JPH09182337A - Manufacture of rotor for electric rotating machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing the rotor for electric rotating machine in which a coil projecting from the armature core can be shaped correctly. SOLUTION: An upper layer coil 4 having a pair of conductor parts 4b provided at the opposite ends of a conductor part 4a while being connected electrically and substantially perpendicularly thereto and inclining by a predetermined angle, respectively, in the circumferential direction from the conductor part 4a as a center is prepared previously along with a lower layer coil 5 having a pair of conductor parts 5b provided at the opposite ends of a conductor part 5a while being connected electrically and substantially perpendicularly thereto and inclining by a predetermined angle, respectively, in the circumferential direction from the conductor part 5a as a center. Both coils 4, 5 are then inserted into respective slots 2a of armature core from radial outside. Subsequently, the joint 4c of conductor part 4b is jointed to the joint 4c of conductor part 5b of lower layer coil 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a rotor of a rotary electric machine having a coil end which is formed in a substantially disc shape and also serves as a commutator.

[0002]

2. Description of the Related Art Conventionally, a method of manufacturing a rotor of a rotary electric machine is
A pine needle-shaped conductor having a bent portion obtained by eccentrically bending the straight conductor from the center and the first and second linear portions is formed, and a plurality of bent portions of the pine needle-shaped conductors are formed. The projecting portions due to the eccentricity of the bent portions are arranged inwardly in the jig, and then the jig is rotated to separate the first straight line portion and the second straight line portion of each conductive wire. By rotating in a single direction at a first predetermined angle along a relatively concentric circle, the inner peripheral edge of the circular locus formed by the arrangement of the plurality of bent portions is widened, and then the circular locus is expanded. The first straight line portion and the second straight line portion are relatively concentrically arranged along the concentric circle while restricting the circumferential end of the second bend portion and applying pressure to the upper surface of each bent portion. By turning in the other direction (reverse direction) by a predetermined angle, And a second flat portion, formed to have a step. After that, all the conductors formed into a predetermined shape are provided with the first and second straight portions of the same conductor in the slot 1
Along the axial direction of the shaft, the first and second straight line portions of the conductive wires which are different from each other and which are different from each other are radially positioned on the outer peripheral side and the inner peripheral side of the same slot. , Insert into the slot of the armature core from the axial end surface of the slot. Then, a commutator having a plurality of segments on its outer periphery is fixed on this shaft, and further, a first straight line portion and a second straight line portion drawn out from different slots are connected to each segment of the commutator. It was (JP 6
Also, as is well known, the commutator includes a plurality of segments,
The segment is fixed, and the segment is made of resin having a hole in the center, and the shaft of the armature core is press-fitted into the hole of the resin to fix the commutator. Then, in the groove portion provided in each segment of the commutator, insert a conductor wire whose outer periphery is covered with a coating, then, by fusing, first, melt the coating film of the conductor wire, the conductor wire melted the coating film,
That is, it was common to connect the first straight line portion and the second straight line portion to the segment.

[0003]

However, in the above-described conventional method for manufacturing the rotor of the rotary electric machine, the conductor wire having the first straight line portion and the second straight line portion is axially provided in the slot of the armature core. In order to connect the first straight line portion and the second straight line portion drawn out from the different slots on each segment of the commutator after inserting the first straight line portion and the second straight line portion which are projected from the slot, Is cut into a predetermined length, and the first straight line portion and the second straight line portion projecting from the slot are bent toward the axial end face side of the armature core, and in the circumferential direction of the armature core. Also has to be inclined (twisted) at a predetermined angle, and it is difficult to form the protruding first straight line portion and the second straight line portion in an accurate coil shape.

Therefore, the present invention has been made in view of the above problems, and an object of the present invention is to provide a method of manufacturing a rotor of a rotating electric machine in which a coil protruding from an armature core can be formed into an accurate shape. .

[0005]

[Means for Solving the Problems] In order to solve the above problems, the means described in claim 1 can be adopted. According to this means, at both ends of the upper layer coil side, there is a pair of upper layer coil ends that are electrically connected substantially at right angles to the upper layer coil side and that are inclined at predetermined angles in the circumferential direction about the upper layer coil side. The upper coil and both ends of the lower coil side are electrically connected substantially at right angles to the lower coil side,
A lower layer coil having a pair of lower layer coil ends that are inclined in the circumferential direction around the lower layer coil side by a predetermined angle is prepared in advance, and these prepared coils are radially inside the slots of the armature core. Since it was a step of joining the connection part of the upper layer coil end part and the connection part consisting of the tip part of the lower layer coil end part of the lower layer coil inserted in another slot, After inserting the coil into the slot of the armature core, cut the coil protrusion protruding from the slot to a predetermined length, and bend the cut coil protrusion to the axial end face side of the armature core, Inclining the iron core at a predetermined angle in the circumferential direction,
That is, it is not necessary to perform a complicated wire twisting process, and the coil protrusion can have an accurate shape.

Further, the coil having a predetermined shape is simply inserted from the outer peripheral side in the radial direction of the armature core, and the ends of both coils are joined to complete the coil assembly. Can be improved. According to the means of claim 2, the inner disk-shaped insulator is provided on both end faces of the armature core,
In the process of simply stacking and assembling the lower layer coil end and the upper layer outer disk-shaped insulator in order, a ground fault occurring between the lower layer coil and the armature core at the armature core end (coil end), and It is possible to reliably prevent rare earths generated between the lower coil and the upper coil.
Conventionally, the armature core is powder-coated or an insulator is attached to insulate the lower coil from the armature core, and the insulating coating of the expensive coated wire is used to insulate the lower coil and upper coil. However, if this method is used, the preheating, coating, and baking facilities required for powder coating are unnecessary, and defects such as pinholes and peeling occur in the wire coating due to external force during winding. Insulation failure can be prevented, and a strong insulating structure can be obtained easily and easily.

According to the third aspect of the present invention, by using the lower coil and the upper coil as the material of the plate material, it becomes possible to use a press machine, and it is very easy to process both coils if a dedicated mold is prepared. Become. Also, even when changing the cross-sectional area of the coil to obtain a rotor of different output, the cross-sectional area can be changed freely by changing the width dimension from the material of the same plate thickness, and it is possible to use various types of products. It is convenient for manufacturing the product.

According to the means of claim 4, in the past, the first straight line portion and the second straight line portion whose outer periphery was covered with the coating were melted and connected by fusing, respectively. Requires a large amount of heat energy for
Although the main body of the welding machine is large and consumes a lot of power, the joint itself has no coating and is thin, so that the joint can be joined with the minimum required heat energy.

According to the means of claim 5, a simple and easy-to-manufacture bending die can be prepared, and the coil end can be formed by using a general-purpose press machine which is generally widely used.
The coil end can be easily formed. According to the means of claim 6, it is possible to manufacture a large number of coils at a time by taking a large number of them, and it is possible not only to provide the coils at a low cost by improving the production efficiency but also to punch and bend at once. It is easy to stabilize the finished dimensional accuracy such as the bending angle.

According to the means of claim 7, after the conductor plate is fed in the predetermined direction by a certain pitch, the developed shape of the coil conductor to be the lower coil in which the width of the lower coil side and the width of the lower coil end are substantially the same. A shape equal to is cut to form a coil conductor spreader, and both ends of this spreader are bent to form coil sides and coil ends, so even when forming a narrow coil conductor spreader, It is easy to process and has excellent productivity, and the material yield (usage rate) can be dramatically improved.

According to the means of claim 8, after the conductor plate having substantially the same thickness as the lower coil side is fed in the predetermined direction by a constant pitch which is more than twice the width of the coil conductor, the coil conductor is fed from the tip of the conductor plate. The expander is punched out, and then the widthwise end of the remaining part of the conductor plate is cut off to form a new expander from the remaining part to form a expander, and both ends of the expander are bent to form a coil conductor. Since a new coil conductor expanded body can be obtained by using the remaining portion of the conductor plate, the yield of the conductor plate can be dramatically improved.

According to the means of claim 9, when the lower coil end is punched out in a narrower width than the lower coil side, at the same time as or before cutting off the widthwise end of the remaining portion of the conductor plate after punching the expanded body. In the above, since the portion of the remaining portion of the lower layer coil end portion formation scheduled region is punched out to be narrower than the remaining portion of the lower layer coil side formation scheduled region, the following operational effects can be achieved.

That is, even when the coil end portion is narrower than the coil side of the coil conductor, it is not necessary to make the punch die narrower, so that distortion and burrs are prevented from occurring after processing and the punching punch has a long life. Does not spoil. According to the means of claim 10, a rectangular wire having substantially the same cross-sectional area as the lower coil side and having a predetermined length necessary for forming the expanded body of the coil conductor forming the lower coil is prepared. , The outer circumference is partially removed at predetermined intervals in the axial direction of the rectangular wire to form a plurality of locations to form the lower coil end, and each location is cut to form the required number of deployable bodies, and each deployment Since both ends of the body are bent to form the coil conductor, the following operational effects can be obtained.

That is, since the lower coil can be formed from the rectangular wire, the material yield can be dramatically improved. The same applies to the upper coil. According to the means of claim 11, since the lower slot insulator having a U-shaped cross section, the lower coil, the upper slot insulator having a U-shaped cross section, and the upper coil are sequentially stacked in the slot, The lower and upper in-slot insulators can also be inserted from the same direction as the upper and lower coil layers, facilitating assembly to the armature core and generating between the lower coil and armature core in the slot. It is possible to prevent the grounding failure and the short circuit failure between the lower coil and the upper coil. Conventionally, the armature core is powder-coated or an insulator is attached to insulate the lower coil from the armature core. Although the coil has been insulated, this method eliminates the need for preheating, painting, and baking equipment required for powder coating. Also, in the past, defects such as pinholes and peeling occurred in the film of the electric wire due to external force during winding, resulting in poor insulation, but this method makes it easy and easy to use by using an insulator separately. An insulating structure can be obtained.

According to the twelfth aspect of the present invention, since each lower layer coil or each upper layer coil is simultaneously installed in the slot,
The mutual coils serve as guides, and the coil ends of the adjacent coils and the coil ends of the coils to be mounted do not interfere with each other to interfere with the mounting, and the mounting of the coils is facilitated.
Further, as a matter of course, since many conductors are assembled at once, the production efficiency is extremely high, and it is possible to provide a large amount of rotation at low cost.

According to the thirteenth aspect, since the coils are inserted into the slots one by one, the inserting device is simplified.
According to the means of the fourteenth aspect, since the coil end portion is inclined at the predetermined angle around the coil side, the coil can be surely inserted into the slot by rotating the coil. Claim 1
According to the means of 5, each lower layer coil or each upper layer coil is divided into a plurality of coil groups, each coil group is inserted into the slot, and the armature core is rotated to insert the next coil group into the slot. Since it goes, the insertion can be done from only one direction, and the insertion device can be simplified. That is, it is possible to mount the coils by hand or by using a simple jig without the need for a special device for mounting all at once, and it is possible to realize a mounting method suitable for small to medium volume production.

According to the means of claim 16, in the past, the first straight line portion and the second straight line portion whose outer periphery was covered with the coating were melted and connected by fusing, respectively. For this reason, a large amount of heat energy was required, the main body of the welding machine was large, and the power consumption was also great, but while sequentially rotating the armature iron core, welding each joint in order. Therefore, it is possible to automatically weld with a simple device.

In particular, the welding is preferably TIG welding. That is, if TIG welding is adopted, continuous welding is possible and the speed can be increased, and since it is not necessary to position the welding electrode and the processed portion in the rotational direction for each slot, the structure of the welding machine is simple and procurement at low cost is possible. Yes, because it is a non-contact type welding, there is little deterioration of (welding torch) and it is excellent in economic efficiency.

According to the means of the seventeenth aspect, by cooling the coil by bringing the upper layer coil and the lower layer coil close to the welding planned region into contact with the cooling means, it is possible to reduce the temperature rise other than the connecting portion, and to cool the portion other than the connecting portion. Melting can be prevented. That is, when welding the coil end, melting easily occurs beyond the welding planned region to the root of the coil end. When this phenomenon occurs, in the worst case, there is a possibility that circumferentially adjacent coil ends, which should not originally come into contact with each other, may come into contact with each other, resulting in a rare defect, which can be prevented.

According to the means of claim 18, 2 having different widths
Since the protrusions of the armature core are plastically deformed in two stages by using different types of tabs, not only the outer diameter of the armature core can be secured with high accuracy, but also the protrusions can be easily collapsed, and the open slot can be easily and reliably opened. It is possible to realize the narrowed opening. According to the means of claim 19, since only the commutator surface is pressed, a simple and inexpensive general-purpose press or the like can be used and the flattening process can be realized. In other words, when the surface of the upper coil end is used as a commutator surface, this surface must be flattened. Therefore, if the conventional method, that is, cutting or polishing, is used, the commutator surface can be accurately finished. But this way,
The processing speed is slow, and a consumable tool such as a cutting tool and a large-scale cutting machine or polishing machine are required, which is expensive, but this can be solved.

According to the twentieth aspect of the invention, since the upper coil ends and the like are connected to each other by the solidified resin portion, their relative displacement can be prevented and the rigidity can be enhanced. According to the means of claim 21, it has the same effect as that of claim 20, and can be easily realized. In other words, a liquid resin that is easy to handle is dropped near the strengthening planned area of the upper coil end, and the liquid is used to permeate the gap between the upper coil ends using the permeation phenomenon, and by further rotation, It is possible to homogenize and remove the unnecessary resin liquid, the required insulating layer can be constituted by the resin liquid of the minimum required source, and the recovered resin liquid can be reused.

According to the twenty-second aspect, since the solidified resin portion between the upper coil ends is removed, the undercut groove can be easily formed when the surface of the upper coil end is a commutator surface. If a plurality of rotary blades are used, the processing time can be shortened.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION

[Embodiment 1] Hereinafter, Embodiment 1 of the present invention will be described in detail. FIG. 1 is a schematic perspective view showing an assembled state of a rotor of a rotary electric machine. The rotor 3 is punched from a thin steel plate into a disk shape by a press machine, and then a plurality of laminated lamination cores (armature cores) 2 are fitted and fixed to the shaft 1. A predetermined number of slots 2a are provided at regular intervals on the outer periphery of the lamination 2.

FIG. 3A shows a side view of the lower coil 5, and FIG. 3B shows a developed view thereof. 4 (a) (b)
The shape of the upper coil 4 is shown in (c). Since the upper coil 4 has almost the same shape as the lower coil 5, the shape of the lower coil 5 will be described as an example. The lower coil 5 includes a lower central coil side 5a having a straight central portion, a pair of lower coil ends 5b extending from both ends thereof, and a pair of connecting portions 5c further extending from both ends of the lower coil end 5b. (The tip). The lower coil end 5b has a predetermined twist angle θ with respect to the longitudinal (extending) direction of the lower coil side 5a in the expanded shape.
have. The connecting portion 5c is a portion for joining with the connecting portion 4c of the upper coil 4 which will be described later. The connecting portion 5c also has a predetermined twist angle with respect to the longitudinal (extending) direction of the lower layer coil end portion 5b in the expanded shape. As shown in FIG. 3A, the lower coil end 5b is bent in a U shape as a whole at right angles to the lower coil side 5a, and the connecting portion 5c is substantially parallel to the lower coil side 5a. Moreover, it is bent outward.

The upper coil 4 also has substantially the same shape as the lower coil 5, and similarly has an upper coil side 4a, a pair of upper coil ends 4b, and a pair of connecting portions 4c. When the respective tips of the connecting portions 5c and 4c are assembled to the armature core 2,
As shown in the half cross-sectional view of the rotor of FIG. 2, the dimensions and angles are determined so that they coincide with each other. Next, a method of manufacturing the upper layer coil 4 and the lower layer coil 5 will be described. FIG.
(A) (b) (c) is a schematic perspective view which shows the manufacturing method of an upper coil. Since the lower layer coil 5 has substantially the same shape as the upper layer coil 4, only the upper layer coil 4 will be described below.

First, the flat plate of the material is sent to a distortion removing process (not shown), and in order to correct the warp / distortion generated in the flat plate, it is forcedly passed between two pairs of upper and lower rolls. Next, the straightened flat plate is sent to a step of punching out the expanded shape of the conductor by a press described later, and punches out the expanded body having the shape shown in FIG. 4A from the copper plate. The expanded body is composed of the upper coil side 4a, the upper coil end 4b, and the connecting portion 4c described above, and one upper coil end 4b is used as a commutator. The plate thickness is approximately 1 mm or more. Next, as shown in FIG. 4 (b), the connecting portion 4c of the expanded body is bent at about 90 degrees, and then the upper layer coil end portion 4b of the expanded body, that is, the connection portion 4c is separated by a predetermined distance. The distant position is shown in FIG.
As shown in FIG. Upper coil end 4
4b, as shown in FIG. 4 (a), is obliquely provided in the plane of the expander by an angle θ with respect to the upper coil side 4a, and the connecting portion 4c is also expanded as shown in FIG. 4 (a). In the plane of, the upper coil end portion 4b is obliquely provided at a predetermined angle.

The step of bending the connecting portion 4c may be performed after the step of bending the upper coil end portion 4b. A mold used for punching the upper coil 4 is shown in FIG. Reference numeral 51 is a punching die. The plate material between the die 51 and the die 51 is punched out by a punch (not shown) having a shape substantially the same as the developed shape of the upper layer coil 4. Since the armature coil made of copper wire used in the past is purchased from the material manufacturer with the wire wound, the twist remains in the material, so it is extremely difficult to completely correct this twist. Met. However, when the conductor forming process described below is performed using a wire material with a twist remaining, it is difficult to solve the problem that the twist adversely affects the finished product and the dimensional accuracy such as the bending angle of the finished product deteriorates. When the plate material of this embodiment is used, the plate material has variations in plate thickness and warpage / strain in the winding direction as base material defects peculiar to the plate material, but the influence of the variation in plate thickness on the bending angle is small, and the straightening roller is used. As a result, the warp / distortion in the winding direction can be corrected, and a conductor with a highly accurate shape can be obtained. Further, since the plate material is punched out by a press, the conductor cross-sectional shape becomes substantially rectangular, and the space factor of the rotor can be dramatically improved.

Next, the bending process of the connecting portion 4c shown in FIG. 4 (b) will be described with reference to FIGS.
10 is a plan view of the bending die of the connecting portion 4c showing the state in which the upper layer coil 4 is set in the lower die 63, and FIG. 11 shows the state in which the connecting portion 4c of the upper layer coil 4 is bent. It is sectional drawing of a bending type. First, as shown in FIG. 10, the corrected flat plate is engaged with the four holding members 64 provided on the lower mold 63 on the outer circumference of the upper coil side 4a.
Next, the upper die 61 shown in FIG. 11 is placed on the flat plate, the flat plate is set between the upper die 61 and the lower die 63, and the upper die 61 is placed along the guide 62 arranged on the outer periphery of the lower die 63. Mold 61 and lower mold 63
Is bent to bend the flat plate, that is, the connecting portion 4c of the upper coil 4.

By setting the clearance between the upper die 61 and the guide 62 to be less than the plate thickness of the plate material serving as the base material of the upper layer coil 4, the plate thickness of the connecting portion 4c is made slightly thinner than the base material during bending, and at the same time, ironing is performed. To do. By reducing the plate thickness of the joint, the heat capacity of the joint is small and the thermal energy required for joining is small, so that the welding work can be performed at high speed and at low cost, and the joining is also easy. Is obtained.

Next, the upper coil end portion 4 shown in FIG.
The bending process of b will be described with reference to FIGS. 12 and 13. 12 is a plan view of a bending die showing a state in which the upper layer coil 4 is set in the lower die 73 for bending the conductor 4b, and FIG. 13 is a bending die of the upper layer coil end portion 4b of the upper layer coil 4. It is a cross-sectional view of a bending die showing a processed state.

An upper die 71, a guide 72 which is a bending die,
The lower mold 73 is used. As shown in FIG. 12, the connecting portion 4
The upper layer coil 4 obtained by bending c is arranged in the lower die 73, and the upper layer coil 4 is set between the upper die 71 and the lower die 73 (not shown), and as shown in FIG. The upper die 71 and the lower die 73 are lowered along the guides 72 arranged in the above to bend and lower the upper coil end portion 4b of the upper coil 4.

The upper coil end portion 4b may be bent before the connecting portion 4c, or both may be formed by the same die. Next, before explaining the following steps, members used in this step will be described first. FIG. 5 shows a perspective view of the lower slot insulator 7, and FIG. 6 shows a perspective view of the upper slot insulator 6. The lower in-slot insulator 7 is formed by cutting or punching a resin insulating film into a predetermined shape, and then bending and shaping it into a U shape, or molding a resin material into a predetermined shape. The height of the insulator 7 is made larger than the depth of the slot 2a by a predetermined dimension. The in-slot insulator 6 is also formed similarly to the in-slot insulator 7.

As shown in the perspective view of FIG. 7, the inner disk-shaped insulator 10 is made of a ring-shaped resin insulating plate and is formed by cutting, punching, or resin molding. The inner disk-shaped insulator 10 includes the armature core 2 and the lower coil end 5b.
It is interposed between. The outer disk-shaped insulator 9 is provided between the upper layer coil end portion 4b and the lower layer coil end portion 5b. The outer disk insulator 9 and the inner disk insulator 10
Are not necessarily the same material, and may be, for example, paper, plastic, tape containing glass, or the like.

A cross-sectional view of the reinforcing member 11 is shown in FIG. The reinforcing member 11 is made of a rigid body having a high metal ratio (resin or the like), and has an inner cylinder portion 11a, a ring plate portion 11b extending from one end thereof in a flange shape, and an outer circumference of the ring plate portion 11b coaxial with the inner cylinder portion 11a. It is composed of an outer cylinder portion 11c extending in a shape. The insulating ring 8 is shown in FIG. The insulating ring 8 is necessary when the reinforcing member 11 is made of a conductive material, and is a brim-shaped member made of a thin resin molded member having electrical insulation. It is composed of an inner wheel plate portion 81, a cylindrical portion 82 extending axially from the outer circumference of the wheel plate portion 81, and an outer wheel plate portion 83 extending from the tip of the cylindrical portion 82 to the outer peripheral side.

The process of insulating the rotor 3 and sequentially assembling the conductors will be described with reference to FIG. First, the pair of inner disk-shaped insulators 10 are attached to the rotor 3
Make sure that both end faces of the are adhered (adhered or assembled) simultaneously or sequentially,
The both end surfaces of the rotor 3 are insulated. Next, the in-slot insulator 7 is inserted into the slot 2a of the rotor 3 from the radially outer side or the axial direction. At this time, the in-slot insulator 7 is held from the outer peripheral side in the radial direction by a jig (not shown).

Next, the lower layer coil 5 is sequentially inserted slot by slot. A state in which the lower layer coil 5 is sequentially inserted slot by slot will be described below with reference to FIG. Insert the lower coil 5 into each slot from the radially outer side to the slot 2
Assemble to the bottom of a. At this time, the first assembling of the first slot is performed with the slot 2a and the lower coil side 5 of the lower coil 5.
It is possible to position a substantially parallel and insert it as it is from the radial outer peripheral side toward the center, but since the lower layer coil end 5b of the previously inserted conductor 5 interferes with the assembly after the second slot, The lower layer coil side 5a of the lower layer coil 5 to be assembled with the slot 2a is inserted into the slot 2a while being slightly twisted from a state in which the lower layer coil side 5a is swung by a predetermined angle with the longitudinal direction of the lower layer coil side 5a as an axis. At this time, the lower coil 5 is held from the outer peripheral side in the radial direction by a jig (not shown).

FIG. 15 is a partial sectional view showing a state in which the conductor 5a of the lower coil 5 is inserted into the slot 2a.
A method of assembling a large number of lower layer coils 5 at a time is also possible, and a state in which a large number of lower layer coils 5 are inserted into a plurality of slots 2a, that is, several lower layer coils 5 (three positions) are included in one coil group. FIG. 16 shows a state in which this coil group is divided and inserted into a plurality of pieces, which will be described.

A jig (not shown) having an inner circumferential surface portion for holding and inserting the lower layer coil 5 is arranged on the radially outer side of the lower layer coil 5. A jig (not shown) for holding a predetermined number of lower layer coils 5 is arranged on the outer peripheral portion of the rotor 3, and the lower layer coil side 5a of each lower layer coil 5 is connected to the slot 2a.
Hold parallel to. A jig (not shown) is moved from the outer peripheral side in the radial direction toward the center to simultaneously assemble a plurality of lower layer coils 5 from the outer peripheral side in the radial direction to the bottom of the slot 2a.

Next, a pair of outer disk-shaped insulators 9 are assembled simultaneously or sequentially. As shown in FIG. 1, the outer disk-shaped insulator 9 is inserted until it contacts the outer end surface of the lower coil end 5b of the lower coil 5. The inserted slot insulator 6 is held by a jig (not shown). Conventionally, an insulating tape or the like is wound around an expensive coated electric wire or conductor to perform an insulation treatment, which requires man-hours and cost. However, when the present embodiment is used, the insulation treatment can be performed only by combining an inexpensive bare conductor and an insulating member manufactured at a low cost by pressing or resin molding. Further, not only a conductor formed from a plate material but also a conductor formed from a wire material or the like can be applied. Furthermore, it is possible to assemble all the insulators and conductors having a U-shaped cross section (substantially U-shaped) in the radial direction of the rotor, and it is possible to manufacture a rotor by simple work without requiring skill. it can. With regard to automation, it can be automated with a simple structure and inexpensive equipment.

In the above process, in the slot 2a,
Although one lower layer coil 5 is inserted, or a large number of lower layer coils 5 are inserted at once, even if the number of lower layer coils 5 corresponding to all the slots 2a are all simultaneously inserted into all the slots 2a. Good. The same applies to the upper layer coil 4. Next, a process for joining the connecting portions 4c and 5c, which are the tip portions of the upper layer coil 4 and the lower layer coil 5, to obtain the armature coil structure will be described. Prior to this explanation, the connecting portion 4c,
5c is connected to the upper coil 4 and the lower coil 5 in FIG.
As shown in the schematic perspective view showing the arrangement state of the above, the connecting portion 4c of the upper layer coil 4 and the connecting portion 5c of the lower layer coil 5 arranged in the same slot are not connected, but in another slot. The connecting portion 5c of the lower layer coil 5 and the connecting portion 4c of the upper layer coil 4 are connected to each other. FIG. 18 schematically shows a connection between the upper layer coil 4 and the lower layer coil 5, in which the brush 900 is arranged on the outer peripheral surface of the upper layer coil end 4b of the upper layer coil 4. There is.

Next, in the half sectional view of the rotor shown in FIG. 2, the connecting portions 4c and 5c are superposed in the radial direction, and their tip portions are TIG (tungsten, inert, gas).
It is continuously welded by welding. An example of a vertical welding machine will be described below. The workpiece 600, that is, the rotor 3, the lower layer coil 5, the upper layer coil 4, the in-slot insulator 7, the in-slot insulator 6, the inner disk-shaped insulator 10, and It is also possible to use a horizontal type in which a rotating shaft for rotating the one to which the outer disk-shaped insulator 9 is attached is held horizontally.

First, the structure of the welding machine will be described with reference to FIGS. Note that FIG. 19 shows the connecting portion 4 c of the upper coil 4.
And FIG. 20 is a block diagram for welding the connecting portion 5c of the lower layer coil 5 and FIG. 20 is a schematic partial sectional view showing a welding operation of the apparatus of FIG. 130 is a welding power source, 131 is a power switching element for a welding controller that controls on / off of an arc and output of an arc, 132 is a computer or sequencer for operation control, and 133 is a motor 1
A motor control unit for on / off and speed control of 45, 134 a shield gas supply device for supplying a shield gas for stabilizing the welding state, and 135 a high frequency generation for generating a high frequency voltage necessary for welding A device 136 is a cooling water supply device for circulating cooling water inside the torch, and a device 137 is a work 6 while holding the work 600.
Work holder 138 that follows the rotation of 00, 138 is the work 6
Work holder for rotating the work 600 while holding 00, 139 is a speed reducer, 140 is a welding torch, 141 is an arc, 142 is a ground and upper layer coil cooling jig, 14
Reference numeral 3 is a lower coil cooling jig, 145 is a motor, and 146 is a base.

Next, details of the welded portion will be described with reference to FIG. Reference numeral 13 denotes a welded portion, which is a portion in which the tip portions of the upper layer coil 4 and the lower layer coil 5 are overlapped. The workpiece 600 is held by a cylindrical workpiece holder 138 and driven at a predetermined rotation speed. The TIG welding torch 140 includes a tungsten electrode, a cooling water circulation path, and a shield gas nozzle. From the tip of the torch 140 to the arc 14
1 is released, and the heat energy melts, cools, and joins the welded portion 13. The earth (ground) and the cooling jig 142 of the upper coil 5 are connected to the workpiece 6 up to the vicinity of the welded portion 13.
By covering 00, it is possible to prevent melting of the parts other than the welded part 13.

The lower layer coil cooling jig 143 is the shaft 1
Between the upper and lower layer coils 4 and 5c by being inserted between the lower layer coil 5 and the lower layer coil 5 and pushing the lower layer coil 5 to the outer peripheral side. Eliminates the gap and keeps the welded part stable. Work 6
00 is rotated integrally with the lower layer coil cooling jig 143, the ground and upper layer coil cooling jig 142, and the work holder 138 by the motor 145 at a predetermined rotation speed. Torch 1
Although 40 is held by the base, the position, posture, etc. of the tip end portion are variable, and are appropriately adjusted depending on the shape of the welded portion 13, the rotation speed, the arc output, and the like.

The feature of this welding is that the workpiece 600, the workpiece holder 137, the lower layer coil cooling jig 143, the ground and upper layer coil cooling jig 142, and the workpiece holder 138 are integrally rotated at a predetermined speed. . By adopting TIG welding, the welding speed can be extremely increased as compared with the fusing, ultrasonic welding, etc. used in the conventional rotor. In particular, the ability to continuously join the workpieces 600 while rotating the workpieces 600 is effective in significantly improving productivity. However,
In this embodiment, the vertical type has one torch 140, but in order to further improve the working efficiency, the torch 140 is used.
It is also possible to arrange a plurality of.

In addition to the TIG welding described above, it is possible to use laser welding, tilt the posture of the rotor, etc.
Contributes to the improvement of weldability. Next, in order to reinforce the upper coil 4 and the lower coil 5 so as not to jump out of the slot 2a due to the centrifugal force during rotation, the step of bending the protrusion 2f projecting to the outer periphery of the armature core 2 is shown in FIGS. , Fig. 2
This will be described with reference to FIG. 21 is a schematic diagram showing a step of tilting the protrusion 2f of the lamination core 2, FIG. 22 is a schematic perspective view of FIG. 21, and FIG. 23 is a partial cross-sectional view near the slot 2a.

The steps will be described in order. First, a narrow caulking punch having a central axis extending in a radial direction between a pair of projections 2f projecting in a V shape adjacent to the slot opening (claw down). A plate) 151 and a wide caulking punch (claw down plate) 152 having a substantially flat tip are provided at a predetermined angle offset from each other.
Then, the caulking punch 151 that moves toward the center is projected on the projection 2f.
The protrusion 2f is slightly deformed in the direction of the arrow 153, the caulking punch 151 is pulled up, and then the rotor 3 is rotated in the direction shown by the arrow 154 to reposition the caulking punch 152. The protrusion 2f is deformed in the direction of arrow 155 by the movement toward the center, and the slot 2
Block a. According to the two-step bending method of this embodiment, thereafter, it is not necessary to finish the outer peripheral portion of the rotor 3 by cutting or the like, and a marked improvement in productivity is realized. Also,
The upper ends of the in-slot insulators 6 and 7 are also bent at the same time to insulate the protrusion 2f from the upper coil side 4a and hold the in-slot insulators 6 and 7.

There is no problem if this step is carried out before the above-mentioned welding step of the lower coil 4 and the upper coil 5. Next, the assembling of the insulating ring 8 which is an insulating member will be described. Regarding the shape of the insulating ring 8, the assembled state of the rotor of FIG. 1 will be described with reference to the insulating ring 8 shown in the schematic perspective view.

The insulating ring 8 is formed by punching from a film-shaped or plate-shaped insulating material with a press machine, or is molded from a resin material. Next, the insulating rings 8 are inserted into both ends of the rotor 3 until they come into contact with the upper coil ends 4b of the upper coil 4. Alternatively, it may be mounted in advance on the side of the reinforcing member 11 which will be described later in contact with the rotor 3 and may be mounted on the rotor 3 at the same time as the reinforcing member 11.

Next, the upper coil end 4b of the upper coil 4
A step of pressing the outer end surface (commutator surface) 12 (see FIG. 2) of FIG. 24 with a press or the like to improve the flatness will be described. The jig is composed of a lower jig 163 for the workpiece, an upper holding jig 161, and a pressure jig 162 for shaping the commutator surface 12. In the processing, the pressing jig 162 is pressed in the direction of arrow 164 while holding the workpiece with the jigs 161 and 163, so that the unevenness of the upper coil end 4b used as a commutator is smoothed. This step may be performed individually or in combination before the upper coil 4 is attached, or may be performed before or after the reinforcement member 11 is attached. By this step, the dimensional error (particularly the thickness) of the component can be easily absorbed, and the mechanical strength of the rotor as a whole can be improved. Depending on the usage environment, finishing processing (cutting, grinding) of the commutator surface is unnecessary, and expensive equipment and running costs are unnecessary.

Next, the step of mounting the reinforcing member 11 will be described. FIG. 8 shows an example of the cross-sectional shape of the reinforcing member 11.
The reinforcing member 11 is obtained, for example, by press working, forging, cutting, resin molding, or the like. Explaining the process, the inner cylindrical portion 11a of the reinforcing member 11 shown in FIG. 8 is press-fitted into the shaft 1. When the reinforcing member 11 is pressed in the direction of arrow 110, the tip of the outer tube end 303 of the reinforcing member 11 presses and holds the upper coil end 4b of the upper coil 4 through the insulating ring 8. This firmly holds the lower coil 5 and the upper coil 4.

Next, the resin reinforcement of the commutator surface 12 will be described. When using a liquid resin to reinforce by the dropping method,
An example of such a method is to use a powdery resin for reinforcement by a fluidized dipping method or an electrostatic coating method. An example of the liquid resin dropping method is shown in FIGS. FIG. 25 shows the liquid resin dropping step, and FIG. 26 shows the resin blowing step. These two steps may be sequentially processed in the same unit or may be separate units.

As shown in FIG. 25, the work 600 is held by the upper holding jig 173 and the lower holding jig 178, and is rotated in the direction of arrow 178 integrally with the jig by the motor 176a and the speed reducer 176b, and the liquid The resin 172 is supplied and dropped onto the outer peripheral surface (commutator surface) of the upper coil end 4b of the upper coil 4 by the resin supply mechanism 171 (resin dropping nozzle).

In the blow-off process shown in FIG. 26, the work 6
00 is rotated similarly to the dropping step. On the commutator surface, air is blown from the inside to the outside by the air nozzle 180, and the scattered resin is sucked by the suction nozzle 179 outside the work 600. Conventionally, the mold resin type commutator has been manufactured separately from the lamination core 2. The manufacturing of this mold resin type commutator requires a great deal of labor and is expensive. However, in the present invention, it is not necessary to separately prepare a commutator, and the commutator surface can be manufactured and the main body can be reinforced by dropping the resin liquid on the commutator surface, dispersing and flattening it during the rotor manufacturing process.

Next, the curing process of the resin material for the above-mentioned reinforcement and the heating process for removing the stress inside the rotor will be described. Put the rotor into a heating furnace, etc., and make it in a thermal state similar to the worst usage environment of the rotor. When the hardening temperature of the resin material is higher than the worst use environment of the rotor, the furnace temperature is set to the hardening temperature of the resin material. In a structure containing a resin material, the size of the commutator surface may change due to thermal expansion, volatilization of residual gas inside the resin, etc., depending on the operating environment, which may lead to deterioration of rotor performance. After exposing the rotor to a state similar to the usage environment during manufacturing,
Finishing the commutator surface has the effect of stabilizing the dimensional accuracy. As a matter of course, if the lower layer coil 5 and the upper layer coil 4 are not reinforced with a resin material, this heating step can be omitted, but even if the resin is not used, the internal stress remaining in the conductor itself can be removed. Since it has an effect, only the heating step may be performed.

Next, the undercut process between the commutator segments, which is carried out as necessary when the above-mentioned resin reinforcing step for the commutator surface is carried out, will be explained. As for the undercut processing method, several methods are conceivable. For example, in the case where the commutator pieces are linear grooves as shown in FIG. As shown in FIG. 6, when the commutator pieces have curved grooves, an example of processing with a laser will be described.

First, the undercut method using a cutter will be described. FIG. 27 is a plan view of the commutator surface 12 shown in FIG. The processed portion is a resin-filled undercut groove formation-scheduled region (hatched portion in the figure) 182a between the upper coil ends 4b of the upper coil 4 used as a commutator surface in the figure, and is located with respect to the central axis. It is twisted by an angle θ. FIG. 29 shows a processing machine that undercuts the region 182a. This processing machine includes a cutter driving source (motor etc.) 181a, a mechanism 181b for branching a rotational force,
Mechanism 181c that changes the direction of rotational force, cutter (with joint) 181d, workpiece positioning and holding mechanism 18
1e and the cutter drive shafts 181f and 181f 'after branching. The cutter 181d is positioned at a position twisted by an angle θ with respect to the axis of the workpiece 600 (see FIG. 2).
The area 182a of No. 7 is shown in black. Drive source 18
The turning force generated in 1a is branched by the branching mechanism 181b by the required number of shafts, converted into the required direction by the mechanism 181c that changes the rotation direction, and then transmitted to the cutter 181d. The workpiece 600 rotates in the direction of the arrow 181h and is positioned at a predetermined angle (the angle at which the cutter 181d and the area 182a match). After positioning, arrow 181g
Predetermined undercut processing is performed by sending the work piece in the direction of. Since the efficiency is poor in the processing at each location,
The rotational force is also branched to the cutter drive shaft 181f 'so that the cutter can be installed at another site to perform simultaneous processing.

FIG. 30 shows details of the processed portion. The cutter 181d is rotating in the direction of arrow 183a. The workpiece 600 is sent in the direction of the arrow 181g, and the upper coil 4
The commutator surface 12 of the upper layer coil end portion 4b is a hatched portion 183b.
The cross-sectional shape shown by is removed. In FIG. 31, the distance between the upper coil ends 4b is preferably narrower than the width of the cutter 181d.

FIG. 32 shows details of the feed size. 185a
Is a brush. Undercut removal part 183b
The depth is 0.5 mm or more, the insulator 9 is not pierced, and the cutter 181d does not contact the welded portion 13 at the same time satisfy the three conditions. According to this embodiment, there is an advantage that the undercut groove can be formed even if the resin region between the upper coil ends 4b is bent or curved in the plane direction.

Next, a laser undercut method will be described when the resin region between the upper coil ends 4b and 4b changes in a curved line. As shown in FIG. 28, the processed region is curved like a groove unlike the groove of FIG. This shape has a large area of the upper coil end 4b and is effective in improving the rectification performance. First, FIG. 33 shows a conceptual diagram of a laser undercut processing machine. The processing machine is work 6.
00 holding mechanism 191b, laser irradiation unit 191d,
Laser positioning mechanism 191e, laser oscillator 1
It is composed of 91f. The work 600 is held at a predetermined position by the holding mechanism 191b. Laser irradiation machine 1
91d is a positioning mechanism (cam or servo motor) 191
It is controlled by e to draw a locus of a predetermined curve. By using this method, it is possible to perform undercut processing of an arbitrary curved shape that cannot be processed by a conventional cutter.

Next, regarding the finishing of the commutator surface, depending on the conditions of use and the required accuracy of the product, in addition to the above commutator surface shaping step, the commutator surface is finished by cutting, grinding or the like. To process. Then, if necessary, electrical inspection, balance inspection, dimension inspection, etc. are performed to complete the rotor. [Effects of Embodiment 1] In the method for manufacturing a rotor of the present invention, the upper coil side 4a is electrically connected to both ends of the upper coil side 4a substantially at right angles to the upper coil side 4a, and the upper coil side 4a serves as a center. Upper layer coil 4 having a pair of upper layer coil ends 4b each inclined in a predetermined direction, and lower layer coil sides 5a are electrically connected to both ends of lower layer coil side 5a at substantially right angles to lower layer coil side 5a. And a lower layer coil 5 having a pair of lower layer coil ends 5b which are inclined in the circumferential direction with respect to each other in the circumferential direction, and these prepared coils 4 and 5 are respectively inserted into the slots 2a of the armature core. And the connecting portion 4c of the upper layer coil end 4b and the connecting portion 5 of the lower layer coil end 5b of the lower layer coil 5 inserted in another slot 2a.
Since the step of joining with c is performed, the coil is inserted into the slot of the armature core as in the conventional case, the coil protrusion protruding from the slot is cut into a predetermined length, and the cut coil protrusion is cut into an electric machine. The step of tilting the armature core in the circumferential direction of the armature core at a predetermined angle while bending it toward the end face side in the axial direction, that is, the complicated wire twisting step is not required, and the coil protrusion can be formed into an accurate shape.

Further, the coil 4, which is formed in a predetermined shape in advance,
Since the assembly of the coils 4 and 5 is completed only by inserting 5 from the outer peripheral side in the radial direction of the armature core 2 and joining the two connecting portions 4c and 5c, the assembling property can be dramatically improved. Further, before inserting the lower layer coil 5 into the slot 2a, the inner disk-shaped insulator 10 is attached to the end surface of the armature core 2, and after the lower layer coil 5 is inserted, the lower layer coil end 5b is inserted.
The outer disk-shaped insulator 9 is mounted on the upper side in the axial direction, and then the upper coil 4 is inserted. Alternatively, the in-slot insulator 7 having a U-shaped cross section, the lower coil 5, the in-slot insulator 6 and the upper coil 4 having a U-shaped cross section are arranged in the above order in the slot 2a from the radially outer side of the armature core 2. And then, the protrusion 2f for narrowing the slot opening adjacent to the slot 2a of the armature core 2 is plastically deformed to the slot opening side to narrow the opening of the slot 2a and close the upper portion of the in-slot insulator 6 to the opening of the slot 2a. Bend to the side. According to such a method, the armature core 2 is simply assembled by sequentially stacking the inner disk-shaped insulator 10, the lower layer coil end 5b, and the outer disk-shaped insulator 9 on both end surfaces of the armature core 2. Lower coil 5 at end 2 (coil end)
It is possible to reliably prevent a ground failure that occurs between the armature core 2 and the armature core 2 and rare earth that occurs between the lower coil 5 and the upper coil 4. Conventionally, the armature core is powder-coated or an insulator is attached to insulate the lower coil from the armature core, and the insulating coating of the expensive coated wire is used to insulate the lower coil and upper coil. However, if this method is used, the preheating, coating, and baking facilities required for powder coating are unnecessary, and defects such as pinholes and peeling occur in the wire coating due to external force during winding. Insulation failure can be prevented and a strong insulating structure can be easily obtained.

The lower layer coil 5 and the upper layer coil 4 are
Both coils 4, 5 are punched out from a plate material into a predetermined shape.
To form connecting portions 4a and 5a by bending the tip portions of the coils 4 and 5a substantially at right angles. Before or after the bending of the connecting portions 4a and 5a, bend at a predetermined distance from the tip portions of both coils 4 and 5 and bend them at a substantially right angle. The coil end portion 5b and the upper layer coil end portion 4b are formed. According to such a method, it is possible to use a press machine by using the lower coil 5 and the upper coil 4 as the material of the plate material, and it is very possible to process both coils 4 and 5 if a dedicated mold is prepared. It will be easy. Further, even when the cross-sectional areas of the coils 4 and 5 are changed in order to obtain rotors having different outputs, the cross-sectional areas can be freely changed by changing the width dimension from the material having the same plate thickness. It is convenient for producing a wide variety of products.

Further, in the step of forming the connecting portions 4c and 5c, one of the upper die 61 and the lower die 63 for sandwiching the lower layer coil 5 or the portion excluding the tip portion of the upper layer coil 4 and one of the upper die 61 and the lower die 63 is held. And a bending die 62 that is relatively movable in the thickness direction of the coils 4 and 5 with respect to the upper die 61 and the lower die 63 at the position of sliding contact with the outside of the upper die 61 and the lower die 63. The clearance between the end face and the bending die 62 is set to less than the thickness of the plate material, and the relative movement of the bending die 62 bends the tip portions 4c, 5c of the coils 4, 5 and irons them to a predetermined thickness. According to such a method, conventionally, the first linear portion whose outer periphery is covered with the coating and the second linear portion
The straight parts of the above were melted and connected by fusing, but a large amount of heat energy is required to melt this film, the welding machine body becomes large, and the power consumption is also large. However, since the connection portions 4c and 5c themselves have no coating film and the thickness is thin, the connection portions 4c and 5c can be joined with the minimum required heat energy. In the joining step of joining the connecting portion 5c of the lower coil end portion 5b and the connecting portion 4c of the upper coil end portion 4b, both connecting portions 4c,
Welding torch 14 of the welding machine near the welding area of 5c
A welding step of arranging the tip of 0 close to each other, and then welding the planned welding area with the welding torch 140 while grounding the coils 4 and 5 close to the welding torch 140, and after the completion of welding,
If the rotating step of rotating the armature core 2 by a predetermined angle is performed and then both of the steps are sequentially performed, the armature core 2 is further sequentially rotated in addition to the effects of the above method. Since the joints are sequentially welded, it is possible to automatically weld them with a simple device.

Further, the lower layer coil cooling jig 143 and the upper layer coil cooling jig 142 are brought into contact with the upper layer coil 4 and the lower layer coil 5 which are close to the welding planned region except for the welding planned region to cool the coils 4 and 5. According to this method, the upper layer coil 4 and the lower layer coil 5 which are close to the welding planned area are attached to the lower layer coil cooling jig 143 and the upper layer coil cooling jig 142.
By cooling the coils 4 and 5 by bringing them into contact with each other, it is possible to reduce the temperature rise except for the connecting portions 4c and 5c.
It is possible to prevent melting other than c and 5c. That is, the connection part 4
When c and 5c are welded, melting is likely to proceed beyond the planned welding region to the roots of the connection portions 4c and 5c.
If this phenomenon occurs, in the worst case, there is a possibility that the upper coil ends 4b, 5b adjacent to each other in the circumferential direction, which should not be in contact with each other, may come into contact with each other, resulting in a rare defect, which can be prevented. .

Further, the step of forming the lower layer coil end 5b or the upper layer coil end 4b is carried out by excluding the portion which is the predetermined region of the lower layer coil end 5b of the lower layer coil 5 or the upper layer coil end 4b of the upper layer coil 4. The upper die 71 and the lower die 73 sandwiching the central portions of the coils 4 and 5, and the coils 4 and 5 of the coils 4 and 5 with respect to the upper die 71 and the lower die 73 at a position in sliding contact with one outer side of the upper die 71 and the lower die 73. A bending die 72 that is relatively movable in the thickness direction is prepared, and the relative movement of the bending die 72 bends a portion of the lower layer coil end portion 5b or the upper layer coil end portion 4b that is a predetermined region. According to such a method, a simple and easy-to-manufacture bending die 72 can be prepared, and the upper layer coil ends 4b and 5b can be formed by using a general-purpose press machine that is generally widely used. 5,
b can be easily formed.

Further, the number of lower layer coils 5 or upper layer coils 4 corresponding to all the slots 2a are set close to the openings of all the slots 2a provided in the armature core 2, and then set. The coils 4 and 5 are pushed simultaneously into the slot 2a. According to this method, since each lower layer coil 5 or each upper layer coil 4 is simultaneously installed in the slot 2a, the coils 4 and 5 serve as guides, and the upper layer coil end portions 4b of the adjacent coils 4 and 5 are provided. 5b
The upper layer coil ends 4b, 5b to be mounted on the coils 4 and 5 do not interfere with each other and interfere with the mounting.
It becomes easy to install. Also, as a matter of course, all the coils 4 and 5 are assembled at once, so the production efficiency is extremely high,
It is possible to provide a large amount of rotation at low cost.

Also, a setting step of setting a plurality of coil groups consisting of the lower layer coil 5 or the upper layer coil 4 so as to face the openings of the slots 2a, and then an insertion step of inserting each of the set coil groups into the slot 2a. After that, the rotating step of rotating the armature core 2 by a predetermined angle until the next coil group is inserted is sequentially repeated. According to this method, each lower coil 5 or each upper coil 4 is divided into a plurality of coil groups, each coil group is inserted into the slot 2a, and the armature core 2 is rotated to move the next coil group to the slot 2a. The insertion device can be simplified because the insertion is performed from only one direction. That is, it is possible to mount the coil manually or by a simple jig or the like, and it is possible to realize a mounting method suitable for small to medium volume production.

A pressing jig 162 having a flat pressing surface extending in the radial direction while facing the outer end surface of the upper coil end 4b is prepared so as to be movable in the axial direction.
The pressing surface of is pressed against the outer end surface of the upper coil end 4b (commutator surface 12) to flatten the commutator surface 12. According to this method, since only the commutator surface 12 is pressed, a simple and inexpensive general-purpose press or the like can be used and the flattening process can be realized. That is, if the conventional method, that is, the cutting process or the polishing process is used, the commutator surface can be accurately finished, but with this method, the processing speed is slow, and the consumable tool such as a cutting tool or a large-scale cutting machine or Since a polishing machine is required and it is expensive, this can be solved.

Further, the lower layer coil 5 and the upper layer coil 4 are fitted in the slots 2a of the armature core 2, and are rotated in a state of being set substantially in the vertical direction, and at the same time, the resin dropping nozzle is placed on the surface of the upper layer coil end 4b. 171 to resin liquid 17
2 is dropped to apply the resin liquid 172 to the surface, and the resin liquid 172 is further rotated, and the air nozzle 1 is applied to the surface of the upper coil end 4b.
Gas is blown from 80 to spread the resin liquid 180.
According to this method, a liquid resin which is easy to handle is dropped near the strengthening planned region of the upper coil end 4b, and is permeated into the gap between the upper coil end 4b by utilizing the permeation phenomenon of the liquid. , By rotating, homogenize,
Unnecessary resin liquid 172 can be removed, the necessary minimum source resin liquid 172 can form a required insulating layer, and the collected resin liquid 172 can be reused.

[Second Embodiment] The second embodiment will be described below in order. A manufacturing method for simultaneously forming a large number of upper layer coils 4 and lower layer coils 5 will be described with reference to FIG.
If a punched member is a conductor plate which is a plate material and is punched by a press or the like, the upper layer coils 4 are arranged in parallel and in a row at regular intervals, and the adjacent upper layer coils 4 and 4 are connected by a connecting portion 4f. Has been done. Connecting part 4f
Is arbitrary. Bending of the upper layer coil 4 (the same applies to the lower layer coil 5) using this punching member is performed at the connecting portion 4f.
After separation, the same process as in the above-described embodiment can be performed. In addition, it is also possible to bend the connecting portion 4c or the upper coil end portion 4b before separating the connecting portion 4f. For example, the punching member may be conveyed in one direction while being bent at its tip to separate the connecting portion 4f. Alternatively, a punching member having a predetermined number of upper layer coils 4 may be used to fold it at once, and then the connecting portion 4f may be cut off at once.

With the above arrangement, it is possible to manufacture a large number of upper layer coils 4 and lower layer coils 5 at a time by taking a large number of them, and it is possible to provide the upper layer coils 4 and lower layer coils 5 at a low cost by improving the production efficiency. Not only that, punching and bending are done at once, so it is easy to stabilize the finished dimensional accuracy such as the bending angle. When the punching members having the upper coil 4 arranged in a line in this manner are conveyed in the arrangement direction, each upper layer coil 4 is cut before the connecting portion 4f is cut off in order at the tip of the bent punching member.
Adhesive tape, for example, is attached to (the upper coil side 4a is preferable). Alternatively, a holder for holding the upper layer coils 4 arranged in a line holds the upper layer coil sides 4a of the respective upper layer coils 4. For example, each holder is capable of elastically sandwiching the upper coil side 4a. These holders are connected, driven, and proceed in an annular shape along the outer peripheral surface of the rotor 3 as they are. Alternatively, the pressure-sensitive adhesive tape is similarly advanced in an annular shape along the outer peripheral surface of the rotor 3. After that, each upper layer coil 4 may be pushed into the slot at once. If you do this,
It becomes easy to automate a series of operations for bending the upper layer coil 4 and mounting it in the slot.

[Third Embodiment] A third embodiment is a method of manufacturing the lower coil 5 from the conductor plate 500, which is a plate material. This will be described. FIG. 35 shows a cutting line in the method of sequentially cutting off the expansion body 50 of the lower layer coil 5 from the tip portion of the conductor plate 500, and FIG. 36 is a perspective view showing a state in which one expansion body 50 is cut, and FIG. A plan view of the lower mold 210, 230 of the cutting device is shown, and FIG. 38 is a vertical cross-sectional view of the mold part of the cutting device.

This cutting device includes a feeding device (not shown) for feeding a flat conductor plate 500 in one horizontal direction at a constant pitch and a vertical interval with a gap through which the conductor plate 500 passes. Lower guide (die) 2 that is the type to be installed
10 and the upper guide 220, a holding die 230 for holding the work after cutting, and a cutter 240 which is a cutting die disposed on the holding die 230. Mold 21
The left end faces of 0 and 220 and the right end faces of the molds 230 and 240 are cutting lines, that is, the main edge 200 on the right side in FIG.
It has almost the same shape as.

Details of the processing will be described below. The holding die 220 is slightly raised with respect to the fixed die 210, and the conductor plate 500 is moved at a constant pitch in FIGS. 37 and 38.
Send horizontally to the left. At this time, the work holding mold 2 after cutting
30 stands by in a lower position where it does not hinder the material feeding. After the feeding is completed, the material retainer 220 is lowered and the conductor plate 500 is clamped. Then, the cutter 240 is lowered to cut the tip of the conductor plate 500 to obtain the spread body 50.

The expander 50 cut by the cutter 240, that is, the lower coil 5 is composed of a lower coil side 5a, a lower coil end 5b, and a connecting portion 5c further extending from the tip of the lower coil end 5b. The width of the lower layer coil side 5a, the width of the lower layer coil end 5b, and the width of the connecting portion 5c are substantially the same. Next, the unfolded coil 50 is completed in a predetermined shape by the steps shown in FIGS. 10 to 13 described in the first embodiment.

In this way, the expanded body 50 of the lower layer coil 5 can be obtained easily and with a high yield, and the expanded body 50 is bent in the same process as the above-described manufacturing of the upper layer coil 4 to obtain the first embodiment. The same lower layer coil 5 can be obtained, and the life of the blade is not shortened even if the width of the expander 50 is narrower than the thickness of the conductor plate 500. [Fourth Embodiment] A fourth embodiment will be described below.

Another method of forming the expanded body 50 (see FIG. 3) of the lower coil 5 from the conductor plate 500 will be described below with reference to FIGS. 39 and 40. FIG. 39 shows the conductor plate 5 after punching out three deployable bodies 50 from the conductor plate 500.
00 is a plan view of FIG. First, as shown in FIG. 39, the three deployable bodies 50 arranged in a line in parallel with each other are punched at the same time. Of course, it is also possible to sequentially punch out the deployable body 50.

Next, as shown in FIG. 40, the widthwise both ends 500b of the remaining portion 500a of the conductor plate 500 from which the expander 50 has been punched out are linearly punched in the longitudinal direction of the conductor plate 500 to leave the remaining portion. The portions of the remaining portions 500a between the adjacent punched holes in 500a are referred to as the deployable bodies 50. In this embodiment, the expander 50 is punched so that the longitudinal direction of the lower coil side 5a of the expander 50 coincides with the width direction of the conductor plate 500, and the conductor plate 500 is fed at a single feed pitch. The width is set to twice the width of the lower coil side 5a (width in the feeding direction).

Next, the unfolded coil 50 is completed in a predetermined shape by the steps shown in FIGS. 10 to 13 described in the first embodiment. In this way, the expansion body 50 of the lower layer coil 5 can be easily obtained with a high yield, and the life of the blade is shortened even if the expansion body 50 is narrower than the thickness of the conductor plate 500. Never.

[Embodiment 5] Embodiment 5 will be described below. 41 to 4 for another method of forming the expanded body 50 (see FIG. 3) of the lower layer coil 5 from the conductor plate 500.
This will be described below with reference to FIG. 41 to 44 each show a remaining portion 500a of the conductor plate 500 in which the expansion body 50 has been punched out. FIG. 41 shows the conductor plate 500 to the expanded body 50.
FIG. 6 is a plan view of the conductor plate 500 showing a state after punching three pieces.

First, as shown in FIG. 41, three deploying bodies 50 arranged in a line in a mutually parallel posture are punched simultaneously or sequentially. As a result, three holes 52 are formed in the remaining portion 500a of the conductor plate 500. The width of the lower coil 5 is significantly narrower than that of the lower coil ends 5b and 5c. Therefore, the lower coil end portion 5 of the hole 52 is
The hole portions 52b and 52c of b and 5c are narrower than the hole portion 52a of the lower coil side 5a of the hole 52, and the conductor plate 500 adjacent to the hole portions 52b and 52c by that amount.
Of the remaining portion 500a (both ends in the width direction) 53b, 53
The width c is wider than the area (central portion in the width direction) 53a of the remaining portion 500a of the conductor plate 500 adjacent to the punched hole portion 52a of the lower coil side 5a of the hole 52.

The connecting portion 5c of the lower layer coil end portion 5b described above.
The reason for making the diameter on the side and the connecting portion 5c narrow is that, for example, a sufficient space is provided between adjacent conductor portions adjacent in the circumferential direction as described above, and the connecting portion 5c and the connecting portion 4c are This is to reduce the heat capacity during welding. Next, part of the regions (widthwise both ends) 53b, 53c of the remaining portion 500a including the punched hole portions 52b, 52c of the hole 52 (the punched hole portion 52).
Trimming punches (punching) one by one (parts adjacent to b and 52c). The thick solid line shown in FIG. 42 indicates the area to be trimmed and punched. By doing so, as shown in FIG. 43, the regions (both end portions in the width direction) 53b, 53c of the remaining portion 500a have lower coil end portions 5b, 5c.
It has a shape equal to c.

Next, as in the fourth embodiment, the remaining portion 500a
By punching out the straight portions (extending in the longitudinal direction of the lower layer coil end portion 5b) 500b at both ends in the width direction, the portion of the remaining portion 500a between the holes 52 is formed as a new deployable body 50. Become. Next, the expanded body 50 is completed into the predetermined shape of the lower layer coil 5 by the steps shown in FIGS. 10 to 13 described in the first embodiment.

In this way, as shown in FIG. 42, even if the cut-off portion in the regions 53b and 53c of the remaining portion 500a is extremely thin, punching can be performed without narrowing the punch die. The life of can be greatly extended. [Sixth Embodiment] A sixth embodiment will be described below.

Another method of forming the expanded body 40 (see FIG. 4) of the upper coil 4 from the conductor plate 500 will be described below with reference to FIG. FIG. 45 is a diagram for explaining the cutting pattern of the deployable body 40, and FIG. 46 shows the cutting device.
That is, in this embodiment, the tip portion 500 of the conductor plate 500 is
The development body 40 is cut off from a, and thereafter, the unnecessary remaining portion 500b is cut off, and the development body 40 and the remaining portion 50 are sequentially cut.
0b is cut off alternately. The cutting device will be described with reference to FIG.

This cutting device comprises a feeding device (not shown) for feeding a flat conductor plate 500 in one horizontal direction at a constant pitch and at a constant interval; a first cutting device 201;
It comprises a second cutting device 202. Cutting device 201, 2
The structure and operation of 02 are basically the same as those of the cutting device of the fourth embodiment. The first cutting device 201 includes a lower guide (die) 211 and an upper guide 221 which are vertically arranged with a gap through which the conductor plate 500 passes, and a holding mold 231 for holding a work after cutting. And a cutter 241 which is a cutting die disposed on the holding die 231. With the first cutting device 201, as in the fourth embodiment,
The tip portion 500a of the conductor plate 500 has a cutting line B shown in FIG.
Is cut.

The second cutting device 202 has a lower guide (die) 212 and an upper guide 222, which are a group of dies arranged vertically with a gap through which the conductor plate 500 passes, and a work holding work after cutting. The holding die 232 and a cutter 242 that is a cutting die provided on the holding die 232. Cutting line B by the above-mentioned first cutting device 201
After cutting with the molds, the molds 211 and 231 descend to such an extent that they do not interfere with the feeding of the conductor plate 500, and the molds 221, 241, 2
22 and 242 also rise to a predetermined height. The mold 21
2, 232 have been lowered in advance so as not to interfere with the feeding of the conductor plate 500.

Next, the conductor plate 500 is fed by a predetermined pitch. Next, lower guides (dies) 212 and 232, which are mold groups of the second cutting device 202, are raised to predetermined positions, the upper guide 222 is lowered, the conductor plate 500 is clamped, and then the cutter 242 is lowered. Is cut along the cutting line A.
Next, the molds 212 and 232 descend, the molds 222 and 242 rise, and then the conductor plate 500 retracts to a predetermined position,
This time, cutting is performed along the cutting line B according to the same principle as that of the second embodiment. Hereinafter, by repeating this, the upper coil 4 can also be continuously formed by the cutter.

[Seventh Embodiment] A seventh embodiment will be described below. Although the upper layer coil 4 and the lower layer coil 5 are formed from the plate material in the above-described Examples 3 to 6, in the present Example, the upper layer coil 4 and the lower layer coil 5 are formed from rectangular wires. Next, the manufacturing process of the lower layer coil 5 will be described below.

First, a round wire having a circular cross-sectional area as shown in FIG. 47 (a) is prepared, and this round wire is sent to a distortion removing process (not shown) to cause warping and distortion of the round wire to be paired up and down. The round wire 700 is straightened by forcibly passing it between the rollers. Then, the round wire 700 from which the distortion is removed is shown in FIG.
As shown in FIG. 7B, a rectangular wire 70 having a rectangular cross-sectional area and having a length necessary to form a spread body of a plurality of lower layer coils 5 is formed.

Next, in order to obtain the expanded shape of the lower coil 5, a part of the outer circumference is plastically deformed by a roller at predetermined intervals in the axial direction of the rectangular wire 70 to reduce the cross-sectional area, or a press is performed. By removing processing such as punching or shaving processing, both side surfaces of the rectangular wire 70 are removed to reduce the cross-sectional area, and the shaft detail 5d is formed.
Do as in 7 (c). Note that FIG. 48 shows FIG. 47 (c).
FIG.

Then, as shown in FIG. 48, the shaft detail 5d
A substantially central portion 5e is cut to form a predetermined lower layer coil 5 as shown in FIG. 49 (a). In this embodiment, the round wire 700 is molded into the rectangular wire 70.
The rectangular wire 70 may be prepared in advance. Next, FIG.
FIG. 49 shows a developed body of the predetermined lower layer coil 5 shown in FIG.
As shown in (b), the lower coil end portion 5b of the expanded body is bent at an angle θ with respect to the lower coil side 5a, and a connecting portion 5c is predetermined for the bent lower coil end portion 5b. Bend at an angle.

Next, as shown in FIG. 49 (c), the connecting portion 5c of the deployable body is bent at about 90 degrees. And
As shown in FIG. 49 (d), the lower coil end portion 5b of the expanded body is shown.
Is bent at about 90 degrees, that is, bending is performed. However, only by bending, the connection between the lower layer coil side 5a and the lower layer coil end 5b may have a large R shape.

Therefore, in order to obtain the accurate shape as shown in FIG. 49 (e), as shown in FIG. 24, the lower layer coil end portion 5b is oriented in the direction of the lower layer coil side 5a (direction of arrow 164 in FIG. 24). ) With a predetermined pressure, which can eliminate a large R shape. Note that in this embodiment, FIG.
After the step of (a), the lower coil end portion 5b of the expanded body is bent by an angle θ with respect to the lower coil side 5a, but at the time of the step of FIG. 49 (d), the lower coil side 5a is centered. It may be bent at a predetermined angle in the circumferential direction.

As shown in FIG. 49 (d), the connecting portion between the lower coil side 5a and the lower coil end 5b is made thick so that the lower coil end 5b of the expanded body can be easily bent at about 90 degrees. Stealing may be provided. By doing so, the connecting portion is unlikely to have an R shape, and the lower coil 5 can have an accurate shape. By doing so, the lower layer coil 5 can be formed from the rectangular wire 70, so that the material yield can be dramatically improved.

Needless to say, the upper layer coil can be manufactured in the same process as the lower layer coil 5. [Embodiment 8] Embodiment 8 will be described below. In the seventh embodiment, as shown in FIG. 49 (a), the expanded body has a shape corresponding to the lower coil end portion (conductor portion) 5b of the lower coil 5 with both side surfaces of the rectangular wire 70 removed. In this embodiment, as shown in FIG. 50, this removal has a shape in which only one side surface is removed by the same method as in the seventh embodiment.

The subsequent steps for forming the lower coil are the same as those in Example 7, and the description thereof is omitted. [Modification] In each of the above-described embodiments, the upper coil end 4b and the lower coil end 5b are bent in advance by a predetermined angle θ, but both coil ends 4b and 5b are excellent at a predetermined distance from the tip. The bent position may be bent at a substantially right angle and then twisted in the circumferential direction by the predetermined angle θ. In this case, it is possible to prevent the occurrence of work hardening by shifting the bending processing portion and the twisting processing portion of the upper layer coil and the lower layer coil.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing an assembled state of a rotor according to a first embodiment.

FIG. 2 is an axial half sectional view of the rotor of the first embodiment.

FIG. 3A is a side view of the lower coil 5, and FIG.
FIG. 4 is a development view of the lower coil 5.

4 (a) to (c) are perspective views of an upper layer coil 4. FIG.

5 is a perspective view of an in-slot insulator 7. FIG.

FIG. 6 is a perspective view of an in-slot insulator 6.

7 is a perspective view of the inner disk-shaped insulator 10. FIG.

8 is an axial sectional view of a reinforcing member 11. FIG.

9 is a plan view showing a spreader punching die for the lower layer coil 5. FIG.

FIG. 10 is a plan view of a bending die showing a state where the upper layer coil 4 is set in the lower die 63.

FIG. 11 is a sectional view of a bending die showing a state in which the connecting portion 4c of the upper coil 4 is bent.

FIG. 12 is a plan view of the bending die showing a state where the upper coil 4 is set in the lower die 73 for bending the upper coil end portion 4b of the upper coil 4.

FIG. 13 is a sectional view of a bending die showing a state where the upper coil end portion 4b of the upper coil 4 is bent.

FIG. 14 is a diagram showing the lower coil 5 in the slot 2 a of the armature core 2.
It is a schematic perspective view which shows the state which is sequentially inserted in.

FIG. 15 is an enlarged partial cross-sectional view showing a state in which the in-slot insulator 7 and the lower coil 5 are housed in the slot.

16 is a schematic perspective view showing a state in which the lower layer coil 5 is sequentially inserted into the slot 2a of the armature core 2 as a plurality of coil groups. FIG.

17 is a perspective view showing an arrangement state of upper layer coils 4 and lower layer coils 5. FIG.

FIG. 18 is a diagram schematically showing the connection between the upper coil 4 and the lower coil 5.

19 is a block diagram of an apparatus for welding the connecting portion 4c of the upper layer coil 4 and the connecting portion 5c of the lower layer coil 5. FIG.

20 is a schematic partial cross-sectional view showing the welding operation of the apparatus of FIG.

FIG. 21 is a schematic view showing a step of tilting the protrusion 2f of the lamination core 2.

22 is a schematic perspective view of FIG. 21. FIG.

FIG. 23 is a partial cross-sectional view near the slot 2a.

FIG. 24 is a schematic partial sectional view showing a step of flattening the commutator surface 12.

FIG. 25 is a schematic partial cross-sectional view showing the step of dropping the resin liquid between the upper coil ends 4b (commutator pieces) of the upper coil 4 and the like.

FIG. 26 is a schematic partial cross-sectional view showing a step of blowing off the resin liquid dropped in FIG.

FIG. 27 is a schematic front view showing a portion for resin removal.

FIG. 28 is a schematic front view showing a portion where resin is removed.

FIG. 29 is a schematic partial side view showing a step of removing a portion of the undercut groove region in the resin deposited in the steps of FIGS. 25 and 26.

FIG. 30 is a schematic partial cross-sectional view showing a state where resin is removed in the step of FIG. 29.

FIG. 31 is a schematic partial cross-sectional view showing a state in which resin is removed in the step of FIG. 29.

32 is a schematic partial cross-sectional view showing a state in which resin is removed in the step of FIG. 29.

FIG. 33 is a schematic partial side view showing a step of removing a portion of the undercut groove region of the resin deposited in the steps of FIGS. 25 and 26 with a laser.

FIG. 34 is a plan view of the upper coil 4 according to the second embodiment.

FIG. 35 is a plan view showing a state in which the lower coil 5 is cut off from the conductor plate 500. (Example 3)

36 is a perspective view showing a state in which the lower layer coil 5 is cut off from the conductor plate 500. FIG.

37 is a plan view showing a lower die portion of the lower layer coil cutting device shown in FIG. 35. FIG.

38 is a vertical cross-sectional view of the lower coil cutting device shown in FIG. 35.

FIG. 39 is a plan view showing a state where the lower layer coil 5 of Example 4 is punched.

FIG. 40 is a plan view showing a state where the lower layer coil 5 of Example 4 is punched.

FIG. 41 is a plan view showing a state in which the lower coil 5 of Example 5 is punched.

FIG. 42 is a plan view showing a state in which the lower coil 5 of Example 5 is punched.

FIG. 43 is a plan view showing a state where the lower layer coil 5 of Example 5 is punched.

FIG. 44 is a plan view showing a state where the lower layer coil 5 of Example 5 is punched.

FIG. 45 is a plan view showing a state in which the upper coil 4 of Example 6 is cut off.

FIG. 46 is a vertical sectional view showing a cutting device for the lower layer coil 5 of the sixth embodiment.

47A is a perspective view showing a material of the lower layer coil 4 of Example 7. FIG. (B) is a perspective view showing a state where (a) is formed into a rectangular wire 70. (C) is a perspective view showing a state in which a part of the outer periphery of the rectangular wire 70 of (b) is removed.

48 is an enlarged partial perspective view of FIG. 47 (c).

49 (a) to 49 (e) are plan views sequentially showing bending of the lower layer coil 5.

50 is a development view showing a development body of the lower coil 4 of Example 8. FIG.

[Explanation of symbols]

 1 shaft 2 lamination core (armature iron core) 2a slot 2f core protrusion 3 rotor 4 upper layer coil 4a upper layer coil side 4b upper layer coil end 4c connection 5 lower layer coil 5a lower layer coil side 5b lower layer coil end 5c connection 6 slot Inner insulator 7 Slot inner insulator 9 Outer disk-shaped insulator 10 Inner disk-shaped insulator

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Kenichi Shibayama, 1-1, Showa-cho, Kariya city, Aichi Nihon Denso Co., Ltd.

Claims (22)

[Claims] 1. An armature core having a slot on its outer periphery, a straight upper layer coil side, and both ends of the upper layer coil side, which are electrically connected substantially at right angles to the upper layer coil side. An upper coil having a pair of upper coil ends that are inclined at a predetermined angle in the circumferential direction with respect to the sides, and a linear lower coil side and both ends of the lower coil side that are substantially perpendicular to the lower coil side. And a lower layer coil having a pair of lower layer coil ends inclined in the circumferential direction about the lower layer coil side by a predetermined angle, respectively, the lower layer coil side of the lower layer coil and the upper layer coil side of the upper layer coil being prepared. Is inserted into each of the slots from the outer peripheral side in the radial direction of the armature core, and the slot inserted into a slot different from the connecting portion formed of the tip end portion of the upper layer coil end portion. Method of manufacturing a rotor of a rotating electric machine, characterized in that bonding the connecting portion comprising a distal end portion of the lower layer coil ends of the layer coil. 2. An inner disk-shaped insulator is attached to an end surface of the armature core before inserting the lower layer coil into the slot, and after the lower layer coil is inserted, the upper layer coil end portion is moved upward. The method for manufacturing a rotor of a rotary electric machine according to claim 1, wherein an outer disk-shaped insulator is mounted in the axial direction, and then the upper layer coil is inserted. 3. The lower layer coil and the upper layer coil,
Punching each into a predetermined shape from a plate material, bending the tip portions of both of the coils at a substantially right angle to form the connection portion, and before or after bending the connection portion, at a position apart from the tip portions of the both coils by a predetermined distance. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein the lower layer coil end portion and the upper layer coil end portion are formed by bending at substantially right angles. 4. The step of forming the connecting portion comprises: an upper die and a lower die that hold a portion of the lower layer coil or the upper layer coil excluding the tip portion; and an outer die of one of the upper die and the lower die. A bending die that is relatively movable in the thickness direction of the coil with respect to the upper die and the lower die at a position in sliding contact is prepared, and the other outer end surface of the upper die and the lower die and the bending die. The clearance is set to be less than the thickness of the plate material, and the tip ends of the coils are bent by the relative movement of the bending die and ironed to a predetermined thickness. A method for manufacturing a rotor of a rotating electric machine. 5. The step of forming the lower layer coil end or the upper layer coil end includes the center of the coil excluding a portion to be a predetermined region of the lower layer coil end of the lower layer coil or the upper layer coil of the upper layer coil. An upper die and a lower die that sandwich the portion, and a bending die that is relatively movable in the thickness direction of the coil with respect to the upper die and the lower die at a position in sliding contact with one of the upper die and the lower die. 4. The method for manufacturing a rotor of a rotating electric machine according to claim 3, further comprising: preparing a portion, and bending the portion of the lower layer coil end portion or the upper layer coil end portion that is a predetermined region by the relative movement of the bending die. 6. A plurality of the coils adjacent to each other and a connecting portion for holding the coils are punched at a stroke.
The method for manufacturing a rotor of a rotating electric machine according to claim 3, wherein the connecting portion is cut before or after the bending of the tip portion. 7. A step of feeding a conductor plate in a predetermined direction by a predetermined pitch, and thereafter, a developed shape of a coil conductor to be the lower layer coil in which a width of the lower layer coil side and a width of the lower layer coil end are substantially the same. A step of cutting a shape equal to the edge shape of the coil conductor to obtain the expanded body of the coil conductor is sequentially repeated to form a required number of the expanded body, and both ends of the expanded body are bent to form the coil conductor. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein. 8. A step of feeding a conductive plate body in a predetermined direction by a constant pitch that is at least twice the width of a coil conductor that forms the lower coil, and thereafter, expanding the coil conductor from the tip end portion of the conductive plate body. The step of punching, and then the step of forming a further additional developed body from the remaining portion by cutting off the widthwise end of the remaining portion of the conductor plate adjacent to the punched developed body is sequentially repeated. 2. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein the required number of expanders are formed, and both ends of the expanders are bent to form the coil conductor. 9. After the expanding member punching step of punching the lower layer coil end portion in a narrower width than the lower layer coil side,
And, at the same time as or before the step of cutting off the widthwise end portion of the remaining portion of the conductor plate, the portion of the lower layer coil end portion formation region of the remaining portion is more than the lower layer coil side formation region of the remaining portion. The method for manufacturing a rotor of a rotating electric machine according to claim 8, further comprising a step of punching into a narrow width. 10. A flat wire having a predetermined length necessary to form a plurality of expanded bodies of coil conductors forming the upper coil or the lower coil is prepared, and then a flat wire is provided in the axial direction of the flat wire. Axial details are formed on the outer circumference at intervals, and substantially the central part of the axial details is cut to form a plurality of the expansion bodies, and both ends of each expansion body are bent to form the upper coil end or the lower layer. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein the coil ends are formed. 11. A lower in-slot insulator having a U-shaped cross section, the lower coil, an upper in-slot insulator having a U-shaped cross section, and the upper coil in the radial direction of the armature core in the above order. It is pushed from the outer peripheral side into the slot, and then the projection for slot opening narrowing adjacent to the slot of the armature core is plastically deformed to the slot opening side to narrow the slot opening and insulate the upper slot. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein the upper part of the body is bent toward the closed side of the slot opening. 12. The number of the lower layer coils or the upper layer coils corresponding to all the slots are set close to the openings of all the slots provided in the armature core, and then the set coils are set. 12. The method for manufacturing a rotor of a rotary electric machine according to claim 1 or 11, further comprising: 13. A setting step of setting the lower layer coil or the upper layer coil so as to face the opening of the slot.
After that, an inserting step of inserting the set coil into the opposing slot and a rotating step of rotating the armature core by a predetermined angle until the next coil insertion are sequentially repeated. A method for manufacturing a rotor of a rotating electric machine according to claim 1. 14. The rotor of a rotating electric machine according to claim 13, wherein the second and subsequent insertions of the coil are performed while rotating the coil in a predetermined rotation direction about the longitudinal direction of the coil. Production method. 15. A setting step of setting a plurality of coil groups including the lower layer coil or the upper layer coil so as to face an opening of the slot, and then inserting each of the set coil groups into the slot. Process,
The method of manufacturing a rotor of a rotating electric machine according to claim 1 or 11, wherein the rotating step of rotating the armature core by a predetermined angle is sequentially repeated until the next coil group is inserted. 16. A joining step of joining the connecting portion of the lower coil end portion and the connecting portion of the upper coil end portion,
The tips of the welding torches of the welding machine are arranged in proximity to the welding planned areas of the both connecting portions, and then the welding torch is welded to the welding planned areas while grounding the coils adjacent to the welding torch. The rotating electric machine according to claim 1 or 3, wherein a welding step and a rotating step of rotating the armature core by a predetermined angle are performed after the welding is completed, and then the both steps are sequentially performed. Manufacturing method of rotor. 17. The rotating electric machine according to claim 16, wherein a cooling means is brought into contact with the upper layer coil and the lower layer coil, which are adjacent to the welding scheduled area, except for the welding scheduled area, to cool the coil. Manufacturing method of rotor. 18. A slot is provided on an outer peripheral portion,
An armature core having a pair of protrusions protruding in radial directions different from each other by a predetermined angle is prepared on the outer peripheral portion of the armature core between adjacent slots, and a diameter is provided in the vicinity of the outer peripheral surface of the armature core. A narrow claw tilting plate arranged so as to be movable in the direction is prepared, and is arranged so as to be radially movable near the outer peripheral surface of the armature core at an angle position different from that of the narrow claw tilting plate. Prepare a thick-width claw tab, press a predetermined number of coils into the slot from the outer peripheral side of the armature core, and then move toward the center of the groove between the pair of adjacent protrusions. Push in the narrow width tabs to widen the groove, and then push the thick tabs toward the center with the end faces of the thick tabs in contact with the projections. Narrows the slot opening by plastic deformation of the protrusion The rotor manufacturing method of claim 1 or 11 rotary electric machine, wherein the. 19. A pressing body having a flat pressing surface extending in the radial direction while facing the outer end surface of the upper coil end portion is prepared so as to be movable in the axial direction, and the pressing surface of the pressing body is provided with the pressing surface. 4. The method for manufacturing a rotor of a rotating electric machine according to claim 1, wherein the outer layer end surface of the upper layer coil is pressed to flatten the surface of the upper layer coil end. 20. In a joining step of joining the connection portion of the lower layer coil end portion and the connection portion of the upper layer coil end portion,
A method of depositing a resin liquid between the end portions of the upper layer coil, solidifying the resin liquid to form a solidified resin portion, and thereafter removing the solidified resin portion attached to the surface of the end portion of the upper layer coil. Item 4. A method of manufacturing a rotor of a rotating electric machine according to Item 1 or 3. 21. The lower layer coil and the upper layer coil are fitted in the slots of the armature core, and are rotated in a state of being set substantially in the up-and-down direction, and the resin dropping nozzle is applied to the surface of the upper layer coil end portion. It is characterized in that the resin liquid is dropped to apply the resin liquid to the surface, further rotates, and at the same time, the gas is blown from the blow nozzle to the surface of the end portion of the upper layer coil to spread the resin liquid. A method of manufacturing a rotor of a rotating electric machine according to claim 20. 22. A rotary blade rotating in a plane orthogonal to a radial direction of the armature core at a position facing a surface of the upper layer coil end portion to which the solidified resin portion has been adhered is prepared, and the solidified portion is solidified. Setting the rotary blade in the groove portion between the pair of upper layer coil ends adjacent to each other by relatively moving the armature core to which the resin portion has been adhered relative to the rotary blade in the direction approaching the rotary blade. 21. The method of manufacturing a rotor of a rotary electric machine according to claim 20, wherein the solidified resin portion in the groove is removed by rotating the armature core while rotating the rotary blade.