JP7474297B2 - Rotating electric machine and method for manufacturing the same - Google Patents

Description

The present invention relates to a rotating electric machine and a method for manufacturing a rotating electric machine.

Conventionally, a rotating electric machine is known that includes a stator constructed by inserting insulating coated segment coils into slots in a stator core, bending the ends of the segment coils that protrude from one end face of the stator core, and then welding the ends of the segment coils of the same phase together (see, for example, Patent Document 1).

The end of the segment coil protruding from one end face of the stator core is bent diagonally in the circumferential direction of the stator core at a location near the slot. A coating peeling portion where the insulating coating has been peeled off is formed at the tip side of the diagonally bent portion. The tip side of the diagonally bent segment coil is further bent at the insulating coating portion so that it rises in the axial direction of the stator core.

Japanese Patent No. 4910572

In the stators of conventional rotating electrical machines, when the tip end of a segment coil that is bent at an angle is bent so that it rises at the insulating coating, bending stress acts on the insulating coating, which can cause the insulating coating to peel off and generate peeling debris. The peeling debris can adhere to the stator core and reduce the quality of the stator.

To prevent the generation of peeling residue when bending the rising portion, it is possible to fold the tip side of the end of the segment coil at the area of the peeled coating. However, in this case, the area of the peeled coating near the bent area may come into contact with an area of the insulating coating of a different phase segment coil adjacent in the radial direction of the stator core, which may cause partial discharge. Furthermore, if the length of the end of the segment coil is increased to avoid contact between the peeled coating and the different phase segment coil, the amount of protrusion of the segment coil along the axial direction of the stator increases, making it difficult to miniaturize the rotating electric machine.

The present invention aims to provide a rotating electric machine and a method for manufacturing a rotating electric machine that can be made compact and does not cause partial discharge between segment coils of different phases that are adjacent in the radial direction of the stator core, even if the end of the segment coil protruding from one end face of the stator core is bent so that it stands up at the peeled-off portion.

(1) The rotating electric machine according to the present invention is a rotating electric machine (e.g., rotating electric machine 1 described later) including a stator core (e.g., stator core 5 described later) having a plurality of slots (e.g., slot 52 described later) and a plurality of segment coils (e.g., segment coils 6 described later) with an insulating coating (e.g., insulating coating 6A described later) inserted into the slots, the segment coils each having a coating peeling portion (e.g., coating peeling portion 6B described later) protruding from one end face (e.g., end face 5b described later) of the stator core and at a tip end (e.g., tip end 61a described later) where the insulating coating has been peeled off, the segment coils being a stator (e.g., stator 4 described later) including a stator core having ... In the portion of the insulating coating protruding from the end face, there is a diagonal portion (e.g., diagonal portion 611 described later) bent diagonally in the circumferential direction of the stator core (e.g., X direction described later), and in the coating peeling portion at the tip side of the diagonal portion, there is a rising portion (e.g., rising portion 612 described later) bent so as to be inclined in the opposite direction to the bending direction of the diagonal portion with respect to the axial direction of the stator core (e.g., Z direction described later), and the tips of the rising portions arranged at the tip side of the diagonal portions having different bending directions are aligned in the radial direction of the stator core (e.g., Y direction described later) and welded to form a welded portion (e.g., welded portion 100 described later).

(2) The manufacturing method of a rotating electric machine according to the present invention is a manufacturing method of a rotating electric machine (e.g., rotating electric machine 1 described later) including a stator core (e.g., stator core 5 described later) having a plurality of slots (e.g., slot 52 described later) and a plurality of segment coils (e.g., segment coils 6 described later) with an insulating coating (e.g., insulating coating 6A described later) inserted into the slots, the segment coils each having a coating peeling portion (e.g., coating peeling portion 6B described later) protruding from one end face (e.g., end face 5b described later) of the stator core and having a tip end (e.g., tip end 61a described later) where the insulating coating has been peeled off, the manufacturing method comprising: The insulating coating of the segment coils protruding in the Z direction described below) is bent diagonally in the circumferential direction of the stator core (for example, the X direction described below) to form diagonal sections (for example, the diagonal section 611 described below), and the coating peeling sections at the tip ends of the diagonal sections are bent so as to be inclined in the opposite direction to the bending direction of the diagonal sections with respect to the axial direction of the stator core to form rising sections (for example, the rising section 612 described below), and the tips of the rising sections arranged at the tip ends of the diagonal sections with different bending directions are aligned in the radial direction of the stator core (for example, the Y direction described below) and welded to form a welded section (for example, the welded section 100 described below).

(3) In the manufacturing method of the rotating electric machine of (2) above, a bending tool (e.g., bending tool 71 described below) capable of rotational movement along the circumferential direction of the stator core and linear movement along the axial direction may be used to grip the peeled-off portion of the segment coil protruding in the axial direction from one end face of the stator core, and the bending tool may be rotated in one direction while linearly moving in the axial direction toward the stator core to bend the insulating coating portion of the segment coil obliquely so as to approach the stator core, and the bending tool may be rotated in the other direction while maintaining its axial position, and then the bending tool may be released from its grip to form the slanted portion and the rising portion.

According to the present invention, even if the end of the segment coil protruding from one end face of the stator core is bent so as to rise at the peeled coating portion, partial discharge does not occur between the segment coils of different phases adjacent in the radial direction of the stator core, and it is possible to provide a rotating electric machine and a manufacturing method for a rotating electric machine that can be made compact.

1 is a cross-sectional view that illustrates a schematic diagram of a rotating electric machine according to an embodiment of the present invention; FIG. 2 is an exploded perspective view of a stator in the rotating electric machine according to the embodiment. 2 is an oblique view showing how bundled segment coils are inserted into slots of a stator core in a rotating electric machine of the present embodiment. FIG. 2 is an oblique view showing a state in which all segment coils are inserted into the slots of the stator core in the rotating electric machine of the present embodiment. FIG. A diagram showing the shape of the end of a bent segment coil in a rotating electric machine of this embodiment. 1 is a diagram showing the state in which the tips of the coating peeled-off portions of the segment coils in the rotating electric machine of this embodiment are welded together. 13 is a diagram showing a comparative example in which the tips of the coating peeled portions of the segment coils in a conventional rotating electric machine that does not adopt the bending configuration of this embodiment are welded together. FIG. 2 is a side view showing a configuration of a bending device used in the manufacturing method of the rotating electric machine of the present embodiment. FIG. 4 is a bottom view of a portion of a bending jig of a bending apparatus used in the manufacturing method of a rotating electric machine according to the present embodiment. FIG. 1 is a diagram showing a state in which a bending jig is gripping an end of a segment coil in a manufacturing method for a rotating electric machine according to this embodiment. FIG. 2 is a diagram showing the trajectory of a bending jig and the end of a segment coil to be bent in the manufacturing method of a rotating electric machine of this embodiment. FIG.

The rotating electric machine and the manufacturing method of the rotating electric machine of this embodiment will be described in detail below with reference to the drawings. The rotating electric machine 1 shown in FIG. 1 includes a housing 2, a rotor 3, and a stator 4. The rotating electric machine 1 is, for example, an inner rotor type, and is a brushless DC motor with three-phase AC of U-phase, V-phase, and W-phase. In the rotating electric machine 1 and the stator 4, the circumferential direction is the X direction along the rotation direction of the rotating shaft 31 of the rotor 3. The radial direction is the Y direction along the radial direction centered on the rotating shaft 31 of the rotor 3. The axial direction is the Z direction along the length direction of the rotating shaft 31 of the rotor 3.

The housing 2 is formed into a cylindrical shape from a metal material with good thermal conductivity, such as copper or aluminum. Inside the housing 2, a refrigerant flow path 21 is formed to allow the refrigerant to flow. The stator 4 is fixed to the inner peripheral surface 2a of the housing 2.

The rotor 3 has multiple permanent magnets for a field magnet (not shown) arranged around the outer periphery of the rotating shaft 31. The rotating shaft 31 of the rotor 3 is rotatably supported by a motor housing (not shown) or the like.

As shown in Figures 1 and 2, the stator 4 includes a stator core 5 and a number of segment coils 6 attached to the stator core 5.

The stator core 5 has, for example, an annular portion 51 made of a laminate of multiple thin core plates, and multiple slots 52 that axially pass through the annular portion 51. The multiple slots 52 are radially arranged at regular intervals in the circumferential direction around a through hole 50 that axially passes through the center of the stator core 5.

The segment coil 6 is formed, for example, by forming a conductor made of a rectangular wire with a rectangular cross section into an approximately U-shape. As shown in Figures 2 and 3, each segment coil 6 has a pair of parallel straight sections 61 and a connecting section 62 that connects one end of the pair of straight sections 61. In this embodiment, as shown in Figure 3, four segment coils 6 are stacked and bundled in the radial direction of the stator core 5. The four bundled segment coils 6 are attached to the stator core 5 by inserting one straight section 61 and the other straight section 61 into two different slots 52, 52, respectively.

In this embodiment, the straight portions 61 of four bundled segment coils 6 and the straight portions 61 of four bundled segment coils 6 are inserted into one slot 52 in a stacked manner in the radial direction of the stator core 5. As a result, the straight portions 61 of eight segment coils 6 are inserted into each slot 52 and stacked in the radial direction of the stator core 5. The straight portions 61, 61 arranged at both ends of each segment coil 6 inserted into the slot 52 protrude upright from the end face (one end face) 5b opposite the end face 5a on the axial insertion side of the stator core 5, as shown in FIG. 4.

In this embodiment, the segment coil 6 is exemplified as being made of a single wire, but the segment coil 6 may be made of two or more conductors arranged in parallel. In this case, two or more conductors constituting one segment coil 6 are arranged in parallel in the slot 52 in the radial direction of the stator core 5. In addition, an insulating member is inserted into each slot 52 of the stator core 5, but the insulating member is omitted in the stator core 5 shown in Figures 3 and 4.

After all the segment coils 6 are inserted into all the slots 52 of the stator core 5, the straight sections 61 protruding from the end faces 5b of the stator core 5 are each bent in the circumferential direction of the stator core 5. The tips of the straight sections 61 of the bent segment coils 6 of the same phase are aligned radially and joined by welding.

Figure 5 shows two straight portions 61, 61 of a segment coil 6 protruding from the end face 5b of the stator core 5. The two straight portions 61, 61 are arranged adjacent to each other in the radial direction of the stator core 5 within the same slot 52. Each segment coil 6 is entirely covered with a resin insulating coating 6A, but only the tip portion 61a of each straight portion 61 of the segment coil 6 has the insulating coating 6A completely peeled off over a predetermined length. This forms a peeled-off coating portion 6B at each tip portion 61a of the straight portion 61.

The straight portions 61 of the segment coils 6 protruding from the end face 5b of the stator core 5 are bent obliquely in the circumferential direction of the stator core 5 at the locations of the insulating coating 6A near the slots 52. This forms the oblique portions 611. Furthermore, the coating peeling portions 6B arranged at the tip side of the oblique portions 611 are bent toward the axial direction of the stator core 5 and inclined in the opposite direction to the bending direction of the oblique portions 611 with respect to the axial direction. This forms the rising portions 612 at the tip side of the oblique portions 611.

A plurality of straight portions 61 that are inserted into the same slot 52 and are adjacent in the radial direction of the stator core 5 are bent obliquely in opposite directions along the circumferential direction of the stator core 5 to form the oblique portions 611. In detail, of the two straight portions 61, 61 adjacent in the radial direction of the stator core 5, the oblique portion 611 of one straight portion 61 is bent in the X1 direction along the circumferential direction of the stator core 5. The rising portion 612 at the tip of the oblique portion 611 is bent so as to be slightly inclined in the X2 direction along the circumferential direction of the stator core 5 with respect to the axial direction of the stator core 5. The oblique portion 611 of the other straight portion 61 is bent in the X2 direction along the circumferential direction of the stator core 5. The rising portion 612 at the tip of the oblique portion 611 is bent so as to be slightly inclined in the X1 direction along the circumferential direction of the stator core 5 with respect to the axial direction of the stator core 5. In each slot 52, the diagonal portions 611 of the straight portions 61 arranged at the same radial position of the stator core 5 are bent in the same direction, the X1 direction or the X2 direction.

The rising portion 612 is formed only by the coating peeling portion 6B. The bending starting point P of the rising portion 612 is located on the coating peeling portion 6B, which is located on the tip side of the boundary portion 6C between the insulating coating 6A and the coating peeling portion 6B, and is not located on the insulating coating 6A. Therefore, the bending stress during bending does not act on the insulating coating 6A, and no peeling residue of the insulating coating 6A is generated. The angle θ1 formed by the line DL along the rising direction of the rising portion 612 after bending at the bending starting point P and the end face 5b of the stator core 5 in the circumferential direction of the stator core 5 is greater than 90 degrees. Therefore, the rising portion 612 is inclined so as to be bent back slightly toward the slot 52 into which the straight portion 61 is inserted.

The straight portions 61 of all the segment coils 6 inserted into the slots 52 of the stator core 5 are bent in the same manner as above to form the diagonal portions 611 and the rising portions 612 consisting of the coating peeling portions 6B. Then, as shown in FIG. 6, the rising portions 612, 612 of the straight portions 61, 61 of the segment coils 6 of the same phase that are adjacent in the radial direction of the stator core 5 and have the diagonal portions 611 bent in opposite directions are aligned in the radial direction of the stator core 5 and welded together. This forms a welded portion 100 at the tip end 61a of the rising portion 612.

The rising portion 612 is inclined so as to be bent back slightly toward the slot 52 into which the straight portion 61 is inserted, so that when the tip portions 61a, 61a of the rising portions 612, 612 of the same-phase segment coils 6 are aligned, the positions of the boundary portions 6C between the insulating coating 6A and the coating peeling portion 6B are arranged closer to each other, as shown by the arrow in FIG. 6. Since all the boundary portions 6C do not intersect with the oblique portions 611 of the different-phase segment coils 6, the different-phase segment coils 6, 6 that intersect with each other have their insulating coatings 6A, 60A in contact with each other, as shown by portion A in FIG. 6, and do not have any portion in contact with the coating peeling portion 6B. Therefore, there is no risk of partial discharge occurring between the different-phase segment coils 6, 6 adjacent to each other in the radial direction of the stator core 5. In addition, there is no need to increase the protruding amount of the straight portion 61 of each segment coil 6 to avoid partial discharge, and the stator 4 is made smaller, so that the rotating electric machine 1 can be made smaller.

In contrast, unlike this embodiment, when the rising portion 612 is not inclined so as to be bent back as shown in FIG. 7, when the tip ends 61a, 61a of the rising portions 612, 612 of the segment coils 6 of the same phase are aligned, the positions of the boundary portion 6C between the insulating coating 6A and the coating peeling portion 6B are positioned farther apart than in the case of this embodiment shown in FIG. 6. Therefore, as shown by part B in FIG. 7, a contact area is generated between the insulating coating 6A and the coating peeling portion 6B, and partial discharge may occur between the segment coils 6, 6 of different phases adjacent to each other in the radial direction of the stator core 5.

Next, an example of a method for manufacturing the stator 4 of the rotating electric machine 1 of this embodiment will be described with reference to Figures 8 to 11.

Figure 8 shows the bending forming device 7 used to manufacture the stator 4 of the rotating electric machine 1 of this embodiment. Figure 9 is a view of a part of the bending forming device 7 from the bottom side. The bending forming device 7 is composed of multiple cylindrical bending jigs 71 arranged in a concentric circle.

The bending jig 71 has multiple gripping grooves 711 that accommodate and grip each of the tip ends 61a of the straight portions 61 of the segment coils 6 arranged in the circumferential direction of the stator core 5. The gripping grooves 711 are formed in a vertically elongated rectangular shape in side view, and are open to the lower surface 71a and outer surface of each bending jig 71. The longitudinal direction of the gripping grooves 711 is disposed perpendicular to the lower surface 71a of the bending jig 71 and extends along the axial direction of the bending jig 71. The lower surface 71a of the bending jig 71 is disposed parallel to the end surface 5b of the stator core 5.

One bending jig 71 holds the tip ends 61a of all straight sections 61 arranged at the same radial position in each slot 52 in the gripping grooves 711. Figure 9 shows four bending jigs 71 arranged concentrically. The four bending jigs 71 each hold the tip ends 61a of the radially outer or radially inner four layers of straight sections 61 out of the eight layers of straight sections 61 stacked radially in the slots 52 of the stator core 5.

The four bending jigs 71 rotate in the circumferential direction by being driven by a drive unit (not shown), and move linearly in the vertical direction as one body. The four bending jigs 71 are configured to be rotatable so that their respective rotation directions are alternately reversed clockwise and counterclockwise by being driven by a drive unit (not shown), as shown by the arrows in FIG. 9.

When bending the straight portion 61 of the segment coil 6 protruding in the axial direction from the end face 5b of the stator core 5, the coating peeling portion 6B of the tip end 61a of the straight portion 61 is gripped by the gripping groove 711 of each bending jig 71 of the bending forming device 7, as shown in FIG. 10. At this time, the lower surface 71a of the bending jig 71 is positioned on the tip side of the boundary portion 6C. Therefore, the bending jig 71 holds the coating peeling portion 6B side of the boundary portion 6C between the insulating coating 6A and the coating peeling portion 6B in the straight portion 61 in the gripping groove 711, and does not grip the insulating coating 6A.

The bending jig 71 of the bending molding device 7, which holds the coating peeling portion 6B of the straight portion 61, moves linearly in the axial direction toward the end face 5b of the stator core 5 while rotating in one direction along the circumferential direction of the stator core 5 (the X1 direction in FIG. 11) as shown in FIG. 11. At this time, the bending jig 71 describes an arc-shaped bending trajectory BT1 toward the X1 direction. As a result, the straight portion 61 protruding from the end face 5b of the stator core 5 is bent obliquely in the X1 direction, with the vicinity of the end face 5b as the bending starting point, so that the portion of the insulating coating 6A approaches the stator core 5.

The bending jig 71 rotates and moves linearly while maintaining the upright position of the tip 61a of the straight portion 61 held by the holding groove 711. Therefore, at the same time that the straight portion 61 is bent in the X1 direction, the coating peeling portion 6B is bent in the opposite direction (X2 direction in FIG. 11) with the portion of the coating peeling portion 6B near the boundary portion 6C as the bending starting point.

The rotational movement of the bending jig 71 in the X1 direction stops at a position where the tip 61a of the straight portion 61 held in the gripping groove 711 is a predetermined distance L along the circumferential direction of the stator core 5 from the base slot 52. This distance L is longer than when bending the conventional inclined portion 611 and rising portion 612 shown in FIG. 7. That is, in this embodiment, the bending device 7 rotates the bending jig 71 a little further to a position where the tip 61a of the straight portion 61 in the gripping groove 711 is farther away from the slot 52 than in the conventional case. As a result, the bent straight portion 61 is bent so as to be stretched along the bending direction.

The bending jig 71 moves linearly toward the stator core 5 and stops at a position where the lower surface 71a of the bending jig 71 is at a predetermined height H along the axial direction of the stator core 5 relative to the end surface 5b of the stator core 5. This height H is lower than that of the conventional bending of the inclined portion 611 and the rising portion 612 shown in FIG. 7. That is, in this embodiment, the bending device 7 moves the bending jig 71 linearly a little further to a position closer to the stator core 5 than in the conventional case. Therefore, the angle θ2 between the bending direction when the bending jig 71 reaches the height H and the extension direction of the tip portion 61a gripped by the gripping groove 711 is smaller than in the conventional case.

When the bending jig 71 reaches a predetermined distance L and a predetermined height H, the rotational and linear movements of the bending jig 71 are temporarily stopped. After that, while maintaining the axial height H, the bending jig 71 rotates a predetermined angle so as to return to the opposite direction (X2 direction) from the bending direction (X1 direction) when bending the straight portion 61 diagonally. At this time, the bending jig 71 describes a linear bending processing trajectory BT2 toward the X2 direction. The rotation angle of the bending jig 71 toward the X2 direction is sufficiently smaller (for example, 1 degree) than the rotation angle toward the X1 direction when bending the straight portion 61.

After tracing the bending trajectory BT2, the bending jig 71 moves linearly away from the stator core 5 and releases the grip on the tip 61a of the straight portion 61. This simultaneously forms the slanted portion 611 and the rising portion 612 on the straight portion 61 protruding from the end face 5b of the stator core 5.

When the bending jig 71 is released from its grip, springback SB occurs in the straight portion 61. The straight portion 61 is formed so that it is bent back by the rotational movement of the bending jig 71 along the bending processing trajectory BT2, so the springback SB of the straight portion 61 is larger than the springback expected after conventional bending. Therefore, as shown in FIG. 5, the angle θ1 between the line DL along the rising direction of the rising portion 612 formed by the coating peeling portion 6B and the end face 5b of the stator core 5 in the circumferential direction of the stator core 5 is larger than 90 degrees, and is formed so as to be inclined in the opposite direction (X2 direction) to the bending direction (X1 direction) of the inclined portion 611.

In FIG. 11, one straight portion 61 is formed with an inclined portion 611 bent in the X1 direction, but the other straight portion 61 adjacent to the straight portion 61 in the radial direction of the stator core 5 is formed with an inclined portion 611 bent in the X2 direction as shown in FIG. 5 by rotating the bending jig 71 in the opposite direction. In addition, after the tip portion 61a of the four radially outer or inner straight portions 61 is gripped and bent by the four bending jigs 71 of the bending forming device 7 shown in FIG. 8 and FIG. 9, the remaining radially inner or outer four straight portions 61 are bent in the same manner as described above by a bending forming device having a bending jig 71 having the same configuration as the bending jig 71 of the bending forming device 7 except for the outer diameter. The bending forming device may be configured to simultaneously bend and form eight straight portions 61 in the slot 52 by eight bending jigs 71.

After the slanted portions 611 and rising portions 612 are formed on all straight portions 61, as shown in FIG. 6, the rising portions 612, 612 of the straight portions 61, 61 of the segment coils 6 of the same phase that are adjacent in the radial direction of the stator core 5 and have the bending directions of the slanted portions 611 in opposite directions are aligned in the radial direction of the stator core 5 and welded together. The rotating electric machine 1 is manufactured by fixing the stator 4 obtained in this way to the inner peripheral surface 2a of the housing 2.

The rotating electric machine 1 and the manufacturing method for the rotating electric machine 1 of this embodiment provide the following advantages:

The rotating electric machine 1 of this embodiment is a rotating electric machine 1 having a stator 4 including a stator core 5 having a plurality of slots 52 and a plurality of segment coils 6 with insulating coating 6A inserted into the slots 52. The segment coils 6 protrude from one end face 5b of the stator core 5 and have a coating peeling portion 6B at the tip 61a where the insulating coating 6A is peeled off. The segment coils 6 have an oblique portion 611 bent obliquely in the circumferential direction of the stator core 5 at the portion of the insulating coating 6A protruding from one end face 5b of the stator core 5, and a rising portion 612 bent at the coating peeling portion 6B so as to be inclined in the opposite direction to the bending direction of the oblique portion 611 with respect to the axial direction of the stator core 5. The tips of the rising portions 612, 612 arranged at the tip side of the oblique portions 611, 611, which have different bending directions, are aligned in the radial direction of the stator core 5 and welded to form a welded portion 100.

According to this, when the tip portions 61a, 61a of the rising portions 612, 612 of the segment coils 6 of the same phase are aligned, the positions of the boundary portions 6C between the insulating coating 6A and the coating peeling portion 6B are arranged closer to each other. All the boundary portions 6C do not intersect with the oblique portions 611 of the segment coils 6 of different phases. Therefore, even if the end portions of the segment coils 6 protruding from one end face 5b of the stator core 5 are bent so as to rise at the coating peeling portion 6B, the segment coils 6, 6 of different phases that intersect with each other will contact each other with the insulating coatings 6A, 60A, and will not have any portion that contacts the coating peeling portion 6B. Therefore, there is no risk of partial discharge occurring between the segment coils 6, 6 of different phases that are adjacent in the radial direction of the stator core 5. In addition, there is no need to increase the protruding amount of the straight portion 61 of each segment coil 61 to avoid the occurrence of partial discharge, and the stator 4 is made smaller, so that the rotating electric machine 1 can be made smaller.

The manufacturing method of the rotating electric machine 1 of this embodiment is a manufacturing method of the rotating electric machine 1 having a stator 4 including a stator core 5 having a plurality of slots 52 and a plurality of segment coils 6 with insulating coating 6A inserted into the slots 52, the segment coils 6 protruding from one end face 5b of the stator core 5 and each having a coating peeling portion 6B at the tip end 61a where the insulating coating 6A is peeled off, and the portion of the insulating coating 6A of the segment coil 6 protruding in the axial direction from one end face 5b of the stator core 5 is peeled off by the stator core 5. The inclined portions 611 are formed by bending the inclined portions 611 obliquely in the circumferential direction of the stator core 5, and the peeled-off coating portions 6B at the tip ends of the inclined portions 611 are bent in the opposite direction to the bending direction of the inclined portions 611 with respect to the axial direction of the stator core 5 to form the raised portions 612. The tips of the raised portions 612, 612 located at the tip ends of the inclined portions 611, 611, which are bent in different directions, are aligned in the radial direction of the stator core 5 and welded to form the welded portion 100.

This makes it possible to obtain a rotating electric machine 1 that achieves the above-mentioned effects.

In the manufacturing method of the rotating electric machine 1 of this embodiment, a forming device 7 capable of rotational movement along the circumferential direction of the stator core 5 and linear movement along the axial direction is used to grip the coating peeling portion 6B of the segment coil 6 protruding in the axial direction from one end face 5b of the stator core 5, and while rotating the forming device 7 in one direction, it is linearly moved in the axial direction toward the stator core 5, bending the insulating coating 6A portion of the segment coil 6 diagonally so as to approach the stator core 5, and then the forming device 7 is rotated back in the other direction while maintaining its axial position, and then the grip by the forming device 7 is released to form the slanted portion 611 and the rising portion 612, respectively.

This allows the inclined portion 611 and the rising portion 612 to be easily formed simultaneously on the segment coil 6 protruding from one end surface 5b of the stator core 5. Therefore, the rotating electric machine 1 that achieves the above-mentioned effects can be efficiently manufactured.

Reference Signs List 1 Rotating electric machine 4 Stator 5 Stator core 5b End face (one end face)
52 Slot 6 Segment coil 6A Insulating coating 6B Coating peeling portion 61a Tip portion 611 Oblique portion 612 Rising portion 71 Bending jig 100 Welded portion

Claims (3)

A rotating electric machine including a stator comprising a stator core having a plurality of slots, and a plurality of segment coils with insulating coatings inserted into the slots, each of the segment coils having a coating peeling portion at a tip end thereof where the insulating coating is peeled off,
The segment coil has an inclined portion bent obliquely in the circumferential direction of the stator core at a portion of the insulating coating protruding from the one end face of the stator core, and a rising portion bent in the coating peeling portion so as to be inclined in a direction opposite to the bending direction of the inclined portion with respect to the axial direction of the stator core,
a welded portion is formed by arranging tips of the rising portions arranged on the tip sides of the inclined portions, the tips being bent in different directions, in a radial direction of the stator core and being welded to each other. A method for manufacturing a rotating electric machine including a stator comprising: a stator core having a plurality of slots; and a plurality of segment coils with insulating coatings inserted into the slots, each of the segment coils having a coating peeling portion protruding from one end face of the stator core and having a tip portion where the insulating coating has been peeled off, comprising:
a portion of the insulating coating of the segment coil protruding in the axial direction from the one end face of the stator core is bent obliquely in a circumferential direction of the stator core to form an oblique portion,
a rising portion is formed by bending the coating peeling portion at a tip end side of the oblique portion so as to be inclined in a direction opposite to a bending direction of the oblique portion with respect to an axial direction of the stator core,
A manufacturing method for a rotating electric machine, comprising arranging tips of the rising portions, which are located at the tips of the inclined portions, which have different bending directions, in the radial direction of the stator core and welding them to form a welded portion. Using a bending jig capable of rotational movement along the circumferential direction of the stator core and linear movement along the axial direction, the coating peeled portion of the segment coil protruding in the axial direction from the one end face of the stator core is gripped;
3. A method for manufacturing a rotating electric machine as described in claim 2, wherein the bending jig is rotated in one direction while being moved linearly in the axial direction toward the stator core, so that the insulating coating portion of the segment coil is bent diagonally so as to approach the stator core, and the bending jig is rotated back in the other direction while maintaining its axial position, and then the bending jig is released from its grip to form the inclined portion and the raised portion, respectively.

Images