JP7094140B2 - Equipment for manufacturing unit coils for stators of rotary electric machines and methods for manufacturing unit coils - Google Patents

Description

The present application relates to an apparatus for manufacturing a unit coil for a stator of a rotary electric machine and a method for manufacturing a unit coil.

In the coil assembly process of an inner rotor type rotary electric machine equipped with a distributed winding stator coil, the coil is housed in the stator core, and the coil is manually bent so as to suppress the radial overlap of the coil ends of adjacent coils as much as possible. We are doing work that requires labor and skill. That is, conventionally, after the slot accommodating portion of the unit coil intermediate in which the winding is completed in the state of being removed from the winding frame by the operator is accommodated in the slot of the stator core, the coil end portion is convex toward the outer peripheral side of the stator core. Push and bend using a tool such as a mallet or spatula, and incorporate multiple unit coil intermediates over the entire circumference of the stator core so as to minimize overlap with the adjacent coil and reduce swelling of the outer diameter dimension. (See, for example, Patent Document 1).

International publication number WO2011 / 111682A1

The coil assembly process for distributed winding stator coils is cumbersome and can degrade insulation performance and must be done with caution. In the example of Patent Document 1, the productivity of incorporating the coil is poor because the work needs to be performed by an expert. Further, in the coil manufacturing method of Patent Document 1, the final shape is made through a winding step, a bending step of A part, a twisting step of B part, and a coil end R forming step, so that the number of steps is large and productivity is high. There was a problem of being bad. Further, since the work is performed by using a tool such as a mallet or a spatula when forming the coil, there is a problem in terms of quality that the insulating film of the coil is damaged and the insulating performance is deteriorated.

The present application discloses a technique for solving the above-mentioned problems, and of a unit coil manufacturing apparatus and a unit coil for a stator of a rotary electric machine, which has high productivity and can prevent deterioration of coil insulation performance. The purpose is to provide a manufacturing method.

The unit coil manufacturing apparatus for the stator of a rotary electric machine disclosed in the present application is
Consists of the stator coil of a rotary electric machine,
Two slot compartments and
A first coil end portion that connects one end portion in the axial direction of the two slot storage portions, and a first coil end portion.
A device for manufacturing a unit coil for a stator of a rotary electric machine, including a second coil end portion that connects the other ends in the axial direction of the two slot accommodating portions.
It is configured to include an upper mold unit, a lower mold unit, and a movable mechanism for guiding the upper mold unit and the lower mold unit so as to be detachable.
The lower unit is
A first slot storage portion holding jig for holding one of the slot storage portions and a second slot storage portion holding jig for holding the other slot storage portion, which are arranged in parallel with each other,
A first coil end molding lower mold that connects one end of the first slot storage portion holding jig and one end of the second slot storage portion holding jig to form the first coil end portion, and A second coil end molding lower mold that connects the other end of the first slot storage portion holding jig and the other end of the second slot storage portion holding jig to form the second coil end portion. Equipped with
The upper mold unit
The first coil end portion is provided at a position facing the molded lower mold, and the upper mold unit is in the direction toward the lower mold unit in the direction in which the upper mold unit and the lower mold unit are separated from each other. A first coil end molding upper mold that descends in the direction and deforms the first coil end portion in the first direction to mold.
A second coil end molding upper mold provided at a position facing the second coil end molding lower mold , descending in the first direction, and deforming and molding the second coil end portion in the first direction. And with
The first slot storage portion holding jig and the second slot storage portion holding jig are arranged via a slide mechanism.
The first coil end molded lower die and the second coil end molded lower die are arranged in parallel with the slide mechanism.
In the slide mechanism, as the first coil end molding upper die and the second coil end molding upper die descend in the first direction, the first coil end molding lower die and the second coil end die The first slot accommodating portion is held between the lower molding dies along the inner surface of the first coil end molding lower die and the second coil end forming lower die and in a direction orthogonal to the first direction. The jig and the second slot storage portion holding jig are brought close to each other .

Further, the method for manufacturing a unit coil disclosed in the present application is as follows.
Using the unit coil manufacturing equipment,
The unit coil is
Two slot compartments and
A first coil end portion that connects one end portion in the axial direction of the two slot storage portions, and a first coil end portion.
Includes a second coil end that connects the other ends of the two slot compartments in the axial direction.
An arrangement process for holding each of the two slot storage portions of the unit coil before molding, and
It has a molding step of sandwiching the first coil end portion and the second coil end portion and press-molding them into a predetermined shape so that the distance between the two slot storage portions becomes a predetermined length. It is a thing.

According to the apparatus for manufacturing the unit coil for the stator of the rotary electric machine and the method for manufacturing the unit coil disclosed in the present application, the manufacturing of the unit coil for the stator of the rotary electric machine which has high productivity and can prevent deterioration of the insulation performance of the coil. A method for manufacturing an apparatus and a unit coil can be provided.

It is a perspective view of the stator according to Embodiment 1. FIG. It is a perspective view of the unit coil according to Embodiment 1. FIG. It is a schematic diagram which shows the winding process of the unit coil intermediate by Embodiment 1. FIG. It is a perspective view which shows the state which the unit coil intermediate is wound around the winding frame by Embodiment 1. FIG. It is a figure which shows the state which the guide is removed from the winding frame of FIG. 3A. It is a perspective view of the unit coil intermediate removed from the winding frame by Embodiment 1. FIG. It is a front view of the unit coil according to Embodiment 1. FIG. It is a top view of the unit coil according to Embodiment 1. FIG. It is a side view of the unit coil according to Embodiment 1. FIG. FIG. 5 is a perspective view showing the unit coil intermediate before molding and the unit coil after molding of the coil end portion according to the first embodiment in an overlapping manner. It is a figure which shows the processing flow of the coil end part molding process by Embodiment 1. FIG. It is a perspective view of the coil end part molding apparatus according to Embodiment 1. FIG. FIG. 7 is a cross-sectional view taken along the line BB of FIG. It is a perspective view which shows the state which attached the unit coil intermediate to the coil end part molding apparatus according to Embodiment 1. FIG. It is a front view which shows the state which the upper mold unit of the coil end part molding apparatus by Embodiment 1 was lowered to the middle. It is a front view of the coil end part molding apparatus in the pressurizing process by Embodiment 1. FIG. It is a front view of the coil end part molding apparatus in the taking-out process by Embodiment 1. FIG. FIG. 3 is a top view of the stator core 2 in which the first unit coil according to the first embodiment is housed in a slot. FIG. 5 is a side view of a stator core in which the first unit coil according to the first embodiment is housed in a slot. FIG. 5 is a cross-sectional perspective view of a stator core in which the first unit coil according to the first embodiment is inserted inside. FIG. 5 is a cross-sectional perspective view of a stator core in which one of the slot storage portions according to the first embodiment is stored in the slot. FIG. 5 is a cross-sectional perspective view of a stator core in which the other slot accommodating portion according to the first embodiment is housed in another slot. FIG. 5 is a cross-sectional perspective view of a stator core in which a second unit coil according to the first embodiment is housed in a slot. FIG. 3 is a top view of a stator core in which a second unit coil according to the first embodiment is housed in a slot. It is a side view of the stator core which housed the 2nd unit coil. FIG. 5 is a cross-sectional perspective view of a stator core in which the tenth unit coil according to the first embodiment is housed in a slot. FIG. 3 is a top view of a stator core in which the tenth unit coil according to the first embodiment is housed in a slot. FIG. 5 is a perspective view of a stator core in which all unit coils according to the first embodiment are housed in slots. FIG. 3 is a top view of a stator core in which all unit coils according to the first embodiment are housed in slots. It is a perspective view of the conventional stator as a comparative example. It is a perspective view of the conventional unit coil as a comparative example.

Embodiment 1.
Hereinafter, an apparatus for manufacturing a unit coil for a stator of a rotary electric machine and a method for manufacturing the unit coil according to the first embodiment will be described with reference to the drawings. In the present specification, the terms "axial direction", "circumferential direction", "diameter direction", "outer peripheral side", "inside", and "outside" are used without particular notice, respectively, as "axial direction" and "circumferential direction" of the stator, respectively. It means "direction", "diameter direction", "outer circumference side", "inside", and "outside". When comparing the heights, the one with the longer distance from the center of the stator is regarded as "higher".

When the coil end molding device is referred to as "inside" or "outside", the center side of the device is referred to as "inside" and the opposite is referred to as "outside".

FIG. 1A is a perspective view of a stator 100 for an inner rotor type rotary electric machine. The stator 100 mainly includes a stator core 2 and a stator coil 40. The stator 100 will be described below by taking as an example a stator of a two-pole, 36-slot rotary electric machine having a distributed winding three-phase stator coil 40. Needless to say, the stator is not limited to the stator of a two-pole, 36-slot rotary electric machine having a distributed winding three-phase stator coil.

FIG. 1B is a perspective view of the unit coil 4 constituting the stator coil 40. Actually, it has a terminal portion that is a connection portion with another unit coil 4, but it is omitted in this figure.

FIG. 2 is a schematic view showing a winding process in which the unit coil intermediate 4A is wound around a winding frame 71 mounted on the winding device 70.
FIG. 3A is a perspective view showing a state in which the unit coil intermediate 4A is wound around the winding frame 71.
FIG. 3B is a diagram showing a state in which the guide 71a is removed from the winding frame 71 of FIG. 3A.
FIG. 3C is a perspective view of the unit coil intermediate 4A removed from the winding frame 71.

In the winding step, the conductor 1 having a substantially circular cross-sectional shape drawn from the wire drum 10 is wound around a substantially hexagonal column-shaped winding frame 71 attached to the rotating shaft 73 of the winding device 70.

As shown in the figure, the conductor 1 drawn from the wire drum 10 passes between a pair of guide rollers 12 installed above and below. As a result, the arc-shaped winding habit attached to the conductor 1 by being wound around the wire drum 10 is straightened, and tension is applied to the conductor 1. The tension applied to the conductor 1 can be adjusted by making it possible to set the size of the gap between the guide rollers 12.

The conductor 1 under tension is wound into the groove 71M of the winding frame 71 by rotating the rotating shaft 73 of the winding frame 71 a predetermined number of times. The conductor 1 is wound around the groove 71M in a substantially hexagonal column shape while preventing the winding disorder.

When the winding of the conductor 1 is completed, the winding frame 71 is removed from the rotating shaft 73 of the winding device 70, and the guide 71a of the winding frame 71 forming one side wall of the groove 71M is removed as shown in FIG. 3B. Next, as shown in FIG. 3C, the winding process is completed when the unit coil intermediate 4A for which winding is completed is removed from the winding frame 71.

FIG. 4A is a front view of the unit coil 4.
FIG. 4B is a top view of the unit coil 4.
FIG. 4C is a side view of the unit coil 4.
Similar to FIGS. 1B, the terminal portion is omitted in FIGS. 4A to 4C.

In the present embodiment, the first coil end portion 4AE1 and the second coil end portion 4AE2 of the substantially hexagonal column-shaped unit coil intermediate 4A removed from the winding frame 71 shown in FIG. 3C are shown in FIG. It is molded into a shape as shown in 4A, 4B, and 4C.
The unit coil 4 after molding is symmetrical with respect to the rotation center of the rotary electric machine, that is, the plane A orthogonal to the central axis of the stator core 2 and divided into two in the axial direction while being incorporated in the stator 100. The center of rotation, that is, a three-dimensional corrugated shape that is asymmetric with respect to the plane B including the central axis of the stator core 2 and divided into two in the circumferential direction, that is, the shape as it is after the unit coil 4 is housed in the stator core 2. ing.

Next, the coil end forming process of the unit coil 4 will be described.
FIG. 5 is a perspective view showing the unit coil intermediate 4A before molding of the coil end portion and the unit coil 4 after molding superimposed. It can be seen that the unit coil intermediate 4A is configured in a planar shape, and the unit coil 4 is formed into a three-dimensional corrugated shape.

FIG. 6 is a diagram showing a processing flow of the coil end portion molding process.
FIG. 7 is a perspective view of the coil end molding apparatus 20 (unit coil manufacturing apparatus).
FIG. 8 is a cross-sectional view taken along the line BB of FIG.
FIG. 9 is a perspective view showing a state in which the unit coil intermediate 4A is mounted on the coil end molding apparatus 20.
FIG. 10 is a front view showing a state in which the upper die unit 20u is lowered to the middle.
FIG. 11 is a front view of the coil end molding apparatus 20 in the pressurizing step.
FIG. 12 is a front view of the coil end molding apparatus 20 in the take-out process.

As shown in FIG. 7, in the coil end molding apparatus 20, the upper mold unit 20u (molding portion), the lower mold unit 20d (molding portion), and the upper mold unit 20u can be vertically separated from the lower mold unit 20d. It consists of a guide post 27 (movable mechanism) that guides the user. As shown in FIG. 8, the guide post 27 has a first shaft rod 27g whose lower end is fixed on the mounting table 20d1 of the lower unit 20d and a first compression coil spring 27b inserted around the first shaft rod 27g. It consists of. A pair of guide posts 27 are provided at diagonal corners of the mounting table 20d1. Here, the upper mold unit 20u is movable up and down using a guide post, but it is particularly upper if the configuration uses a movable mechanism that changes the distance between the upper mold unit and the lower mold unit. It does not have to be configured to move the mold unit. Further, although not shown, those skilled in the art can easily assume that the same function can be realized by using a gear instead of the guide post 27 or using a rack and pinion mechanism.

The first shaft rod 27 g penetrates the upper die unit upward. The first compression coil spring 27b is sandwiched between the upper surface of the lower mold unit and the lower surface of the upper mold unit 20u so that the upper mold unit 20u can be moved in the vertical direction, and the lower mold unit 20d and the upper mold unit 20u The upper mold unit 20u is supported with a gap between the two.

As shown in FIG. 8, the lower die unit 20d includes a first slot accommodating portion holding jig 25A, a second slot accommodating portion holding jig 25B, a slide mechanism 23, and a first coil end portion molded lower die 21A. It is composed of a second coil end molded lower die 21B, a second shaft rod 24Ag, a third shaft rod 24Bg, a second compression coil spring 24Ab, and a third compression coil spring 24Bb.

The first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B are provided in parallel on the mounting table 20d1 via the slide mechanism 23. The first slot storage portion holding jig 25A includes a groove 25AM that holds one of the two linear slot storage portions 41A of the unit coil intermediate 4A. The second slot storage portion holding jig 25B includes a groove 25BM that holds the other of the linear slot storage portions 41A of the unit coil intermediate 4A.

The first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B are arranged on the slide mechanism 23 so as to be independent and accessible to each other. The slide direction of the slide mechanism 23 and the direction in which the grooves 25AM and 25BM extend are perpendicular to each other.

Further, the lower mold unit 20d is formed by molding the first coil end portion molded lower mold 21A used for molding the first coil end portion 4AE1 of the unit coil intermediate 4A and the second coil end portion 4AE2 of the unit coil intermediate 4A. It is provided with a second coil end molded lower die 21B, which is used for the above.

The first coil end molded lower die 21A and the second coil end molded lower die 21B are arranged on the mounting table 20d1 in parallel with the slide mechanism 23 with the slide mechanism 23 sandwiched between them.

The first coil end molded lower mold 21A connects the one end 25AE1 of the groove 25AM and the one end 25BE1 on the same side of the groove 25BM, and has an asymmetric arc shape that is recessed downward in FIG. 10 from the groove 28AM and the groove 25BM. It is a type having. The second coil end molded lower mold 21B is a mold having an asymmetric arc shape that is recessed downward in FIG. 10 by connecting the other end 25AE2 of the groove 25AM and the other end 25BE2 on the same side of the groove 25BM. be. The asymmetric arc shape that is recessed downward in FIG. 10 of the first coil end portion molded lower mold 21A and the second coil end portion molded lower mold 21B is, for example, an operator adjacent to the coil end portion as a conventional work described later. While molding with a mallet, spatula, etc. so as to avoid overlapping with the coil end part, after incorporating the unit coil in order, remove it when the shape is familiar, disassemble it again and convert the shape into data, and obtain it there. You can take a method of designing based on the obtained data. In addition, it can be designed by creating original simulation software that obtains the ideal shape of each unit coil from the shape after incorporation. Image data of a stator in which a single coil is ideally incorporated is available to those skilled in the art, and it is possible to infer the shape of each unit coil from this image data. Further, those skilled in the art can derive a shape that minimizes contact and pressure between adjacent coil end portions.

One end of the second shaft rod 24Ag penetrates the first slot storage portion holding jig 25A from the inside in the same direction as the slide direction of the slide mechanism 23, and the other end portion is the first slot storage portion holding jig. It is fixed to a fixing portion 28 provided between 25A and the second slot storage portion holding jig 25B. The second compression coil spring 24Ab is inserted around the second shaft rod 24Ag, one end of which abuts on the inner surface of the first slot storage portion holding jig 25A, and the other end of which abuts on the fixing portion 28. There is.

Similarly, one end of the third shaft rod 24Bg penetrates the second slot storage portion holding jig 25B from the inside in the same direction as the slide direction of the slide mechanism 23, and the other end portion is the first slot storage portion. It is fixed to a fixing portion 28 provided between the holding jig 25A and the second slot storage portion holding jig 25B. The third compression coil spring 24Bb is inserted around the third shaft rod 24Bg, one end of which abuts on the inner surface of the second slot storage portion holding jig 25B, and the other end of which abuts on the fixing portion 28. There is.

The first slot storage portion holding jig 25A and the second slot storage portion holding jig 25B are placed between the first coil end portion molded lower mold 21A and the second coil end portion molded lower mold 21B installed in parallel. Along these inner surfaces, the second compression coil spring 24Ab and the third compression coil spring 24Bb can be moved in directions toward each other while being compressed. A stopper 29 is attached to each of the outer ends of the second shaft rod 24Ag and the third shaft rod 24Bg, and the stopper 29 holds the first slot storage portion holding jig 25A and the second slot storage portion. The initial value of the distance from the jig 25B can be adjusted.

As shown in FIG. 7, the upper die unit 20u is attached to the flat movable plate 20U1 and the lower surface of the movable plate 20U1, and is the first of the unit coil intermediate 4A together with the above-mentioned first coil end portion molded lower die 21A. Used for molding the second coil end portion 4AE2 of the unit coil intermediate 4A together with the first coil end portion molding upper mold 22A used for molding the coil end portion 4AE1 and the above-mentioned second coil end portion molding lower mold 21B. A second coil end portion molding upper mold 22B is provided. The lower surface of the first coil end molded upper die 22A protrudes downward and has a shape along the dent on the upper surface of the first coil end molded lower die 21A. Similarly, the lower surface of the second coil end molded upper die 22B protrudes downward and has a shape along the recess on the upper surface of the second coil end molded lower die 21B.

The movable plate 20U1 is lowered to form the first coil end portion of the lower mold unit 20d. The first coil of the unit coil intermediate body 4A is formed between the lower mold 21A and the first coil end portion molding upper mold 22A of the upper mold unit 20u. The end portion 4AE1 is sandwiched, and at the same time, the second coil intermediate body 4A is sandwiched between the second coil end molding lower mold 21B of the lower mold unit 20d and the second coil end molding upper mold 22B of the upper mold unit 20u. The unit coil intermediate 4A is formed into the unit coil 4 by applying pressure while sandwiching the coil end portion 4AE2.

Next, the molding process of the unit coil 4 will be specifically described with reference to FIGS. 6 to 12.
First, a step of arranging the two slot storage portions of the unit coil before molding at predetermined positions will be described.
The two slot storage portions 41A of the unit coil intermediate body 4A, which is the unit coil 4 before molding, are grooved in the first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B of the coil end molding device 20. Insert one by one into 25AM and 25BM as shown in FIG. 9, and set the unit coil intermediate 4A in the coil end molding apparatus 20 (unit coil intermediate arrangement step: step S001).

Next, the space between the two slot storage portions is stored while sandwiching the first coil end portion and the second coil end portion, which are coil end portions provided on both sides of the slot storage portion, and pressurizing them into a predetermined shape. The molding process of molding so as to have a length based on the distance between two predetermined slots will be described. The molding step includes a moving step and a pressurizing step.
The upper die unit 20u is lowered along the guide post 27 (upper die unit moving step: step S002), and as shown in FIG. 10, the first coil end portion forming upper die 22A and the second coil end portion forming upper die 22B are formed. The upper coil end portion 4AE1 and the second coil end portion 4AE2 are brought into contact with each other, and the upper die unit 20u is further lowered. Then, the first coil end portion 4AE1 and the second coil end portion 4AE2 gradually start to be deformed.

As shown in FIG. 11, the first coil end portion molding upper mold 22A and the first coil end portion molding lower mold 21A pressurize until the first coil end portion 4AE1 is completely sandwiched, and at the same time, the second coil end portion molding is performed. Molding of the second coil end portion between the upper mold 22B and the second coil end portion When pressure is applied until the second coil end portion 4AE2 is completely sandwiched between the lower mold 21B, molding of the unit coil 4 is completed (pressurization step: step S003). When the molding is completed, the upper die unit 20u is raised to remove the unit coil 4 from the first slot storage portion holding jig 25A and the second slot storage portion holding jig 25B (step S004: take-out step).

By the way, when the first coil end portions 4AE1 and 4AE2 are deformed from the planar shape to the three-dimensional corrugated shape, the distance between the two slot accommodating portions 41A is from P1 (about 200 mm) shown in FIG. 10 to P2 (about 200 mm) shown in FIG. 163 mm), the mold gradually narrows as the first coil end molding upper mold 22A and the second coil end molding upper mold 22B descend. Therefore, the first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B are configured to be able to translate with each other.

As shown in FIGS. 7 to 10, the first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B are placed on the slide mechanism 23 so as to be movable in the left-right direction of the paper surface in FIG. Has been done. The slide mechanism 23 is configured to be movable by urging and opening the second compression coil spring 24Ab and the third compression coil spring 24Bb in both the direction of shortening the distance between the two slot storage portions 41A and the opposite direction of widening. It has become.

Further, as shown in FIG. 11 and the like, the first coil end portion 4E1 and the second coil end portion 4E2 of the unit coil 4 are not symmetrical in the circumferential direction when viewed from the axial direction, and the left side of the paper is on the right side. It is greatly bent compared to. Therefore, the first slot storage portion holding jig 25A moves more from the initial position to the inside than the second slot storage portion holding jig 25B.

For this reason, in the present application, the first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B can independently move different distances, so that the first slot storage unit holding jig 25A and the second slot storage unit holding jig 25B can be independently moved. A fixing portion 28 provided between the tool 25A and the second slot storage portion holding jig 25B, a second shaft rod 24Ag and a third shaft rod 24Bg separately fixed to the fixing portion 28, and insertion into each of them. The second compression coil spring 24Ab and the third compression coil spring 24Bb are provided.

FIG. 13A is a top view of the stator core 2 in which the first unit coil 4 is housed in the slot.
FIG. 13B is a side view of the stator core 2 in which the first unit coil 4 is housed in the slot.

The stator 100 for a rotary electric machine shown in this embodiment is for a 36-slot, three-phase rotary electric machine. Thirty-six unit coils 4 are housed in the stator core 2 in order across nine teeth t. That is, as shown in FIG. 13A, the two slot storage portions 41 are housed in the slots S at equal intervals of the core slot pitch C (167 mm in the case of FIG. 13A). One axial end of the two slot storage portions 41 is connected to each other by the first coil end portion 4E1, and the other ends of the two slot storage portions 41 are connected to each other by the second coil end portion 4E2. It is connected.

The pitch between the two slot storage portions 41 of the unit coil 4 before being stored in the slot S is slightly narrower than the core slot pitch C so that it can be easily inserted into the slot S (163 mm in this case). Is set to. In this way, by making the pitch (distance) between the slot storage portions 41 before storage slightly narrower than the core slot pitch C between the slot storage portions after storage, the first coil end portion 4E1 of the unit coil 4 is set. The unit coil 4 can be housed in the slot S in an ideal shape without the height of the second coil end portion 4E2 extending in the axial direction.

FIG. 14A is a cross-sectional perspective view of the stator core 2 in which the first unit coil 4 is inserted inside.
FIG. 14B is a cross-sectional perspective view of the stator core 2 in which one of the slot storage portions 41 is housed in the slot S.
FIG. 14C is a cross-sectional perspective view of the stator core 2 in which the other slot accommodating portion 41 is housed in another slot S.

Next, the process of storing the unit coil 4 in the stator core 2 will be described with reference to FIGS. 14A to 14C. First, as shown in FIG. 14A, the unit coil 4 is inserted inside the stator core 2 in the axial direction. Next, as shown in FIG. 14B, one slot storage portion 41 of the unit coil 4 is stored in the slot S. Next, as shown in FIG. 14C, the other slot storage unit 41 is stored in the slot S, which is 10 pieces away from the slot S in which one slot storage unit 41 is stored, on the right side.

At this time, within the range of the elastic deformation amount of the unit coil 4, while slightly extending the distance between the two slot storage portions 41 in the circumferential direction, the slot storage portion 41 previously stored is centered on the arrow in FIG. 14C. While rotating the unit coil 4 in the indicated direction, the other slot storage portion 41 is stored in the slot S, and the storage of one unit coil 4 in the stator core 2 is completed.

FIG. 15A is a cross-sectional perspective view of the stator core 2 containing the second unit coil 4.
FIG. 15B is a top view of the stator core 2 in which the second unit coil 4 is housed.
FIG. 16 is a side view of the stator core 2 in which the second unit coil 4 is housed.
FIG. 17A is a cross-sectional perspective view of the stator core 2 containing the tenth unit coil 4.
FIG. 17B is a top view of the stator core 2 containing the tenth unit coil 4.
FIG. 18A is a perspective view of the stator core 2 containing all the unit coils 4.
FIG. 18B is a top view of the stator core 2 containing all the unit coils 4.

As shown in each figure, when the storage of all 36 unit coils 4 in the stator core 2 is completed in the same procedure as the storage of the first unit coil 4, the states shown in FIGS. 18A and 18B are obtained. .. After that, a terminal portion (not shown) is connected to obtain a stator 100. As shown in FIGS. 15B and 16, the distance P3 between the slots S adjacent to each other in the circumferential direction is the highest portion (top) in the most axial direction of the first coil end portion 4E1 of the unit coil 4 adjacent to each other in the circumferential direction. ) Equal to the circumferential distance P4 between them.

FIG. 19A is a perspective view of a conventional stator 100N as a comparative example.
FIG. 19B is a perspective view of a conventional unit coil 4N as a comparative example.
In the conventional unit coil storage work in which the molding of the coil end portion into the stator core 2N is completed, the unit coil intermediate is taken out from the winding frame, the operator forms the unit coil intermediate, and the slot storage portion on one side is first slotted. Then, after the pitch between the slot storage parts of the unit coil intermediate is adjusted to the core slot pitch and stored in the slot, the coil end part is stored in the slot so as not to overlap with the adjacent coil end part. It was a work to incorporate in order while molding using such as.

However, according to the unit coil manufacturing apparatus for the stator of the rotary electric machine and the unit coil manufacturing method according to the present embodiment, the unit coil 4 can be completed in two steps of the winding step and the coil end three-dimensional waveform forming step. Further, since the molding from the unit coil intermediate 4A to the unit coil 4 is performed by using the coil end portion molding device 20, the pair of slot storage portions 41 of the unit coil 4 can be simply stored in the slot S of the stator core 2. The unit coil storage process can be completed. As described above, it is possible to omit the bending work of the coil end portion, which has been conventionally performed after mounting the unit coil intermediate on the stator core, and it is possible to improve the productivity.

Further, since the coil end portion forming step can be completed by simultaneously press forming the two coil end portions, there is an effect of contributing to the improvement of the productivity of the unit coil 4.

Further, when the unit coil 4 is stored in the slot S, the unit coil 4 can be easily stored in the slot S by not deforming the unit coil 4 or by minimizing the amount of deformation, so that a skilled worker is required. However, the productivity of the stator coil 40 is high.

Further, since the stator coil 40 of the stator 100 can be formed only by accommodating the unit coils 4 in order, the insulating film of the conductor 1 may be damaged in the insulating film of the unit coil in the molding process of the stator coil 40. It is possible to obtain a stator coil 40 having high insulation quality.

Further, since the unit coil 4 constituting the rotary electric machine can be formed into an ideal shape in advance, by sequentially accommodating the unit coil 4 in the stator core 2, the first coil end portions 4E1 of the adjacent unit coil 4 and each other and , Interference between the second coil end portions 4E2 can be suppressed as much as possible. As a result, the heights of the first coil end portion 4E1 and the second coil end portion 4E2 in the axial direction are lowered, and the stator 100 provided with the stator coil 40 and the rotary electric machine can be miniaturized. As a result, the amount of copper used for the stator coil 40 can be reduced, which leads to improvement in performance as a rotary electric machine.

In the present embodiment, a conductor having a substantially circular cross section is used as the conductor 1. However, in order to improve the efficiency of the rotary electric machine, when the area occupied by the conductor 1 inside the slot is increased, the conductor 1 has a rectangular cross section. However, it can be applied.

Further, although an example in which the grooves 25AM and 25BM are provided in the first slot storage portion holding jig 25A and the second slot storage portion holding jig 25B, the slot storage portion 41A may be fixed by another method.

Further, the fixing portion 28 may be removed, the second shaft rod 24Ag and the third shaft rod 24Bg may be used as one shaft rod, and the second compression coil spring 24Ab and the third compression coil spring 24Bb may be used as one compression coil spring.

Although the present application describes exemplary embodiments, the various features, embodiments, and functions described in the embodiments are not limited to the application of a particular embodiment, either alone or. Various combinations are applicable to the embodiments.

Therefore, innumerable variations not illustrated are envisioned within the scope of the art disclosed in the present application. For example, it is assumed that at least one component is modified, added or omitted.

100,100N stator, 1 conductor, 2,2N stator core,
4,4N unit coil, 4A unit coil intermediate, 41,41A slot compartment,
4AE1, 4E1 1st coil end part, 4AE2, 4E2 2nd coil end part,
10 wire drum, 12 guide roller, 20 coil end molding device,
20d lower unit, 20d1 mount, 20u upper unit,
20U1 movable plate, 21A first coil end molded lower mold,
21B second coil end molding lower mold, 22A first coil end molding upper mold,
22B 2nd coil end molding upper mold, 23 slide mechanism,
24Ab 2nd compression coil spring, 24Ag 2nd shaft rod, 24Bb 3rd compression coil spring, 24Bg 3rd shaft rod, 25A 1st slot storage holding jig,
25B 2nd slot storage holding jig, 25AM, 25BM groove, 27 guide post, 27b 1st compression coil spring, 27g 1st shaft rod, 28 fixing part, 29 stopper,
40 stator coil, 70 take-up device, 71 winding frame, 71M groove, 71a guide,
73 Rotating shaft, S slot, t teeth.

Claims (5)

Consists of the stator coil of a rotary electric machine,
Two slot compartments and
A first coil end portion that connects one end portion in the axial direction of the two slot storage portions, and a first coil end portion.
A device for manufacturing a unit coil for a stator of a rotary electric machine, including a second coil end portion that connects the other ends in the axial direction of the two slot accommodating portions.
It is configured to include an upper mold unit, a lower mold unit, and a movable mechanism for guiding the upper mold unit and the lower mold unit so as to be detachable.
The lower unit is
A first slot storage portion holding jig for holding one of the slot storage portions and a second slot storage portion holding jig for holding the other slot storage portion, which are arranged in parallel with each other,
A first coil end molding lower mold that connects one end of the first slot storage portion holding jig and one end of the second slot storage portion holding jig to form the first coil end portion, and A second coil end molding lower mold that connects the other end of the first slot storage portion holding jig and the other end of the second slot storage portion holding jig to form the second coil end portion. Equipped with
The upper mold unit
The first coil end portion is provided at a position facing the molded lower mold, and the upper mold unit is in the direction toward the lower mold unit in the direction in which the upper mold unit and the lower mold unit are separated from each other. A first coil end molding upper mold that descends in the direction and deforms the first coil end portion in the first direction to mold.
A second coil end molding upper mold provided at a position facing the second coil end molding lower mold , descending in the first direction, and deforming and molding the second coil end portion in the first direction. And with
The first slot storage portion holding jig and the second slot storage portion holding jig are arranged via a slide mechanism.
The first coil end molded lower die and the second coil end molded lower die are arranged in parallel with the slide mechanism.
In the slide mechanism, as the first coil end molding upper die and the second coil end molding upper die descend in the first direction, the first coil end molding lower die and the second coil end die The first slot accommodating portion is held between the lower molding dies along the inner side surface of the first coil end molding lower die and the second coil end forming lower die and in a direction orthogonal to the first direction. A device for manufacturing a unit coil for a stator of a rotary electric machine that brings a jig and the holding jig for the second slot storage portion close to each other . The unit coil manufacturing apparatus for a stator of a rotary electric machine according to claim 1 , wherein the first slot storage portion holding jig and the second slot storage portion holding jig are independently accessible to each other. The unit coil for a stator of a rotary electric machine according to claim 1 or 2, wherein the first slot storage portion holding jig and the second slot storage portion holding jig have a groove for holding the slot storage portion. manufacturing device. One end penetrates the first slot storage portion holding jig from the inside in the same direction as the slide direction of the slide mechanism, and the other end portion is the first slot storage portion holding jig and the second slot storage portion. The second shaft rod fixed to the fixing part provided between the holding jig and
A second compression coil spring that is inserted around the second shaft rod, one end of which is in contact with the inner surface of the first slot storage portion holding jig, and the other end of which is in contact with the fixed portion.
One end portion penetrates the second slot storage portion holding jig from the inside in the same direction as the slide direction of the slide mechanism, and the other end portion is a third shaft rod fixed to the fixing portion.
It is provided with a third compression coil spring that is inserted around the third shaft rod, one end of which is in contact with the inner surface of the second slot storage portion holding jig, and the other end of which is in contact with the fixed portion. The device for manufacturing a unit coil for a stator of a rotary electric machine according to any one of claims 1 to 3. A method for manufacturing a unit coil for a rotary electric machine using the apparatus for manufacturing a unit coil for a rotary electric machine according to any one of claims 1 to 4 .
The unit coil is
Two slot compartments and
A first coil end portion that connects one end portion in the axial direction of the two slot storage portions, and a first coil end portion.
Includes a second coil end that connects the other ends of the two slot compartments in the axial direction.
An arrangement process for holding each of the two slot storage portions of the unit coil before molding, and
It has a molding step of sandwiching the first coil end portion and the second coil end portion and press-molding the second coil end portion into a predetermined shape so that the distance between the two slot accommodating portions becomes a predetermined length. A method for manufacturing a unit coil for a stator of a rotary electric machine.

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