulation surface 21A, and here, as shown in FIG. 5 and the like, a region outside the axial direction L of the regulation jig 2. Is. In this example, in the first fixing step S3, only the target region NR in the inner peripheral portion 121A of the coil end portion 121 is solidified by the first varnish 31. In other words, in the first fixing step S3 according to this example, the outer peripheral portion 121B and the slot accommodating portion 120 of the coil end portion 121 are not solidified by the first varnish 31. Further, although it does not exist in this example, if the inner peripheral portion 121A of the coil end portion 121 has an facing region facing the regulation surface 21A, the facing region should also be solidified with the first varnish 31. I don't.

In the first fixing step S3, a plurality of conductor wires W constituting the inner peripheral portion 121A of the coil end portion 121 are mutually fixed by the first varnish 31. At this time, at least two (3) of the conductor wire W arranged on the innermost side of the radial direction R among the plurality of conductor wires W and the other conductor wire W adjacent to the conductor wire W in the radial direction R. The conductor wires W may be fixed to each other. As a result, even if the position restriction (support in this embodiment) of the slot accommodating portion 120 by the regulating jig 2 is released, the radial direction R of the inner end surface 120A (see FIG. 3) of the slot accommodating portion 120 Movement can be regulated. Therefore, even if the slot accommodating portion 120 tries to move inward in the radial direction R by springback after the jig removing step S4, the core inner peripheral surface 11F to the inner end surface 120A of the slot accommodating portion 120. Distance can be maintained above the allowable distance AD. That is, even after the regulating jig 2 is removed in the jig removing step S4, the movement of the slot accommodating portion 120 from the proper position with respect to the stator core 11 inward in the radial direction R is restricted to the stator core 11. On the other hand, it is possible to maintain a state in which the slot accommodating portion 120 is in an appropriate position (or a state close to it) in the radial direction R.

In the present embodiment, in the first fixing step S3, the target region NR in the inner peripheral portion 121A of the coil end portion 121 is solidified by the first varnish 31, and the target region NR is solidified by the first varnish 31 in the outer peripheral portion 121B of the coil end portion 121. Form no open region OR. Here, as shown in FIG. 2, the "outer peripheral portion 121B of the coil end portion 121" is a portion outside the radial direction R of the middle portion of the thickness of the radial direction R in the coil end portion 121. Further, since the "open region OR" is not solidified by the first varnish 31, the gaps between the plurality of conductor wires W constituting the stator coil 12 are not filled by the first varnish 31 and remain open. Area. This open area OR communicates with the inside of the slot 110.

As shown in FIG. 4, in the present embodiment, the first fixing step S3 includes a first heating step S31 for heating the stator coil 12 and a first varnish supply step S32 for supplying the first varnish 31 to the target region NR. And, are included.

In the present embodiment, in the first heating step S31, the stator coil 12 is energized to generate heat in the stator coil 12 to heat the stator coil 12. That is, in the first heating step S31, the stator coil 12 is heated by self-heating (Joule heat). As shown briefly in FIG. 5, the stator 1 includes a connection terminal 4 (external terminal, lead wire terminal) electrically connected to the power line of the stator coil 12. In drawings other than FIG. 5, the connection terminal 4 is not shown. In the first heating step S31, the connection terminal 4 and the power supply 5 are electrically connected by a cable or the like, and the power supply 5 supplies power to the stator coil 12 via the connection terminal 4 to energize and heat the stator coil 12. .. Here, it is assumed that the stator 1 is used for a rotary electric machine driven by three-phase alternating current, and the stator 1 is provided with three connection terminals 4. Then, in the first heating step S31, for example, a three-phase AC power source can be used as the power source 5.

In the present embodiment, in the first heating step S31, the stator coil 12 is heated so as to be equal to or higher than the curing start temperature of the first varnish 31. That is, in the first heating step S31, the temperature of the stator coil 12 is maintained above the temperature set to be equal to or higher than the curing start temperature of the first varnish 31 (hereinafter, referred to as “set heating temperature”) (for example,). Heat the stator coil 12 (so that it is maintained at the set heating temperature). Here, the curing start temperature of the first varnish 31 is a temperature at which the first varnish 31 begins to cure, and is determined by the physical properties of the first varnish 31 and the like. For example, the curing start temperature of the first varnish 31 is in the range of 120 ° C. to 140 ° C., and in this case, the set heating temperature can be set to, for example, around 130 ° C. The set heating temperature can also be set to a temperature equal to or higher than the curing temperature of the first varnish 31. Here, the curing temperature of the first varnish 31 is a temperature at which the first varnish 31 is completely cured, and is determined by the physical properties of the first varnish 31 and the like. The curing temperature of the first varnish 31 is equal to or higher than the curing start temperature of the first varnish 31. For example, the curing temperature of the first varnish 31 is in the range of 140 ° C. to 160 ° C., and in this case, the set heating temperature can be set to, for example, around 150 ° C.

In the present embodiment, the set heating temperature of the first varnish 31 is set to a temperature at which the first varnish 31 supplied to the target region NR gels and loses fluidity by the time it reaches the regulation jig 2. It is set. That is, in the present embodiment, in the first heating step S31, the first varnish 31 supplied to the target region NR is gelled by the time it reaches the regulation jig 2 and loses its fluidity. The stator coil 12 is heated. After gelling, the first varnish 31 undergoes a curing reaction to be cured.

As shown in the left figure of FIG. 5, in the present embodiment, in the first varnish supply step S32, the stator core 11 is arranged so that the axial direction L (axial center of the stator core 11) of the stator core 11 is along the vertical direction V. In this state, the first varnish 31 is supplied from above to the target region NR (specifically, the region of the inner peripheral portion 121A of the coil end portion 121 that does not face the regulation surface 21A). In the present embodiment, in the first fixing step S3 (first varnish supply step S32), the first varnish 31 is supplied toward the innermost peripheral portion of the coil end portion 121, so that the innermost circumference of the coil end portion 121 is supplied. The first varnish 31 is supplied from the unit to the target region NR. In the illustrated example, the first varnish 31 is supplied by dropping the first varnish 31 using the nozzle 3. The "state in which the stator core 11 is arranged so that the axial direction L of the stator core 11 is along the vertical direction V" is a state in which the axial direction L of the stator core 11 is parallel to the vertical direction V, as well as the stator core. The state in which the axial direction L of 11 is inclined with respect to the vertical direction V is also included. Therefore, the first varnish supply step S32 may be performed in a state where the axial direction L of the stator core 11 is tilted at an angle smaller than, for example, 45 ° with respect to the vertical direction V.

The first varnish supply step S32 is performed in a state where the stator coil 12 is heated by the first heating step S31, and in the present embodiment, the stator coil 12 is heated so as to be equal to or higher than the curing start temperature of the first varnish 31. It is done in a state of being. This makes it easy to start curing the first varnish 31 in a short time (for example, immediately after) after being supplied to the target region NR, and to cure the first varnish 31 in or near the target region NR. ing. In the present embodiment, the supply flow rate (supply amount per unit time) of the first varnish 31 in the first fixing step S3 (specifically, the first varnish supply step S32) is set to the second fixing step S5 (specifically, the supply amount per unit time) described later. Specifically, it is less than the supply flow rate of the second varnish 32 in the second varnish supply step S51). This makes it easy to rapidly raise the temperature of the first varnish 31 supplied to the target region NR, and shortens the time from the supply to the target region NR to the start of curing of the first varnish 31. , The first varnish 31 is easily cured in or near the target region NR. The flow rate is the volume (volumetric flow rate) of the fluid flowing per unit time, and is expressed in units of [cm ³ / s], for example.

Since the curing of the first varnish 31 can be started in a short time after being supplied to the target region NR in this way, in the method for manufacturing a stator according to the present disclosure, the first varnish 31 is supplied to the target region NR. After the completion of the 1 varnish supply step S32, it is possible to eliminate the need to separately perform a heating step of heating and curing the first varnish 31. That is, as shown in FIG. 4, in the present embodiment, after the first fixing step S3, the jig removing step S4 and the second fixing step S5 are performed without performing the step of heating and curing the first varnish 31. Continue to do.

In the present embodiment, in the first fixing step S3, the temperature of the stator coil 12 is set during the execution period of the first varnish supply step S32 by performing the first heating step S31 and the first varnish supply step S32 in parallel. Keep above the heating temperature. That is, in the present embodiment, in the first fixing step S3 in which the first varnish 31 is supplied to the target region NR while the stator coil 12 is heated and the target region NR is solidified by the first varnish 31, the stator coil 12 is heated. This is a step of supplying the first varnish 31 to the target region NR and solidifying the target region NR with the first varnish 31. If the temperature of the stator coil 12 does not fall below the set heating temperature at the end of the first fixing step S3 even if the first heating step S31 is completed before the first varnish supply step S32, the first The heating step S31 may be completed before the first varnish supply step S32. Further, it is also possible to start the first varnish supply step S32 after finishing the first heating step S31 on the condition that the temperature of the stator coil 12 does not fall below the set heating temperature at the end of the first fixing step S3. Is.

By curing the first varnish 31 in the first fixing step S3 in this way, as shown in the left figure of FIG. 5, the first varnish 31 is cured in the target region NR in the inner peripheral portion 121A of the coil end portion 121. The hardened varnish portion 30C is formed. The varnish hardening portion 30C fills the gaps between the plurality of conductor wires W, and the plurality of conductor wires W are fixed to each other.

In the present embodiment, the first fixing step S3 is separately for the coil end portion 121 arranged on one side of the stator core 11 in the axial direction L and the coil end portion 121 arranged on the other side in the axial direction L. To execute. That is, in this example, after the first fixing step S3 is executed for the coil end portion 121 arranged on one side in the axial direction L, the stator core 11 is turned upside down as shown in the central view of FIG. Perform the core reversal step. After the execution of the core inversion step, the coil end portion 121 on the side where the varnish hardening portion 30C is not formed (the other side in the axial direction L) is arranged on the upper side in the vertical direction V. Then, the first fixing step S3 is executed for the coil end portion 121 in the same manner as described above. As a result, as shown in the right figure of FIG. 5, the varnish hardening portions 30C are formed on both of the coil end portions 121 on both sides in the axial direction L.

[Jig removal process]
The jig removing step S4 is a step of removing the regulating jig 2 from the stator core 11 after the first fixing step S3. In the present embodiment, the jig removing step S4 is executed after the first fixing step S3 is executed for both of the coil end portions 121 arranged on both sides of the stator core 11 in the axial direction L. In the present embodiment, the regulating jig 2 is moved along the axial direction L and removed from the stator core 11. Here, the jig removing step S4 may include a jig cooling step for cooling the regulated jig 2. As a result, the regulating jig 2 that has been expanded by heating in the first fixing step S3 can be contracted, so that the regulating jig 2 can be smoothly removed from the stator core 11. Therefore, the possibility of damaging the stator coil 12 when the regulating jig 2 is removed can be reduced. In the jig cooling step, for example, the regulation jig 2 may be cooled at room temperature, or may be positively cooled by using a cooling medium (for example, water or the like).

[Second fixing process]
The second fixing step S5 is a step of supplying the second varnish 32 to a region other than the target region NR in the stator coil 12 after the jig removing step S4 and solidifying the region with the second varnish 32. As shown in FIG. 6, in the second fixing step S5, the slot accommodating portion 120 is solidified with the second varnish 32. In the second fixing step S5, the plurality of conductor wires W constituting the slot accommodating portion 120 are mutually fixed by the second varnish 32, and the plurality of conductor wires W and the inner surface (side surface portion 110A and bottom surface portion 110B) of the slot 110 are fixed to each other. (See FIG. 3)) and is fixed by the second varnish 32. In the present embodiment, the conductor wire W constituting the slot accommodating portion 120 and the insulating sheet 13 are fixed by the second varnish 32, and the insulating sheet 13 and the inner surface of the slot 110 are fixed by the second varnish 32. Then, the conductor wire W constituting the slot accommodating portion 120 and the inner surface of the slot 110 are fixed. Although detailed description is omitted, a preheating step of preheating the stator 1 may be executed between the jig removing step S4 and the second fixing step S5.

In the present embodiment, in the second fixing step S5, as shown in the left figure of FIG. 6, the second varnish 32 is supplied from the open region OR to the inside of the slot 110. As described above, since the open area OR and the inside of the slot 110 communicate with each other, the second varnish 32 is supplied from the open area OR to the inside of the slot 110 by supplying the second varnish 32 to the open area OR. It can be supplied. In the second fixing step S5, the heating step (second heating step S52 described later) for heating and curing the second varnish 32 is performed in a region other than the target region NR (here, inside the slot 110). This is performed after the supply step of supplying the varnish 32 (second varnish supply step S51 described later). Therefore, it is easy to impregnate the entire slot 110 with the second varnish 32 through the open region OR without starting to cure the second varnish 32. The second varnish 32 supplied from the open region OR flows through the gaps between the plurality of conductor wires W and the gaps between the conductor wires W and the inner surface of the slot 110 by a capillary phenomenon, and permeates the entire slot 110. .. Thereby, the slot accommodating portion 120 can be appropriately fixed by the second varnish 32.

As shown in FIG. 4, in the present embodiment, the second fixing step S5 includes a second varnish supply step S51 for supplying the second varnish 32 so that the second varnish 32 reaches the slot accommodating portion 120, and a second varnish supply step S51. 2 The second heating step S52, in which the varnish 32 is heated and cured, is included.

As shown in the left figure of FIG. 6, in the present embodiment, in the second varnish supply step S51, the stator core 11 is arranged so that the axial direction L of the stator core 11 is along the vertical direction V, and the open region OR is arranged. The second varnish 32 is supplied from above. In the present embodiment, in the second fixing step S5 (second varnish supply step S51), the coil end portion 121 is directed toward a region (specifically, an open region OR) outside the radial direction R of the target region NR. By supplying the second varnish 32, the second varnish 32 is supplied from the region (open region OR) of the coil end portion 121 that is not solidified by the first varnish 31 to a region other than the target region NR (here, inside the slot 110). The varnish 32 is supplied. In the illustrated example, the second varnish 32 is supplied by dropping the second varnish 32 using the nozzle 3. Similar to the first varnish supply step S32, in the second varnish supply step S51, the axial direction L of the stator core 11 may be parallel to the vertical direction V or may be inclined with respect to the vertical direction V.

Then, in the second fixing step S5, the second varnish 32 is cured by executing the second heating step S52 after the second varnish supply step S51. In the second heating step S52, the stator coil 12 is heated so as to be equal to or higher than the curing temperature of the second varnish 32. The curing temperature of the second varnish is a temperature at which the second varnish 32 is completely cured, and is determined by the physical properties of the second varnish 32 and the like. For example, the curing temperature of the second varnish 32 is in the range of 140 ° C. to 160 ° C., and in this case, in the second heating step S52, the temperature of the stator coil 12 is maintained at 150 ° C. or higher (for example). , To be maintained at 150 ° C.) to heat the stator coil 12. By curing the second varnish 32 in the second heating step S52, as shown in the right figure of FIG. 6, the varnish cured portion 30C in which the second varnish 32 is cured is formed in the entire slot accommodating portion 120. That is, the varnish cured portion 30C is composed of a portion where the first varnish 31 is cured and a portion where the second varnish 32 is cured. In this example, by executing the first fixing step S3 and the second fixing step S5, the varnish hardening portion 30C is formed on the entire stator coil 12 including the slot accommodating portion 120 and the coil end portion 121. As the heating method in the second heating step S52, for example, energization heating, induction heating, furnace heating, hot air heating, light heating, or the like can be used, and at least two of these can be used in combination. good.

2. 2. Second Embodiment Next, a method for manufacturing a stator according to the second embodiment will be described with reference to FIG. 7. Hereinafter, the points different from the above-mentioned first embodiment will be mainly described. The points not particularly described are the same as those in the first embodiment described above. In this embodiment, the stator coil 15 corresponds to the "coil", and the first coil end portion 151 corresponds to the "coil end portion".

As shown in FIG. 7, in the present embodiment, the stator coil 15 includes a plurality of joint portions 153 of the conductor wires W. The joint portion 153 is formed by joining the ends of a plurality of conductor wires W to each other. In the present embodiment, the joint portion 153 is a welded portion in which the ends of the pair of conductor wires W are welded to each other. Such a joint portion 153 is formed to electrically connect a pair of coil units when the stator coil 15 is configured by connecting a plurality of coil units.

As shown in FIG. 7, the stator coil 15 has a coil end portion 150 projecting outward in the axial direction L from the stator core 11. In the present embodiment, the coil end portion 150 includes a first coil end portion 151 projecting from the stator core 11 to one side in the axial direction L, and a second coil end portion 152 projecting from the stator core 11 to the other side in the axial direction L. , And the first coil end portion 151 and the second coil end portion 152 have different configurations from each other.

That is, in the present embodiment, the plurality of joint portions 153 are arranged at the second coil end portion 152. Here, the plurality of joint portions 153 are dispersedly arranged along the circumferential direction of the second coil end portion 152 (in FIG. 7, a part of the plurality of joint portions 153 is shown). Each joint portion 153 is formed so as to project outward in the radial direction R from the end portion of the second coil end portion 152 in the axial direction L. The plurality of conductor wires W constituting the second coil end portion 152 are in a state in which relative movement in the radial direction R and the circumferential direction C is restricted by such a joint portion 153. Therefore, in the present embodiment, the first fixing step S3 for the second coil end portion 152 is unnecessary. The portion of the second coil end portion 152 other than the joint portion 153 is a crossover portion (not shown) extending in the circumferential direction C so as to connect a pair of slot accommodating portions 120 arranged in different slots 110. ing.

On the other hand, in the present embodiment, the joint portion 153 is not arranged on the first coil end portion 151. That is, the first coil end portion 151 is configured to have a plurality of crossover portions as in the coil end portion 121 of the first embodiment.

In the present embodiment, the first fixing step S3 (see FIG. 4 and the like) of fixing the coil end portion 150 with the first varnish 31 is executed for the first coil end portion 151 and for the second coil end portion 152. Does not run. That is, as shown in FIG. 7, in the first fixing step S3, in the first fixing step S3, the region of the inner peripheral portion 151A of the first coil end portion 151 that does not face the regulation surface 21A is set as the target region NR. The region NR is solidified with the first varnish 31. As a result, as shown in FIG. 7, the varnish cured portion 30C in which the first varnish 31 is cured is formed in the target region NR in the inner peripheral portion 151A of the first coil end portion 151, and the first coil end portion 151 is formed. An open region OR that cannot be solidified by the first varnish 31 is formed on the outer peripheral portion 151B.

As described above, in the present embodiment, the first fixing step S3 is executed only for the first coil end portion 151, and the first fixing step S3 is not executed for the second coil end portion 152. Therefore, unlike the first embodiment, it is not necessary to execute the first fixing step S3 a plurality of times (twice), and therefore, the core reversing step of changing the posture of the stator core 11 is not required. Then, also in this embodiment, after the execution of the first fixing step S3, the jig removing step S4 and the second fixing step S5 are executed.

3. 3. Other Embodiments Next, other embodiments of the method for manufacturing the stator will be described.

(1) In each of the above embodiments, in the first fixing step S3, the inner circumferences of the coil end portions 121 and 151 are arranged in a state where the stator core 11 is arranged so that the axial direction L of the stator core 11 is along the vertical direction V. An example of supplying the first varnish 31 from above to the parts 121A and 151A has been described. However, the present invention is not limited to such an example, and as shown in FIG. 8, for example, in the first fixing step S3, the axial direction L of the stator core 11 (the axial center of the stator core 11) is aligned with the horizontal direction H. With the stator core 11 arranged, from the inside of the radial direction R with respect to the inner peripheral portions 121A, 151A (target region NR) of the coil end portions 121, 151 (that is, on the inner peripheral surface of the coil end portions 121, 151). The first varnish 31 may be supplied. At this time, it is preferable to supply the first varnish 31 to the inner peripheral portions 121A and 151A of the coil end portions 121 and 151 while rotating the stator core 11 around its axis. In the illustrated example, the first varnish 31 is supplied by dropping the first varnish 31 using the nozzle 3. When the first fixing step S3 is such a step, in the second fixing step S5, the coil end portion 121, with the stator core 11 arranged so that the axial direction L of the stator core 11 is along the horizontal direction H, The second varnish 32 may be supplied from the outside of the radial direction R (that is, toward the outer peripheral surface of the coil end portions 121, 151) with respect to the outer peripheral portions 121B, 151B (open region OR) of 151. The "state in which the stator core 11 is arranged so that the axial direction L of the stator core 11 is along the horizontal direction H" is a state in which the axial direction L of the stator core 11 is parallel to the horizontal direction H, and the stator core. The state in which the axial direction L of 11 is inclined with respect to the horizontal direction H is also included. In other words, "a state in which the stator core 11 is arranged so that the axial direction L of the stator core 11 is along the horizontal direction H" means that the axial direction L of the stator core 11 is inclined at a predetermined angle with respect to the horizontal direction H or the horizontal direction H. This is a state in which the stator core 11 is arranged so as to follow the direction of the horizontal movement. Therefore, the first fixing step S3 may be performed in a state where the axial direction L of the stator core 11 is tilted at an angle smaller than, for example, 45 ° with respect to the horizontal direction H.

(2) In each of the above embodiments, an example of supplying the varnish 30 by dropping the varnish 30 (first varnish 31, second varnish 32) using the nozzle 3 has been described. However, the method of supplying the varnish 30 is not limited to such an example, and various methods such as coating and spraying can be adopted.

(3) In each of the above embodiments, an example in which only the inner peripheral portions 121A and 151A of the coil end portions 121 and 151 are fixed by the first varnish 31 in the first fixing step S3 has been described. However, the present invention is not limited to such an example, and in the first fixing step S3, in addition to the inner peripheral portions 121A and 151A of the coil end portions 121 and 151, the portions other than the inner peripheral portions 121A and 151A are also the first. It may be fixed by the varnish 31, and for example, both the inner peripheral portions 121A and 151A and the outer peripheral portions 121B and 151B of the coil end portions 121 and 151 may be fixed by the first varnish 31. That is, the target region NR is a region including both the regions of the inner peripheral portions 121A and 151A of the coil end portions 121 and 151 that do not face the regulation surface 21A and the outer peripheral portions 121B and 151B of the coil end portions 121 and 151. May be. Even in this case, it is preferable to form an open region OR that cannot be solidified by the first varnish 31 in the portion of the coil end portions 121 and 151 close to the stator core 11. Thereby, when the second fixing step S5 is executed, the second varnish 32 can be appropriately supplied to the slot 110 by utilizing the open region OR.

(4) In each of the above embodiments, in the first heating step S31, the stator coils 12 and 15 are energized to generate heat in the stator coils 12 and 15 to heat the stator coils 12 and 15 (that is, the stator coils 12). , 15 are energized and heated) An example has been described. However, the present invention is not limited to such an example, and in the first heating step S31, the stator coils 12 and 15 are heated by using energization heating and another heating method (for example, induction heating) in combination. May be good. In induction heating, the stator core 11 is mainly heated, and the stator coils 12 and 15 are heated by heat transfer from the stator core 11. Further, in the first heating step S31, the stator coils 12 and 15 may be heated only by a heating method other than energization heating (a single heating method or a combination of a plurality of heating methods).

(5) In each of the above embodiments, an example in which the first varnish 31 and the second varnish 32 are the same type of varnish 30 has been described. However, without being limited to such an example, the first varnish 31 and the second varnish 32 may be different types of varnish 30. For example, as the first varnish 31, a varnish 30 having a higher viscosity (that is, lower fluidity) than the second varnish 32 can be used. When the first varnish 31 has a higher viscosity than the second varnish 32 as described above, in the first fixing step S3, the first varnish 31 supplied to the target region NR can be easily retained in the target region NR. 1 The varnish 31 can be easily cured in or near the target region NR.

(6) In each of the above embodiments, an example in which the thermosetting varnish 30 that is cured by heating is used as the second varnish 32 has been described in the second fixing step S5. However, without being limited to such an example, various types of varnish 30 can be used as the second varnish 32. For example, in the second fixing step S5, a photocurable varnish 30 that cures in response to light energy such as ultraviolet rays may be used as the second varnish 32. Further, in the second fixing step S5, for example, a two-component varnish 30 that is cured by adding a liquid curing agent to the liquid present agent may be used as the second varnish 32.

(7) In each of the above embodiments, the regulation jig 2 is arranged so as to be in contact with the facing region (specifically, the slot accommodating portion 120) which is a part of the stator coils 12 and 15. (In other words, an example of being arranged so as to support the facing region) has been described. However, the regulation jig 2 may be arranged with a gap from the facing region without being limited to such an example. In this case, for example, the regulating jig 2 can be arranged so as to be in contact with the core inner peripheral surface 11F (in other words, to support the core inner peripheral surface 11F).

(8) In each of the above embodiments, an example in which the jig mounting step S2 is executed after the coil mounting step S1 has been described. However, without being limited to such an example, the jig mounting step S2 may be executed before the coil mounting step S1, and the coil mounting step S1 and the jig mounting step S2 may be executed in parallel. You may. For example, when the jig mounting step S2 is executed before the coil mounting step S1, the regulation surface 21A is slotted in the jig mounting step S2 in a state where the slot accommodating portion 120 is not arranged inside the slot 110. The step of mounting the regulation jig 2 on the stator core 11 so as to face the bottom surface portion 110B of the 110 can be performed. The manufacturing method of executing the jig mounting step S2 before the coil mounting step S1 can be applied, for example, to the case where the stator coils 12 and 15 are formed by joining a plurality of segment conductors. In this case, the coil. The mounting step S1 can be a step of inserting the slot accommodating portion 120 into the slot 110 from the outside in the axial direction L.

(9) In each of the above embodiments, an example in which the stator 1 targeted by the manufacturing method has coil end portions 121 on both sides in the axial direction L with respect to the stator core 11 has been described. However, the present invention is not limited to such an example, and the method for manufacturing a stator may target a stator 1 having a coil end portion 121 only on one side in the axial direction L with respect to the stator core 11.

(10) In each of the above embodiments, the stator core 11 is formed in a cylindrical shape in which a plurality of slots 110 opening in the radial direction R are arranged in the circumferential direction C, that is, the stator 1 is an inner rotor type. The configuration of the stator for the rotary electric machine of is described as an example. However, the stator core 11 is not limited to such a configuration, and the stator core 11 is formed in a cylindrical shape in which a plurality of slots 110 opening in the radial direction R are arranged in the circumferential direction C, that is, the stator 1. It can also be configured as a stator for an outer rotor type rotary electric machine. In this case, the regulating jig 2 regulates the movement of the slot accommodating portion 120 from the proper position to the outside in the radial direction R, so that the slot accommodating portion 120 is in the proper position in the radial direction R with respect to the stator core 11. It is configured to regulate the positions of the stator coils 12 and 15 as described above. Further, the stator 1 may be configured for an axial gap type rotary electric machine or a linear motor, and the manufacturing method of the stator 1 according to the present disclosure can be applied regardless of the shape of the stator core 11. be.

(11) The configurations disclosed in each of the above-described embodiments should be applied in combination with the configurations disclosed in the other embodiments as long as there is no contradiction (the embodiments described as the other embodiments are used). (Including combinations) is also possible. With respect to other configurations, the embodiments disclosed herein are merely exemplary in all respects. Therefore, various modifications can be appropriately made without departing from the spirit of the present disclosure.

4. Outline of the above-described embodiment The outline of the method for manufacturing the stator described above will be described below.

A method for manufacturing a stator (1) including a core (11) and a coil (12,15) mounted on the core (11), wherein the coil (12,15) is attached to the core (11). The coil mounting step (S1) to be mounted on the coil (S1) and the regulation jig (2) that regulates the position of the coil (12, 15) so that the coil (12, 15) is in an appropriate position with respect to the core (11). ) Is attached to the core (11) in the jig mounting step (S2), and the coil (12,15) in the regulation jig (2), which is a part of the coil (12,15). The coil (12, 15) is after the coil mounting step (S1) and the jig mounting step (S2), with the region not facing the regulation surface (21A) that regulates the position of) as the target region (NR). ) Is heated, the first fixing step (S3) of supplying the thermosetting first varnish (31) to the target region (NR) and solidifying the target region (NR) with the first varnish (31). ), After the first fixing step (S3), after the jig removing step (S4) for removing the regulating jig (2) from the core (11), and after the jig removing step (S4). The second fixing step (S5) of supplying the second varnish (32) to the region other than the target region (NR) in the coils (12, 15) and solidifying the region with the second varnish (32). Has.

According to this configuration, in the first fixing step (S3), the target region (NR) that does not face the regulation surface (21A) of the regulation jig (2) in the coil (12, 15) is the first varnish (31). ), The target region (NR) can be hardened with the first varnish (31) while reducing the possibility that the first varnish (31) adheres to the regulating jig (2). Here, in the first fixing step (S3), since the first varnish (31) is supplied to the target region (NR) in a state where the coils (12, 15) are heated, after being supplied to the target region (NR). Curing of the first varnish (31) can be started in a short time (for example, immediately after). As a result, the first varnish (31) can be easily cured in or near the target region (NR), and from this point as well, the possibility that the first varnish (31) adheres to the regulation jig (2) can be reduced. Is possible.

Then, as described above, in the first fixing step (S3), the target region (NR) of the coil (12, 15) is solidified with the first varnish (31), so that the conductor wire (12, 15) constituting the coil (12, 15) is formed. The relative movement of W) can be regulated. As a result, even after the regulation jig (2) is removed in the jig removal step (S4), the movement of the coil (12, 15) from the proper position with respect to the core (11) is restricted, and the core is restricted. It is possible to maintain a state in which the coil (12, 15) is in an appropriate position (or a state close to it) with respect to (11). Then, in this state, the second fixing step (S5) can be continuously performed to appropriately manufacture the stator (1).

As described above, according to the above configuration, the regulating jig (2) has a varnish (30) while the regulating jig (2) has a function of regulating the position of the coil (12, 15). Can be reduced. As a result, it is possible to prevent the regulating jig (2) and the stator (1) from being adhered to each other by the varnish (30) and making it difficult to remove the regulating jig (2) from the stator (1). The labor of removing the varnish (30) adhering to the tool (2) can also be reduced.

Here, in the second fixing step (S5), the thermosetting varnish (30) is used as the second varnish (32), and the first varnish (31) and the second varnish (32) are used. It is preferable that the varnish (30) is of the same type.

According to this configuration, the management cost of the varnish (30) and the like are reduced as compared with the case where the first varnish (31) and the second varnish (32) are different types of varnish (30), and the stator ( The manufacturing cost of 1) can be reduced. In this configuration, the viscosity of the varnish (30) used as the first varnish (31) and the second varnish (32) is appropriately impregnated with the varnish (30) in the second fixing step (S5). Although it is necessary to match the viscosity, as described above, in the first fixing step (S3), the first varnish (31) is supplied to the target region (NR) in a state where the coils (12, 15) are heated. Therefore, regardless of the viscosity of the first varnish (31), curing of the first varnish (31) is started in a short time after being supplied to the target region (NR), and the first varnish (31) is applied to the target region (31). It can be cured at or near NR). Therefore, even when the same type of varnish (30) is used as the first varnish (31) and the second varnish (32), there is a possibility that the first varnish (31) adheres to the regulation jig (2). Can be reduced.

Further, in the first fixing step (S3), it is preferable to heat the coil (12, 15) so as to be equal to or higher than the curing start temperature of the first varnish (31).

According to this configuration, in the first fixing step (S3), the curing of the first varnish (31) is promoted, and from the time when the first varnish (31) is supplied to the target region (NR) until the curing of the first varnish (31) starts. Time can be shortened.

Further, in the first fixing step (S3), the first varnish (31) supplied to the target region (NR) gels by the time it reaches the regulation jig (2) and loses its fluidity. It is preferable to heat the coils (12, 15) so as to be in a normal state.

According to this configuration, in the first fixing step (S3), the first varnish (31) supplied to the target region (NR) can be cured in a region separated from the regulation jig (2). Therefore, the possibility that the first varnish (31) adheres to the regulation jig (2) can be suppressed to a low level.

Further, in the first fixing step (S3), it is preferable to energize the coil (12, 15) to generate heat in the coil (12, 15) to heat the coil (12, 15).

According to this configuration, the coil (12, 15) can be heated by self-heating. Therefore, it is possible to suppress heating around the coil (12,15) more than necessary as compared with the case where the coil (12,15) is heated by heat transfer from the surroundings. It is possible to reduce the possibility that the supply unit is heated and the first varnish (31) starts to harden before being supplied to the target region (NR). Therefore, in the first fixing step (S3), the temperature of the target region (NR) is set to the temperature of the first varnish (NR) while avoiding hindering the proper supply of the first varnish (31) to the target region (NR). It becomes easy to maintain the curing of 31) within a temperature range that can be promoted.

Further, it is preferable that the supply flow rate of the first varnish (31) in the first fixing step (S3) is smaller than the supply flow rate of the second varnish (32) in the second fixing step (S5). be.

According to this configuration, when the supply flow rate of the first varnish (31) in the first fixing step (S3) is equal to or larger than the supply flow rate of the second varnish (32) in the second fixing step (S5). In comparison, it becomes easy to rapidly raise the temperature of the first varnish (31) supplied to the target region (NR). Therefore, the time from the supply to the target region (NR) to the start of curing of the first varnish (31) can be shortened, and the first varnish (31) can be easily cured in or near the target region (NR). Become.

Further, the coil (12, 15) is mounted on the core (11) by being accommodated in the slot (110) formed in the core (11), and in the second fixing step (S5), the coil (12, 15) is mounted on the core (11). It is preferable to supply the second varnish (32) so that the second varnish (32) reaches the inside of the slot (110).

According to this configuration, since the second varnish (32) can be cured inside the slot (110) in the second fixing step (S5), the coil (12, 15) is cored by the second varnish (32). It can be fixed to (11). At this time, as described above, the second fixing step (S5) is performed in a state where the coil (12, 15) is in an appropriate position (or a state close to it) with respect to the core (11). Therefore, the coil (12, 15) can be fixed at an appropriate position with respect to the core (11).

Further, the core (11) is formed in a cylindrical shape in which a plurality of slots (110) that open inside in the radial direction (R) are arranged in the circumferential direction (C), and the coils (12, 15) are the above. It has a slot accommodating portion (120) arranged inside the slot (110), and a coil end portion (121, 151) protruding outward in the axial direction (L) from the slot (110). The jig (2) has the radial direction with respect to the slot accommodating portion (120) so that the slot accommodating portion (120) is in an appropriate position in the radial direction (R) with respect to the core (11). The regulation surface (21A) is configured to face from the inside of (R), and in the first fixing step (S3), the said in the inner peripheral portion (121A, 151A) of the coil end portion (121, 151). It is preferable that the region not facing the regulation surface (21A) is the target region (NR).

According to this configuration, in the first fixing step (S3), the coil end portion (121, 151) does not face the regulation surface (21A) of the regulation jig (2) in the inner peripheral portion (121A, 151A). Since the region is the target region (NR), the inner peripheral portion (121A, 121A,) of the coil end portion (121, 151) is reduced while reducing the possibility that the first varnish (31) adheres to the regulation jig (2). 151A) can be hardened with the first varnish (31). Then, by solidifying the inner peripheral portions (121A, 151A) of the coil end portions (121, 151) with the first varnish (31) in this way, not only the coil end portions (121, 151) but also the coil end portions (121) are solidified. , 151) can also be restricted from moving inward in the radial direction (R) of the slot accommodating portion (120). As a result, even after the regulation jig (2) is removed in the jig removal step (S4), the inside of the slot accommodating portion (120) in the radial direction (R) from an appropriate position with respect to the core (11). It is possible to limit the movement to the core (11) and maintain a state in which the slot accommodating portion (120) is in an appropriate position (or a state close to it) in the radial direction (R). Then, in this state, the second fixing step (S5) can be continuously performed to appropriately manufacture the stator (1).

As described above, in the first fixing step (S3), the region of the inner peripheral portion (121A, 151A) of the coil end portion (121, 151) that does not face the regulation surface (21A) is the target region. In the case of (NR), in the first fixing step (S3), the coil is arranged in a state where the core (11) is arranged so that the axis of the core (11) is along the vertical direction (V). The first varnish (31) is supplied toward the innermost peripheral portion of the end portion (121, 151), and in the second fixing step (S5), the axis of the core (11) is vertically (V). In a state where the core (11) is arranged along the It is preferable to supply the varnish (32).

According to this configuration, in the first fixing step (S3) and the second fixing step (S5), the core (11) is arranged so that the axis of the core (11) is along the vertical direction (V). When executing, in the first fixing step (S3), the first varnish (31) is appropriately supplied from the innermost peripheral portion of the coil end portion (121, 151) to the target region (NR), and the second fixing step is performed. In (S5), the second varnish (for example, the inside of the slot (110)) is changed from the region not hardened by the first varnish (31) in the coil end portion (121, 151) to the region other than the target region (NR). 32) can be appropriately supplied.

Further, as described above, in the first fixing step (S3), the region of the inner peripheral portion (121A, 151A) of the coil end portion (121, 151) that does not face the regulation surface (21A) is described. In the case of the target region (NR), in the first fixing step (S3), the axis of the core (11) is along a direction inclined by a predetermined angle with respect to the horizontal direction (H) or the horizontal direction (H). The first varnish (31) is supplied toward the inner peripheral surface of the coil end portions (121, 151) in a state where the core (11) is arranged so as to be formed, and in the second fixing step (S5). The coil end portion (11) is arranged so that the axis of the core (11) is aligned with the horizontal direction (H) or the direction inclined by a predetermined angle with respect to the horizontal direction (H). It is preferable to supply the second varnish (32) toward the outer peripheral surface of 121, 151).

According to this configuration, the first fixing step (S3) and the second fixing step (S5) are inclined in a predetermined angle with respect to the horizontal direction (H) or the horizontal direction (H) with respect to the axis of the core (11). In the first fixing step (S3), the first varnish is applied to the target region (NR) from the inner peripheral surface of the coil end portions (121, 151) when the core (11) is arranged so as to be aligned with the coil end portion (S3). (31) is appropriately supplied, and in the second fixing step (S5), a region (NR) other than the target region (NR) is formed from the outer peripheral surface of the coil end portion (121, 151) not hardened by the first varnish (31). For example, the inside of the slot (110) can be appropriately supplied with the second varnish (32).
In this way, the first fixing step is performed with the core (11) arranged so that the axis of the core (11) is aligned with the horizontal direction (H) or the direction inclined by a predetermined angle with respect to the horizontal direction (H). When (S3) is executed, since it is easy to make it difficult for the supplied first varnish (31) to flow toward the side approaching the regulation jig (2), the first one is applied to the regulation jig (2). The possibility that the varnish (31) adheres is low and it becomes easy to suppress it.

The method for manufacturing a stator according to the present disclosure may be sufficient as long as it can exhibit at least one of the above-mentioned effects.

1: Stator 2: Regulator jig 11: Stator core (core)
12: Stator coil (coil)
15: Stator coil (coil)
21A: Restriction surface 30: Varnish 31: First varnish 32: Second varnish 110: Slot 120: Slot accommodating portion 121: Coil end portion 121A: Inner peripheral portion 151: First coil end portion (coil end portion)
151A: Inner peripheral portion C: Circumferential direction H: Horizontal direction L: Axial direction NR: Target area R: Radial direction S1: Coil mounting process S2: Jig mounting process S3: First fixing step S4: Jig removing step S5 : Second fixing process V: Vertical direction

Claims (10)

A method for manufacturing a stator including a core and a coil mounted on the core.
The coil mounting process for mounting the coil on the core,
In the jig mounting process of mounting the coil on the core with a regulating jig that regulates the position of the coil so that the coil is in an appropriate position with respect to the core.
After the coil mounting step and the jig mounting step, the region that is a part of the coil and does not face the regulating surface that regulates the position of the coil in the regulating jig is set as the target region. In the first fixing step of supplying the heat-curable first varnish to the target area and solidifying the target area with the first varnish while the coil is heated.
After the first fixing step, a jig removing step of removing the regulating jig from the core, and a jig removing step.
A method for manufacturing a stator, which comprises, after the jig removing step, a second fixing step of supplying a second varnish to a region other than the target region of the coil and fixing the region with the second varnish. In the second fixing step, a thermosetting varnish is used as the second varnish.
The method for manufacturing a stator according to claim 1, wherein the first varnish and the second varnish are the same type of varnish. The method for manufacturing a stator according to claim 1 or 2, wherein in the first fixing step, the coil is heated so as to be equal to or higher than the curing start temperature of the first varnish. In the first fixing step, the coil is heated so that the first varnish supplied to the target region gels and loses fluidity by the time it reaches the regulation jig. Item 6. The method for manufacturing a stator according to any one of Items 1 to 3. The method for manufacturing a stator according to any one of claims 1 to 4, wherein in the first fixing step, the coil is energized to generate heat in the coil to heat the coil. The stator according to any one of claims 1 to 5, wherein the supply flow rate of the first varnish in the first fixing step is smaller than the supply flow rate of the second varnish in the second fixing step. Production method. The coil is mounted on the core by being housed in a slot formed in the core.
The method for manufacturing a stator according to any one of claims 1 to 6, wherein in the second fixing step, the second varnish is supplied so that the second varnish reaches the inside of the slot. The core is formed in a cylindrical shape in which a plurality of slots that open inward in the radial direction are arranged in the circumferential direction.
The coil has a slot accommodating portion arranged inside the slot and a coil end portion protruding outward in the axial direction from the slot.
The restricting jig is configured such that the restricting surface faces the slot accommodating portion from the inside in the radial direction so that the slot accommodating portion is in an appropriate position in the radial direction with respect to the core. ,
The method for manufacturing a stator according to any one of claims 1 to 7, wherein in the first fixing step, a region of the inner peripheral portion of the coil end portion that does not face the regulation surface is set as the target region. In the first fixing step, the first varnish is supplied toward the innermost peripheral portion of the coil end portion in a state where the core is arranged so that the axis of the core is along the vertical direction.
In the second fixing step, the core is arranged so that the axis of the core is aligned in the vertical direction, and the core is directed toward a region outside the target region in the coil end portion in the radial direction. 2. The method for manufacturing a stator according to claim 8, wherein the varnish is supplied. In the first fixing step, the core is arranged so as to be aligned with the horizontal direction or a direction inclined by a predetermined angle with respect to the horizontal direction, and the core is directed toward the inner peripheral surface of the coil end portion. Supplying the first varnish,
In the second fixing step, the core is arranged so as to be aligned with the horizontal direction or a direction inclined by a predetermined angle with respect to the horizontal direction, and the core is directed toward the outer peripheral surface of the coil end portion. The method for manufacturing a stator according to claim 8, wherein the second varnish is supplied.

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