JPWO2012120646A1 - Motor manufacturing method - Google Patents

Abstract

A coil end portion at one end of the coil (11) is formed by being bent toward the rotor (40) side with respect to the in-slot conductor portions (SA, SB) of the stator core (13), and a slope on which the coil (11) is disposed. On the taper-shaped jig (JG1) having the coils (11), the coils (11) are sequentially arranged so as to be arranged in a semicircular shape, and the first semicircular coil rod (20A) and the second semicircular coil rod (20B). ) And the second taper-shaped jig (JG12) is brought into contact with the first taper-shaped jig (JG11), whereby the coil (11) is arranged in an annular shape to form an annular assembly. (21) is formed, and at the same time that the tapered jig (JG1) is removed from the other end of the coil (11) from the annular assembly (21), one end of the coil (11) of the annular assembly (21) Insert the ring-shaped jig (JG2) from the side and Forming a cage (12) is inserted from one end side of the coil (11) in the stator core (13).

Description

  The present invention relates to a motor manufacturing technique, and more particularly to a technique for arranging coils used in a stator in an annular shape and assembling the stator core.

  In recent years, there has been an increasing demand for using motors for driving power of automobiles. Motors used for driving power of automobiles are required to be smaller and have higher output, and as one of the measures, a method of using a flat conductor for a coil has been studied. This is because the use of a rectangular conductor for the coil can be expected to improve the sectional area and the space factor. When using a coil for a motor, it is necessary to insert a coil in the slot which a stator has. In many cases, the slot has a trapezoidal shape, and in terms of geometry, the rectangular section can set a lower porosity than the circular section. Therefore, the use of a rectangular conductor having a rectangular cross section can increase the cross sectional area, and an improvement in the space factor can be expected.

  However, a coil using a flat conductor becomes difficult to be deformed by increasing the cross-sectional area, and it is difficult to apply an assembling method that has been adopted for a conventionally used round wire coil. Even when a round wire coil is used, attention has been paid to the damage and disconnection of the coil. However, when a coil using a flat conductor is assembled to a motor, another difficulty arises.

  Patent Document 1 discloses a technique related to a stator coil insertion device. Using the alignment tool composed of the upper alignment and the lower alignment as a guide, the stator core is inserted and held up to a predetermined position of a plurality of blades arranged at predetermined intervals on the same circumference. A plurality of blades are provided with coils at predetermined positions. When the first stage movable part is raised to a predetermined position, the core guide that contacts the upper end of the fixed blade and the upper alignment also move upward as the fixed blade supported by the first stage movable part among the plurality of blades rises. Slide. When the second stage movable part is raised to a predetermined position, the movable blade supported by the second stage movable part among the plurality of blades rises, and the aligned coils can be inserted into the slots of the stator core.

  Patent Document 2 discloses a technique related to an alignment method and alignment apparatus for segment conductors. A plurality of segment conductors including a pair of parallel insertion portions and a roof-type turn portion that joins one ends of both insertion portions are inserted into predetermined positions from predetermined slots of the stator core from one insertion portion and the other insertion portion, respectively. This is a method of aligning them. For this reason, a positioning step of arranging a plurality of segment conductors in a radial pattern in a plan view, and moving one insertion portion of each segment conductor in a direction substantially perpendicular to the radiation direction in a plan view, more radiation direction than one insertion portion An alignment step of swinging the other insertion portion located on the outside around the one insertion portion and moving the insertion portion radially inward.

  Patent Document 3 discloses a technique related to a method for manufacturing a stator coil. When winding and manufacturing a stator core in which each phase winding consisting of continuous windings is wound, the turn part of the built-in body is turned into a winding radius with respect to the core member in the course of feeding the built-in body into the core member. It is a built-in body in which the turn part is bent and formed into a staircase shape by plastic deformation into a bend R shape having substantially the same bend R radius, and the alignment accuracy and pitch accuracy in the layer part are improved. This technique improves the alignment accuracy in the staircase.

  Patent Document 4 discloses a technique related to an annular alignment jig and an annular alignment method for coil segments. When setting the substantially U-shaped coil segment for one turn in the insertion recess of the hat-shaped annular alignment jig, one straight part of the coil segment is inserted, and the coil for one turn until the other straight part hits the outer peripheral surface Rotate the segments together, align the coil segments for one round in an annular shape, and then cover with a hat-shaped intermediate alignment jig so that the set of coil segments does not collapse. A plurality of coil segments corresponding to the segment type coil of the layer are formed, and the entire assembly is inserted into the slots of the stator core.

JP-A-6-38461 JP 2005-65386 A JP 2009-284754 A JP 2004-72839 A

  However, when forming the stator using the coil proposed by the applicant using the techniques described in Patent Documents 1 to 4, it is considered that there are problems described below.

  The applicant has proposed a motor using a rectangular conductor coil with improved assemblability in the invention separately filed. This rectangular conductor coil is a type in which a plurality of concentric winding coils are stacked and connected, and when the coil is assembled, one end of the coil protruding from the stator coil end is bent to the inner peripheral side of the stator. As a result, the assembly of the stator is improved. However, when the coil having the shape of the present invention is used, it seems that it is not appropriate to perform assembly using the techniques of the conventional Patent Documents 1 to 4.

  Although there is no specific mention about the coil used in Patent Document 1, it is considered that the coil is deformed along the movement of the alignment tool used during assembly. Therefore, it seems that it is not suitable to apply to a coil which has a wide cross-sectional area and is not easily deformed, such as the flat conductor coil of the invention. Moreover, since the coil used in patent document 2 and patent document 4 is a segment coil and the coil used in patent document 3 is a wave winding coil, it is difficult to apply simply to the assembly | attachment of the flat conductor coil of this invention. .

  Accordingly, an object of the present invention is to provide a motor manufacturing method in which coils using flat conductors are aligned and assembled to a stator in order to solve such problems.

  In order to achieve the above object, a motor manufacturing method according to an aspect of the present invention has the following characteristics.

(1) A motor having a distributed winding coil using a rectangular conductor and a stator core and a motor having a rotor having a central axis is combined with the distributed winding coil to form a coil rod, and the coil rod is pivoted on the stator core. In the motor manufacturing method of manufacturing a motor by inserting from the direction, a coil end portion at one end of the coil is formed to be bent toward the rotor side with respect to the in-slot conductor portion of the stator core, and the coil is disposed. A first semicircular coil rod and a second semicircular coil are arranged in a semicircular shape by sequentially arranging the coils on a first tapered jig and a second tapered jig having slopes. Forming a flange and bringing the second tapered jig into contact with the first tapered jig so that the coil is arranged in an annular shape and the first half jig An annular assembly comprising an annular coil rod and the second semi-annular coil rod is formed, and the first tapered jig and the second tapered jig are moved from the annular assembly to the coil. Simultaneously withdrawing from the other end side, inserting a ring-shaped jig from one end side of the coil of the annular assembly, forming the coil cage, and inserting into the stator core from one end side of the coil, The motor is manufactured.

(2) In the motor manufacturing method according to (1), when the second taper-shaped jig is brought close to the first taper-shaped jig, the first taper-shaped jig The second taper-shaped jig is inclined by θ, and after the first taper-shaped jig and the second taper-shaped jig are brought into contact with each other, the inclination of the second taper-shaped jig is set to 0, and the circle It is preferable to form an annular assembly.

  With the motor manufacturing method according to one aspect of the present invention having such characteristics, the following operations and effects can be obtained.

  In the aspect of the invention described in (1) above, a motor having a distributed winding coil using a rectangular conductor and a stator core and a rotor having a central axis is combined with the distributed winding coil to form a coil cage. In the motor manufacturing method for manufacturing the motor by inserting the coil rod into the stator core from the axial direction, the coil end portion at one end of the coil is formed by being bent toward the rotor side with respect to the in-slot conductor portion of the stator core, On the first taper-shaped jig and the second taper-shaped jig having slopes for arranging the coils, the coils are arranged in a semicircular shape in order, and the first semicircular coil rod and the second semicircular coil are arranged. An annular coil rod is formed, and the second taper-shaped jig is brought into contact with the first taper-shaped jig, whereby the coil is arranged in an annular shape and the first semi-circular coil cage is formed. An annular assembly having one second semi-annular coil rod is formed, and the first tapered jig and the second tapered jig are removed from the other end side of the coil from the annular assembly, A motor is manufactured by inserting a ring-shaped jig from one end side of the coil of the annular assembly to form a coil cage and inserting it into the stator core from one end side of the coil.

  The coil used for the stator has an advantage that it is easy to insert the coil cage into the stator core because one end of the coil is bent. However, when forming the coil cage, there is a part that interferes with the direction in which the coils are overlapped. Specifically, since the coil end portion is formed by being bent toward the rotor side, the bent portions interfere with each other except when the coils are assembled from the circumferential direction. However, if all the coils are moved in the axial direction from a position where they do not interfere with each other and assembled at the same time, a large assembly space is required.

  For this reason, a coil rod is created in a semi-annular shape using the first taper-shaped jig and the second taper-shaped jig so as to avoid interference, and the first semi-circular ring formed on the first taper-shaped jig. This is solved by combining the coil rod and the second semi-annular coil rod formed on the second tapered jig. By assembling the second tapered jig close to the first tapered jig, it is possible to avoid the interference between the first semicircular coil rod and the second semicircular coil rod. . Therefore, the coil cage can be formed in a space-saving manner, and the assemblability can be improved.

  The aspect of the invention described in the above (2) is the motor manufacturing method described in (1), wherein the first tapered shape is used when the second tapered jig is brought close to the first tapered jig. The second tapered jig is inclined by θ with respect to the jig, and the inclination of the second tapered jig is set to 0 after the first tapered jig and the second tapered jig are brought into contact with each other. To form an annular assembly.

  By tilting the second taper-shaped jig closer to the first taper-shaped jig, it becomes possible to prevent the coils from interfering with each other and form an annular assembly. The coil is formed in a fan shape so that the outer circumference gently draws an arc when formed as a coil cage. For this reason, interference between the coils can be prevented by inclining the second tapered jig close to the first tapered jig by θ.

It is sectional drawing of the motor of this embodiment. It is a perspective view of a coil cage of this embodiment. It is a perspective view of a coil of this embodiment. It is a front view of a coil of this embodiment. It is a top view of the coil of this embodiment. It is a side view of a coil of this embodiment. It is a top view of the taper-shaped jig | tool of this embodiment. It is a perspective view of the taper-shaped jig | tool of this embodiment. It is a top view of the state which has arrange | positioned the coil of this embodiment to the taper-shaped jig | tool. It is a perspective view in the state where the coil of this embodiment has been arranged on the taper-shaped jig. It is a top view of the state which has arrange | positioned the several coil of this embodiment to the taper-shaped jig | tool. It is a perspective view in the state where a plurality of coils of this embodiment are arranged on a taper jig. It is a perspective view showing a mode that the semi-annular coil is arrange | positioned at the taper-shaped jig | tool of this embodiment. It is a side view showing a mode that the semi-annular coil is arrange | positioned at the taper-shaped jig | tool of this embodiment. It is a perspective view which shows the state by which the annular assembly is arrange | positioned at the taper-shaped jig | tool of this embodiment. It is a side view which shows the state by which the annular assembly is arrange | positioned at the taper-shaped jig | tool of this embodiment. It is a perspective view of the ring-shaped jig | tool of this embodiment. It is a side view which shows a mode that the ring-shaped jig | tool of this embodiment was inserted in the coil cage | basket. It is an enlarged view which shows the mode at the time of inserting the ring-shaped jig | tool of this embodiment in a coil cage | basket. It is a schematic diagram for demonstrating the interference of an axial direction of this embodiment. It is a schematic diagram for demonstrating the interference of radial direction of this embodiment. It is a figure which shows a mode that the coils of this embodiment are assembled | attached to the circumferential direction. It is a perspective view of the coil cage in the middle of assembly of this embodiment.

  First, an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 shows a cross-sectional view of the motor 100 of the present embodiment. In FIG. 2, the perspective view of the coil cage | basket 12 is shown. The motor 100 includes a rotor 40 having a shaft 41 and a rotor core 43, and a stator 10 having a stator core 13 into which a coil rod 12 is inserted. As shown in FIG. 1, one end of the coil rod 12 is bent in the axial direction of the motor 100.

  FIG. 3 shows a perspective view of the coil 11. FIG. 4 shows a front view of the coil 11. FIG. 5 shows a top view of the coil 11. FIG. 6 shows a side view of the coil 11. The coil 11 used for the coil cage 12 is a concentric coil 11 formed by winding a flat conductor D. The flat rectangular conductor D is obtained by applying an insulating coating around a highly conductive metal such as copper having a rectangular cross section.

  The coil 11 includes an in-slot conductor part SA and an in-slot conductor part SB arranged in the slot. As shown in FIG. 3, the in-slot conductor portion SA is obtained by overlapping the five flat conductors D with the long side surfaces (flatwise surfaces) formed by the long sides of the rectangular cross section being in contact with each other. This is an assembly of the in-slot conductor part SA1, the second slot conductor part SA2, the third slot conductor part SA3, the fourth slot conductor part SA4, and the fifth slot conductor part SA5.

  In addition, as shown in FIG. 6, the in-slot conductor portion SB is obtained by superimposing five flat rectangular conductors D in contact with long side surfaces (flatwise surfaces) constituted by long sides of a rectangular cross section. This is an assembly of the in-slot conductor SB1, the second slot conductor SB2, the third slot conductor SB3, the fourth slot conductor SB4, and the fifth slot conductor SB5. An upper concentric circle part G is formed at the center of the coil end part located on the upper side of the coil rod 12.

  As shown in FIG. 6, the upper concentric circle part G is an aggregate of four rectangular conductors D of a second concentric circle part G2, a third concentric circle part G3, a fourth concentric circle part G4, and a fifth concentric circle part G5. The reason why the first concentric circle portion is not included is that a first inclined portion EA1 described later projects as a terminal M to the outer peripheral side of the coil rod 12.

  A bent portion IA is formed at the upper end of the in-slot conductor portion SA. As shown in FIG. 4, the flat conductor D is bent by edgewise bending in the direction of the upper concentric circle G at the bent portion IA. An inclined portion EA is formed between the upper concentric circle portion G and the in-slot conductor portion SA.

  As shown in FIG. 5, the bent portion IA is an aggregate of the first bent portion IA1, the second bent portion IA2, the third bent portion IA3, the fourth bent portion IA4, and the fifth bent portion IA5. As shown in FIGS. 3 and 6, the inclined portion EA is an aggregate of the first inclined portion EA1, the second inclined portion EA2, the third inclined portion EA3, the fourth inclined portion EA4, and the fifth inclined portion EA5. . In the inclined portion EA, five rectangular conductors D are overlapped in the radial direction of the coil rod 12 (left and right direction in FIG. 6), as in the in-slot conductor portion SA, as shown in FIG.

  A bent portion IB and an inclined portion EB are formed at the upper end of the in-slot conductor portion SB. As shown in FIG. 5, the bent portion IB is an aggregate of the first bent portion IB1, the second bent portion IB2, the third bent portion IB3, the fourth bent portion IB4, and the fifth bent portion IB5. As shown in FIG. 6, the inclined portion EB is an aggregate of the first inclined portion EB1, the second inclined portion EB2, the third inclined portion EB3, the fourth inclined portion EB4, and the fifth inclined portion EB5.

  In the inclined portion EB, five flat conductors D are overlapped in the radial direction of the coil rod 12 (left and right direction in FIG. 6), as in the in-slot conductor portion SB, as shown in FIG. Further, as shown in FIG. 6, the terminal M of the first inclined portion EA1 located at the innermost peripheral portion of the inclined portion EA is bent and protrudes toward the outer peripheral side of the coil rod 12. Further, the terminal N of the fifth inclined portion EB5 located on the outermost periphery of the inclined portion EB is bent and protrudes toward the outer peripheral side of the coil rod 12.

  A bent portion JA is formed at the lower end of the in-slot conductor portion SA. As shown in FIG. 6, the bent portion JA is an aggregate of the first bent portion JA1, the second bent portion JA2, the third bent portion JA3, the fourth bent portion JA4, and the fifth bent portion JA5. A bent portion JB is formed at the lower end of the in-slot conductor SB. As shown in FIG. 6, the flat conductor D is bent 90 degrees on the inner peripheral side (left direction in FIG. 6) at the bent portion JB. Further, as shown in FIG. 6, the bent portions JB are the first bent portion JB1, the second bent portion JB2, the third bent portion JB3, the fourth bent portion JB4, and the fifth bent portion JB5 of the five rectangular conductors D. Is a collection of

  A lower concentric circle H is formed at the inner circumferential end of the coil rod 12. As shown in FIG. 4, a horizontal portion FA is formed between the bent portion JA and the lower concentric circle portion H. A horizontal part FB is formed between the bent part JB and the lower concentric part H. As shown in FIG. 6, the lower concentric part H includes a first lower concentric part H1, a second lower concentric part H2, a third lower concentric part H3, a fourth lower concentric part H4, and a fifth lower part. This is an assembly of side concentric circles H5.

  As shown in FIG. 4, the horizontal part FA is an aggregate of a first horizontal part FA1, a second horizontal part FA2, a third horizontal part FA3, a fourth horizontal part FA4, and a fifth horizontal part FA5. Here, in the horizontal portion FA, the horizontal portions of the five rectangular conductors D are overlapped in the axial direction of the coil rod 12 (vertical direction in FIG. 4) as shown in FIG. As shown in FIG. 4, the horizontal portion FB is an aggregate of the first horizontal portion FB1, the second horizontal portion FB2, the third horizontal portion FB3, the fourth horizontal portion FB4, and the fifth horizontal portion FB5. Here, in the horizontal portion FB, the horizontal portions of the five flat conductors D are overlapped in the axial direction of the coil rod 12 (up and down direction in FIG. 4) as shown in FIG.

  The coils 11 are formed in the configuration shown in FIGS. 3 to 6 and described above, and the coil rod 12 is formed by arranging 48 of these in an annular shape. FIG. 7 shows a plan view of the tapered jig. FIG. 8 is a perspective view of the tapered jig. The tapered jig JG1 has a semicircular shape, and as shown in FIGS. 7 and 8, the outer peripheral portion J1 and the tapered portion J2, the upper inner peripheral positioning pin J3 and the upper outer peripheral positioning pin J4, and the lower small positioning pin J5. And a lower large positioning pin J6, a retracting portion J7, and a connecting portion J8.

  FIG. 9 is a plan view showing a state in which the coil 11 is arranged on the tapered jig JG1. FIG. 10 is a perspective view showing a state in which the coil 11 is disposed on the tapered jig JG1. As shown in FIGS. 9 and 10, the coil 11 is arranged with the lower concentric part H side facing the inner peripheral side of the outer peripheral part J1. The in-slot conductor SA of the coil 11 is arranged so as to be sandwiched between the upper inner peripheral positioning pin J3 and the upper outer peripheral positioning pin J4, and the upper inner peripheral positioning pin J3 is in contact with the inner peripheral side of the bent portion IA. Position. Further, the lower small positioning pin J5 is arranged on the side surface of the upper concentric circle part G. A terminal M, a terminal N, and an upper concentric part G are disposed on the outer peripheral part J1.

  FIG. 11 is a plan view showing a state in which a plurality of coils 11 are arranged on the tapered jig JG1. FIG. 12 is a perspective view showing a state in which the plurality of coils 11 are arranged on the tapered jig JG1. As shown in FIGS. 11 and 12, a new coil 11 is arranged on the coil 11 already arranged in the tapered jig JG1. For the sake of convenience, the first coil 11 that is disposed is referred to as a first coil 11A, and the coil 11 that is disposed on the first coil 11A is referred to as a second coil 11B. Thus, the semi-annular coil 20 is formed on the tapered jig JG1 by sequentially stacking the coils 11.

  FIG. 13 is a perspective view showing a state where the semicircular coil is arranged on the tapered jig JG1. In FIG. 14, the side view showing a mode that the semi-annular coil 20 is arrange | positioned at the taper-shaped jig | tool JG1 is shown. A first semicircular coil rod 20A is disposed on the first tapered jig JG11, and a second semicircular coil rod 20B is disposed on the second tapered jig JG12. Here, as shown in the upper side of FIG. 13, the in-slot conductor SB of the first semicircular coil rod 20A and the in-slot conductor SA of the second tapered jig JG12, as shown in the lower side of FIG. In addition, the in-slot portion SA of the first semicircular coil rod 20A and the in-slot portion SB of the second tapered jig JG12 protrude from the first tapered jig JG11 and the second tapered jig JG12, respectively. Yes.

  Here, as shown in FIG. 14, the second tapered jig JG12 is inclined by the angle θ with respect to the first tapered jig JG11. The angle θ is 1 to 2 degrees. In order to prevent the in-slot conductor portion SA from interfering with the tapered jig JG1 due to this inclination, a retracting portion J7 is formed in the tapered jig JG1. In this state, the first tapered jig JG11 and the second tapered jig JG12 are brought close to each other.

  FIG. 15 is a perspective view showing a state where the annular assembly 21 is arranged on the tapered jig JG1. FIG. 16 is a side view showing a state where the annular assembly 21 is arranged on the tapered jig JG1. After the first taper-shaped jig JG11 and the second taper-shaped jig JG12 are brought into contact with each other, the state shown in FIG. 14 is changed to the state shown in FIG. From the state where the taper-shaped jig JG12 is inclined by the angle θ, the angle of the second taper-shaped jig JG12 is changed so that the inclination becomes 0 degree from the angle θ. Thus, the first semicircular coil rod 20A and the second semicircular coil rod 20B are combined to form the annular assembly 21 on the upper surface of the tapered jig JG1.

  FIG. 17 is a perspective view of the ring-shaped jig JG2. FIG. 18 shows a side view of the ring-shaped jig inserted into the coil cage. FIG. 19 is an enlarged view showing a state when the ring-shaped jig JG2 is inserted into the coil cage 12. FIG. The ring-shaped jig JG2 is provided with an upper ring J10, a lower ring J11, and comb teeth J12 formed by connecting them and projecting toward the inner peripheral side. As shown in FIG. 19, the comb tooth J12 is provided with a tapered portion J122 that is formed in a narrow wedge shape from the upper ring J10 side toward the lower ring J11 side. Moreover, as shown in FIG. 17, the parallel part J121 is formed in the part which protrudes in the inner peripheral side of the comb-tooth J12. On the other hand, the support jig JG3 is provided with a support J20. The column J20 has a structure that supports the inner periphery of the coil 11 at the top of the head.

  Although not shown, the annular assembly 21 placed on the tapered jig JG1 is inserted into the support J20 from the upper surface side of the support jig JG3, and the lower concentric part H of the annular assembly 21 is provided. The ring-shaped jig JG2 is inserted from the side provided with. Insertion of the ring-shaped jig JG2 is a process in which the annular assembly 21 is formed into the shape of the coil cage 12, and the comb teeth J12 are inserted between the in-slot conductors SB as shown in FIG. There is a function of aligning the interval between the inner conductor portion SA and the slot conductor portion SB. Then, the ring-shaped jig JG2 is inserted, and the taper-shaped jig JG1 is removed from the annular assembly 21 so as to be close to the base J21 side of the columnar jig JG3. In this way, the coil cage 12 is formed on the support jig JG3.

  The motor 100 is formed by assembling the coil rod 12 thus formed to the stator core 13 and inserting the rotor 40. Although the stator core 13 is not shown and described as a single unit, the stator core 13 is formed by laminating electromagnetic steel sheets punched out into a donut shape by press working, and teeth protrude from the inner peripheral side of the stator core 13, and adjacent teeth are formed. A slot into which the in-slot conductor part SA or the in-slot conductor part SB is inserted is prepared between them. The number of teeth is 48, and the same number of slots as the teeth are prepared.

  The stator 10 is formed by inserting the coil cage 12 into the stator core 13 from the axial direction. And the motor 100 is formed by inserting the rotor 40 from the one coil end side of the stator 10 and the opposite side of the side where the lower concentric part H of the coil rod 12 is disposed. A shaft 41 provided in the rotor 40 is rotatably held by a bearing (not shown), and a casing to which the bearing is fixed is fixed to the stator core 13.

  Since the manufacturing method of the motor 100 of this embodiment is the said structure, there exists an effect | action and effect which are demonstrated below. First, the assembly process can be simplified. The manufacturing method of the motor 100 according to the present embodiment uses the motor 100 having the stator 10 having the distributed winding coil 11 using the flat rectangular conductor D and the stator core 13 and the rotor 40 having the central axis as the distributed winding coil 11. In the motor manufacturing method of manufacturing the motor 100 by forming the coil rod 12 in combination and inserting the coil rod 12 into the stator core 13 from the axial direction, the coil end portion at one end of the coil 11 is the in-slot conductor portion of the stator core 13. The coils 11 are sequentially placed on the first taper jig JG11 and the second taper jig JG12 which are formed to be bent toward the rotor 40 with respect to the SA and the in-slot conductor portion SB and have slopes on which the coil 11 is disposed. The first semi-annular coil cage 20A and the second semi-annular coil cage 20 0B is formed, and the second tapered jig JG12 is brought close to and coupled to the first tapered jig JG11 (or just abutting), so that the coil 11 is arranged in an annular shape. An annular assembly 21 in which the first semicircular coil rod 20A and the second semicircular coil rod 20B are combined is formed, and the first tapered jig JG11 and the second tapered jig JG12 are annularly assembled. Simultaneously withdrawing from the other end side of the coil 11 from the body 21, the ring-shaped jig JG 2 is inserted from one end side of the coil 11 of the annular assembly 21 to form the coil rod 12, and the stator core from one end side of the coil 11 13 to be inserted.

  If the coils 11 are simply stacked to form the coil cage 12, the coils 11 will partially interfere with each other. FIG. 20 is a schematic diagram for explaining the interference in the axial direction. FIG. 21 is a schematic diagram for explaining the interference in the radial direction. For convenience, the coil 11 on the side that is held without moving will be referred to as a first coil 11A, and the coil 11 on the side that is assembled close to the first coil 11A will be described as a second coil 11B.

  When the second coil 11B is assembled to the first coil 11A in the direction close to the direction of the axis when assembled as the coil cage 12, that is, in the axial direction of the coil cage 12, as shown in FIG. The horizontal portion FA of the coil 11A interferes with the inclined portion EB of the second coil 11B. This is because, as shown in FIG. 5, the inclined portion EB has a shape that is disposed on the outer peripheral side (upper side in FIG. 5) of the coil rod 12 with respect to the horizontal portion FA. The horizontal portion FA and the inclined portion EB interfere with each other.

  On the other hand, when the combination as shown in FIG. 21 in which the first coil 11A and the second coil 11B are overlapped in the radial direction of the coil rod 12, the horizontal portion FA of the first coil 11A and the horizontal portion FA of the second coil 11B are obtained. Will interfere. Therefore, it is necessary to assemble the coil rod 12 in the circumferential direction so that the coils 11 do not interfere with each other. FIG. 22 is a plan view showing how the coils 11 are assembled together in the circumferential direction of the coil cage 12. By assembling the second coil 11B in the lateral direction with respect to the first coil 11A, that is, in the circumferential direction of the coil cage 12, interference between the coils 11 can be suppressed.

  However, if the coil 11 is simply assembled in the circumferential direction of the coil rod 12, up to 42 out of the 46 coils 11 to be assembled can be assembled in order, but the remaining 6 cannot be assembled. Problems arise. In FIG. 23, the perspective view of the coil cage | basket 12 in the middle of an assembly | attachment is shown. A coil rod 12 in a state where 42 coils 11 are assembled is shown in FIG. 16. Due to the shape of the coil 11, the 37th slot internal conductor SA37 to the 42th slot internal conductor SA42 are provided in the first slot. It arrange | positions between conducting wire part SB1 and conducting wire part SB42 in 42nd slot. In this state, the entire circumference of the coil cage 12 is filled, and thus the coil 11 cannot be inserted any more. That is, the remaining six coils 11 cannot be assembled.

  Therefore, according to the manufacturing method of the motor 100 shown in the present embodiment, as shown in FIGS. 9 to 16, the first semicircular coil rod 20A and the second semicircular coil rod 20B are formed, and the first semicircular coil rod 20B is formed. The annular coil rod 20A and the second semi-annular coil rod 20B are assembled to face each other. As described above, the first semi-annular coil rod 20A and the second semi-annular coil rod 20B are formed by overlapping the semicircle, that is, the 24 coils 11, and thus can be formed without difficulty.

  As described above, the first semi-annular coil rod 20A is formed on the first tapered jig JG11. The second semicircular coil rod 20B is formed on the second tapered jig JG12. As shown in FIGS. 11 and 12, the coils 11 are sequentially stacked to prevent interference between the coils 11. As a result, the first semicircular coil rod 20A and the second semicircular coil rod 20B can be assembled without interference, and the second taper jig JG12 is inclined by an angle θ with respect to the first taper jig JG11. By bringing them close to each other and returning the inclination, the annular assembly 21 can be formed.

  When the taper-shaped jig JG1 is used, there is an advantage that the coil 11 can be easily held because of the characteristics of the shape of the coil 11, compared with the case where the coil 11 is assembled in an upright state. This is because the coil 11 has a shape as shown in FIG. 6 and when the lower concentric part H is held in the state as shown in FIG. It is necessary to support so as not to fall in the outer peripheral direction (right direction in FIG. 6). However, the method of holding the lower concentric circle portion H or supporting the in-slot conductor portion SB is likely to be unstable, and the assembly direction needs to be the circumferential direction of the coil rod 12, so that the support portion, etc. It is difficult to form so as not to interfere.

  On the other hand, when the lower concentric part H is held on the upper side, the lower concentric part H protrudes and becomes unstable. Therefore, the method of disposing the taper jig JG1 so as to lean against the taper portion J2 is easy to stabilize and the coils 11 are easily stacked. The coil 11 is simply stacked while being shifted in the circumferential direction of the tapered jig JG1, and the workability is also good.

  Next, the first semicircular coil rod 20A and the second semicircular coil rod 20B are assembled. In this case, since the coils 11 at both ends correspond to the assembly of the coil rod 12 from the circumferential direction as shown in FIG. 22, the assembly is possible. As a result, the same state as the state in which the coils 11 are assembled from the circumferential direction can be obtained, and 48 coils 11 can be assembled to the coil cage 12. The second taper jig JG12 is inclined by an angle θ with respect to the first taper jig JG11, and the retracting portion J7 is provided in the first taper jig JG11 and the second taper jig JG12, so that the coil The first semicircular coil rod 20A and the second semicircular coil rod 20B can be assembled without interfering with each other.

  In addition, by using the ring-shaped jig JG2, it is possible to improve the situation where the in-slot conductor part SA and the in-slot conductor part SB are not easily aligned when the annular assembly 21 is deformed to the coil rod 12 state. Is possible. As shown in FIG. 19, the ring-shaped jig JG2 has a conductor width St of the in-slot conductor SB formed between adjacent comb teeth J12. The conducting wire width St is an interval between adjacent comb teeth J12 on the upper ring J10 side.

  The in-slot conductor portion SA and the in-slot conductor portion SB are inserted so that the comb teeth J12 are accommodated in the same slot from the lower concentric circle portion H side. The conducting wire portion SB is aligned by the taper portion J122, and the in-slot conducting wire portion SA and the in-slot conducting wire portion SB are arranged at predetermined positions by the parallel portion J121 having the conducting wire width St. As a result, the coil rod 12 can be easily inserted into the stator core 13. Therefore, the assemblability of the stator 10 can be improved.

  Thus, by using jigs such as the taper-shaped jig JG1, the ring-shaped jig JG2, and the support jig JG3, the assembly of the stator 10 using the coil rod 12 is facilitated, and as a result, the motor The productivity in manufacturing 100 can be increased.

  Although the invention has been described according to the present embodiment, the invention is not limited to the embodiment, and by appropriately changing a part of the configuration without departing from the spirit of the invention. It can also be implemented.

  For example, the materials exemplified in this embodiment are not prevented from being replaced as appropriate, and the number of turns of the coil 11, the number of slots in the stator core 13, or the number of coils 11 used in the coil rod 12 is prevented from being changed depending on the design specifications. Absent.

DESCRIPTION OF SYMBOLS 10 Stator 11 Coil 11A 1st coil 11B 2nd coil 12 Coil cage 13 Stator core 20 Semi-annular coil 20A 1st semi-annular coil cage 20B 2nd semi-annular coil cage 21 Toroidal assembly 40 Rotor 41 Shaft 43 Rotor core 100 Motor θ Angle D Flat conductor G Upper concentric circle H Lower concentric circle JG1 Tapered jig JG2 Ring jig JG3 Post jig M Terminal N Terminal SA In-slot conductor SB In-slot conductor

Claims (2)

A motor having a stator having a distributed winding coil using a rectangular conductor and a stator core and a rotor having a central axis is combined with the distributed winding coil to form a coil rod, and the coil rod is inserted into the stator core from the axial direction. In a motor manufacturing method for manufacturing a motor by
A coil end portion at one end of the coil is formed by being bent toward the rotor side with respect to the in-slot conductor portion of the stator core,
On the first taper-shaped jig and the second taper-shaped jig having slopes for arranging the coils, the coils are arranged in a semicircular shape in order, and the first semicircular coil cage and the first Forming two semi-annular coil cages,
By bringing the second taper-shaped jig into contact with the first taper-shaped jig, the coil is arranged in an annular shape so that the first semicircular coil rod and the second semicircular coil Forming an annular assembly with one ridge,
Simultaneously withdrawing the first tapered jig and the second tapered jig from the other end side of the coil from the annular assembly, a ring-shaped jig is installed from one end side of the coil of the annular assembly. Insert to form the coil cage,
The motor is manufactured by inserting the stator core from one end side of the coil. In the motor manufacturing method of Claim 1,
When the second taper-shaped jig is brought close to the first taper-shaped jig, the second taper-shaped jig is inclined by θ with respect to the first taper-shaped jig,
The annular assembly is formed by setting the inclination of the second taper-shaped jig to 0 after the first taper-shaped jig and the second taper-shaped jig are brought into contact with each other. Method.

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