KR100493608B1 - Stator for an automotive alternator and a method for manufacture thereof - Google Patents

Abstract

The present invention obtains a stator of a vehicular alternator capable of realizing a small high output of the vehicular alternator and improving its insulation and a method of manufacturing the same.

The stator windings insert two conductor segments 15 into each pair of slots 6 slots apart from the first end face of the stator core, joining the ends of the conductor segments 15 extending to the second end face of the stator core. Formed. And the slot accommodating part 16a of the conductor segment 15 is formed in rectangular cross section, and the connection part 17 which comprises a coil end is formed in circular cross section.

Description

Stator of vehicle alternator and its manufacturing method {STATOR FOR AN AUTOMOTIVE ALTERNATOR AND A METHOD FOR MANUFACTURE THEREOF}

The present invention relates to a stator of an alternator, for example, driven by an internal combustion engine, and more particularly, to a stator winding structure of a stator of a vehicle alternator mounted on a ride such as a passenger car, a truck, and a manufacturing method thereof.

In recent years, a small high power is increasingly required in an automotive alternator. In addition, in order to realize a small high output of the automotive alternator, the spot ratio of the electric conductors stored in the magnetic circuit of the stator is improved, and further, the alignment of the bridge portions of the stator windings (bridge portions other than the stator cores are called coil ends) and Densification is required.

In view of such a situation, a structure is proposed in WO98 / 54823, for example, by using a short conductor segment in an electric conductor of a stator winding to improve the area ratio of the electric conductor, or to align and densify the coil end. .

WO98 / 54823 discloses a stator with a stator winding recommended by inserting a plurality of U-shaped conductor segments having a rectangular cross-sectional shape from one end face side of a stator iron core, and then joining the ends of the semi-insertion side to each other. It is. This stator uses a conductor segment having a rectangular cross-sectional shape. The stator is housed in the slot without gaps, and the drop rate is improved. Also, a stator in which coil ends are regularly arranged in comparison with a conventional conventional stator formed by winding a ring winding unit formed by molding a ring winding unit formed by winding a continuous conductor wire in a ring shape with a star core It is characterized by the ease of forming a winding. That is, the coil end of the stator winding is aligned and the density is increased.

However, in the stator described in WO98 / 54823, a short conductor line having a rectangular cross-sectional shape is bent at its center portion to form a U-shape to produce a conductor segment. In this bending process, a large stress is generated in the bent portion of the conductor wire having a rectangular cross section, which damages the insulating film covered by the conductor segment and deteriorates the insulation.

Thus, attempts have been made to form only the center portion of a short conductor wire having a rectangular cross-sectional shape in a circular cross-sectional shape, and to reduce the stress generated in the bent portion when bent, thereby suppressing damage to the insulating film. It is proposed in the 2000-299949 publication.

Fig. 26 is a sectional view showing the main part of a stator of a conventional vehicular alternator described in, for example, Japanese Patent Laid-Open No. 2000-299949, and Fig. 27 is a perspective view showing a conductor segment constituting a stator winding of the stator in Fig. 26. to be.

In FIG. 26, the stator windings recommended in the slots 2a of the stator iron cores 2 are constituted by a plurality of insulated conductors, four electrical conductors are stored in each slot 2a, and the insulator 3 is 4. It is arranged to surround two electrical conductors. In each slot 2a, four electrical conductors are arranged in a row in the order of the first address, the second address, the third address and the fourth address in the radially inner side in the slot.

Then, the electrical conductor 4a of the first address of one slot 2a is paired with the electrical conductor 4b of the fourth address in another slot 2a spaced one stimulus pitch clockwise of the stator core 2. have. The electrical conductor 5a of the second address of one slot 2a is paired with the electrical conductor 5b of the third address in another slot 2a spaced one stimulus pitch clockwise of the stator core 2. . These pairs of electrical conductors are connected by using a continuous line on one end surface side of the stator core 2 in the axial direction via the turn portions 4c and 5c described later.

Therefore, the continuous line connecting the electrical conductor 5b of the third address and the electrical conductor 5a of the second address is connected to the electrical conductor 4b of the fourth address and the first address on one end face side of the stator core 2. The continuous line which connects the electrical conductor 4a of is enclosed. That is, on one end surface side of the stator iron core 2, the turn part 5c is surrounded by the turn part 4c. Thus, in one end surface side of the stator iron core 2, the turn part 4c, 5c becomes two layers, arrange | positioned in the circumferential direction, and comprises the coil end group.

On the other hand, the electrical conductor 5a of the second address of one slot 2a is paired with the electrical conductor 4a of the first address in another slot 2a spaced one stimulus pitch clockwise of the stator iron core 2. It is coming true. Similarly, the electrical conductor 4b of the fourth address of one slot 2a is paired with the electrical conductor 5b of the third address in the other slot 2a spaced one stimulus pitch clockwise of the stator core 2. have. These paired electrical conductors are connected by joining at the other end surface side in the axial direction of the stator iron core 2.

Therefore, on the other end surface side of the stator iron core 2, the outer junction part which connects the electrical conductor 4b of 4th address and the electrical conductor 5b of 3rd address, the electrical conductor 4a of 1st address, and the 1st The inner junctions connecting the two electrical conductors 5a are arranged in a state shifted from each other in the radial direction and the circumferential direction. Thus, in the other end surface side of the stator iron core 2, the outer joining part and the inner joining part become one row in the radial direction, and are arranged in two rows in the circumferential direction to form a coil end group.

In addition, as shown in Fig. 27, the electrical conductor 4a of the first address and the electrical conductor 4b of the fourth address are provided by a large segment 4 formed by forming a short conductor wire in a U shape, and the second The electric conductor 5a of the bungee and the electric conductor 5b of the third bungee are provided by the small segment 5 which forms the short conductor wire in a U shape. Each of the segments 4, 5 has a portion which is received in the slot 2a and extends in the axial direction, and at the same time, the meandering portions 4f, 4g, 5f, 5f which are inclined at a predetermined angle with respect to the axial direction. 5g) and turn portions 4c and 5c for connecting the meandering portions 4f, 4g, 5f, and 5g. The coil ends protruding from one side of the stator core 2 in the axial direction are formed by the meandering portions 4f, 4g, 5f, 5g and the turn portions 4c, 5c. have.

Moreover, on the other end surface side of the stator iron core 2, the extension end side of the large segment 4 is bent in the direction which opposes each other, and the extension end side of the small segment 5 is bent in the direction which mutually approaches. Then, the end 4d of the large segment 4 and the end 5d of the small segment 5 are joined by welding to form an inner joint, and the end 4e and the small segment 5 of the large segment 4 are joined. The edge part 5e of) is joined by welding, and forms the outer side junction part. Thus, from the stator iron core 2 by the inner joints of the meandering portions 4h, 4i, 5h, 5i, the end portions 4d, 5d and the outer junction portions of the end portions 4e, 5e. Coil ends protruding from the other end face in the axial direction are formed.

Further, the large segment 4 and the small segment 5 are formed by plastically deforming the central portion of the short conductor line having a rectangular cross section (flat cross section) into a circular cross section, and then bending it in a substantially U shape to form a turn portion 4c. Only 5c is formed in a circular cross section, and other portions are formed in a rectangular cross section.

In the conventional stator described in WO98 / 54823, since the conductor segments have a flat cross-sectional shape, the area ratio of the electrical conductors can be improved, the coil ends can be aligned, and the density of the coil ends can be increased, and the compact high output of the automotive alternator can be realized. However, when bending a conductor wire, which is a short cross-section of a flat cross section, to a U-shape, there is a problem that a large stress is generated in the bent portion, the insulation coating coated on the bent portion is damaged, and the insulation property is deteriorated. In addition, when the coil ends interfere with each other due to vibrations generated during assembly of the stator winding or during operation of the actual machine equipped with the stator, the parts of the conductor segments or the parts and the flat surface are rubbed and the insulation film is damaged. There was also a problem that the insulation was deteriorated by the generation of.

In the conventional stator disclosed in Japanese Patent Laid-Open No. 2000-299949, the large segments 4 and the small, in which only the turn portions 4c and 5c are formed in the circular cross section, and the other portions are formed in the rectangular cross section. Since the stator winding is formed using the segment 5, when the short conductor wire is bent in a U shape, the stress generated in the turn portions 4c and 5c is reduced, and the turn portions 4c and 5c are covered. The occurrence of damage to the insulating film is suppressed. However, the meandering portions 4f, 4g, 5f, and 5g have flat cross-sectional shapes, so the meandering portions 4f are caused by vibrations generated during assembling the stator windings or during operation of the actual machine mounted with the stator. ), (4g), (5f), and (5g) interfere with each other, each of the sections of the meandering portion or each portion and the flat surface is rubbed, there is a problem that the insulation film is damaged and the insulation deteriorates.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems. The present invention provides a flat cross-sectional shape of a portion to be housed in a slot of a conductor wire, and forms a coil end of a meandering portion and a turn portion in a circular cross-sectional shape. It is an object of the present invention to obtain a stator of a vehicular alternator capable of realizing a small high power and improving its insulation and a manufacturing method thereof.

In the stator of the automotive alternator according to the present invention, in the stator of the automotive alternator having a stator iron core formed with a plurality of slots, and a stator winding formed by recommending a conductor wire coated with insulating coating to the slot,

The stator windings are accommodated in the plurality of slots by 2n (n: integer), each formed in a flat cross-sectional shape, and the flat surfaces are brought into close contact with the sidewall surfaces of the slots, and are arranged side by side in the slot depth direction in each slot. Non-flat cross section of each of the arranged slot housing portions and the slot receiving portions stored at different addresses with respect to the slot depth direction in both slots on the first end face side in the axial direction of the stator core in each of the slot pairs separated by a predetermined number of slots. In each of the n first coil ends connected in series by a continuous conductor wire having a predetermined number of slots, and the predetermined slot number of slot pairs, in the slot depth direction of the two slots on the second end surface side in the axial direction of the stator iron core. And n second coil ends for serially connecting the slot accommodating portions housed at different addresses.

On the first end face side of the stator iron core, the n first coil ends connecting the slot accommodating units stored at different addresses with respect to the slot depth direction in the two slots in series are arranged at a slot pitch in the circumferential direction and the first N second coil ends constituting one coil end group and connecting the slot accommodating parts stored at different addresses in series with respect to the slot depth direction in the two slots on the second end face side of the stator iron core in the main direction The second coil end group is arranged at one slot pitch.

The second coil end is formed of a continuous conductor line having a non-flat cross section.

In addition, the cross-sectional area of the coil end having a non-flat cross section is larger than that of the slot housing portion.

The slot accommodating portion accommodated at the outermost address in the slot is formed in a cross-sectional shape in which the radius of curvature of each corner portion in the radial direction is larger than the radius of curvature of the corner portions in the radial direction.

The slot accommodating portion housed at the innermost address in the slot is formed in a cross-sectional shape in which the radius of curvature of each corner portion in the radial direction is larger than the radius of curvature of the corner portions in the radial direction.

The slot accommodating portion is formed such that the insulating film of the flat surface closely contacting the side wall surface of the slot is thinner than the insulating film of the outer and inner portions in the radial direction.

The slot housing portion is covered with two layers of insulating coating.

The insulating film is composed of a lower insulating film made of an adhesive reinforcement resin and an upper insulating film made of a heat resistant resin.

Further, the first and second coil end groups have a meandering portion in which the first and second coil ends are inclined with respect to the axial direction of the stator iron core positioned between the rising part and the top part from the slot accommodating part. Are arranged in contact with each other.

Further, the slot housing portion is formed to have a higher hardness than the meandering portion located between the rising portion and the top portion from the slot housing portion inclined with respect to the axial direction of the stator iron core in the coil end having a non-flat cross section. .

Moreover, the lead wire of the stator winding which is produced by one of the first and second coil end groups is formed to have a circular cross section.

Moreover, the linear part is connected by the connection part, it arranges in predetermined slot pitch, and this adjacent linear part is formed in the pattern pushed so that the inner layer and the outer layer may be alternately selected by this connection part in the slot depth direction, and the insulating film is non-flat cross-sectional shape. A pair of conductor wires having two conductor wires arranged at a distance of the predetermined slot pitches from each other and overlapping the straight slots are pushed by one slot by one pitch to produce a strip-shaped winding unit having a plurality of pairs equal to the predetermined slot pitches. Fair,

Manufacturing a winding assembly by press molding the straight portion of the winding unit into a flat cross section;

Inserting the straight part of the winding assembly into the slot of the laminated iron core of the rectangular parallelepiped at the slot opening side, and mounting the winding assembly to the laminated iron core;

And a step of bending the laminated iron core on which the winding assembly is mounted in an annular manner to match the cross-sections of the laminated iron cores to weld integrally the cross-sections of the laminated iron cores.

Further, in the manufacturing process of the winding assembly, a second press groove having a groove width greater than or equal to the width of the linear portion and a groove width narrower than the width of the linear portion and extending in the groove depth direction continuously to the first press groove. Using a mold provided with a press groove, the straight portion of the winding unit is accommodated in the first press groove, and then the straight portion is pressed on the first press groove side to press the straight portion into the second press groove. The straight portion is transformed into a flat cross-sectional shape.

Further, in the winding assembly attached to the laminated iron core, the curvature radius of each portion of the slot bottom side in the straight portion stored at the deepest position in the slot depth direction in the slot is the curvature radius of each portion of the slot opening side. It is formed in larger cross-sectional shape.

Further, in the winding assembly attached to the laminated core, the straight portion accommodated at the shallowest position in the slot depth direction in the slot has a radius of curvature greater than the curvature radius of each corner portion of the slot opening side. It is formed in cross-sectional shape.

In the manufacturing process of the winding assembly, all the linear parts of the winding unit are press-molded collectively.

In addition, in the manufacturing process of the winding assembly, all the linear parts of the plurality of winding units are press-molded collectively.

Moreover, it has a process of apply | coating and forming a 2nd insulating film in the linear part of the said winding assembly.

The insulating film is an adhesive reinforcing resin, and the second insulating film is a heat resistant resin.

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described by drawing.

Embodiment 1.

BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which looked at the principal part of the stator of the vehicular alternator which concerns on Embodiment 1 of this invention from the 1st cross-sectional side of an axial direction, and FIG. 2 is the principal part of the stator of the vehicular alternator which concerns on Embodiment 1 of this invention. 3 is a perspective view showing a conductor segment applied to the stator winding of the stator of the vehicular alternator according to Embodiment 1 of the present invention, and FIG. 4 is shown in FIG. Fig. 5 is a perspective view for explaining a method for forming a conductor segment, Fig. 5 is a perspective view for explaining a method for mounting a conductor segment on a stator core of a stator of a vehicular alternator according to Embodiment 1 of the present invention, and Fig. 6 is a present invention. Fig. 7 is a process chart explaining the manufacturing method of the stator of the vehicle alternator according to Embodiment 1 of the present invention. 8 is a cross-sectional view illustrating an arrangement of conductor segments in a slot of a stator iron core in a ruler. FIG. 8 is a cross-sectional view illustrating a connection state of a winding of one phase in a stator winding of a stator of an automotive alternator according to Embodiment 1 of the present invention. to be. In Fig. 8, the solid line indicates the connection state on the first end face side of the stator iron core, the black circle indicates the joint portion, and 1, 7, 13... 91 indicates the slot number.

In each figure, the stator 10 consists of a stator core 11, a stator winding 12 recommended for the stator core 11, and an insulator 13 mounted in each slot 11a of the stator core 11. Consists of.

The stator iron core 11 is made of a laminated iron core molded in a cylindrical shape, and a plurality of slots 11a extending in the axial direction are formed in a predetermined pitch in the circumferential direction so as to open on the inner circumferential side. Here, the stator 10 is applied to an alternator having a 16-pole magnetic pole rotor. 96 slots 11a are formed in the stator core 11. That is, the slot 11a is formed in two ratios per pole sales. In this case, six slot pitches correspond to one stimulus pitch.

The stator windings 12 are inserted into each pair of slots 11a in which a plurality of conductor segments 15 formed in a U shape are inserted two by one on the first cross-sectional side of the stator core 11 in the axial direction. The ends of the conductor segments 15 extending to the second cross-sectional side of the iron core 11 in the axial direction are joined to each other and constituted by a plurality of windings formed by wave winding.

The conductor segment 15 is formed in a substantially U shape in which a pair of straight portions 16 are connected by a connecting portion 17. And the straight part 16 has a rectangular cross section, and the connection part 17 has a circular cross section.

Moreover, the slot accommodating parts of the four conductor segments 15 are arranged in each slot 11a in the order of a 1st address, a 2nd address, a 3rd address, and a 4th address in radial direction inside.

Next, the manufacturing method of the stator 10 is demonstrated.

First, as shown in FIG. 4, the press jig 20 is used to press the center part of the short copper wire material 21 which has the rectangular cross section by which the insulating film 14 was coat | covered, and deform | transforms into circular cross section. Subsequently, the conductor segment 15 shown in FIG. 3 is produced by bending the central portion of the copper wire 21.

Subsequently, as shown in Figs. 5 and 6 (a), each of the slots 11a in which the conductor segment 15 is spaced 6 slots (one magnetic pole pitch) away from the first end face in the axial direction of the stator core 11 is formed. 2 inserts per pair. As a result, as shown in Fig. 7, the slot accommodating portion 16a of the straight portion 16 of the conductor segment 15 is accommodated side by side in each slot 11a in a longitudinal direction coincident with the longitudinal direction of the rectangular cross section. . In addition, although the insulator 13 is not shown in FIG. 7, each slot accommodating part 16a is in close contact with the side wall surface of the slot 11a through the insulator 13. As shown in FIG.

The front end side of the straight portion 16 of the conductor segment 15 is directed from the slot 11a to the second end face side of the stator core 11 as shown in Fig. 6B. The front end side of the straight portion 16 of each conductor segment 15 extending to the second end face side of the stator iron core 11 can be bent in the circumferential direction.

Then, as shown in Fig. 8, the end portions 16c of the conductor segment 15 extending from the 1st, 7th, ..., 91th slot group at the 2nd position of the mth slot 11a and ( The end 16c of the conductor segment 15 extending from the first slot 11a of the m + 6 slot is overlapped in the radial direction and joined by TIG welding to produce two one-turn wave winding windings. Similarly, the end portion 16c of the conductor segment 15 extending from the 4th slot 11a and the end portion 16c of the conductor segment 15 extending from the 3rd position of the slot 11a of (m + 6). Are superimposed in the radial direction and joined by TIG welding, and two one-turn wave winding windings are produced.

Subsequently, the connecting portion 17 of the two conductor segments 15 inserted into the pair of slots 11a of 55 and 61 is cut, and inserted into the pair of slots 11a of 61 and 67. The connection 17 of the two conductor segments 15 which are present are cut off. Then, the cutting end of the conductor segment 15 to be produced at address 1 of 55 slot 11a and the cutting end of the conductor segment 15 to be produced at 4 address of slot 11a at 61 are TIG. The cutting end of the conductor segment 15, which is joined by welding and is produced at address 3 of the 55th slot 11a, and the cutting end of the conductor segment 15, which is produced at 4 of the slot 11a, at 67 is TIG welding. The cut end of the conductor segment 15 to be produced at the 1st position of the 61st slot 11a and the cut end of the conductor segment 15 to be produced at the 2nd position of the 61st slot 11a are joined by TIG welding. . As a result, a winding of one phase is obtained in which four wave winding windings of one turn are connected in series. Then, the cutting end of the conductor segment 15 to be produced at the 2nd position of the slot 11a of 67 and the cutting end of the conductor segment 15 to be produced at the 3rd position of the slot 11a of the 61th slot are each drawn out of the winding for one phase. It becomes line O and neutral point N.

Although not shown, slot numbers 2, 8, ..., 92 slot groups, slot numbers 3, 9, ... 93 slot groups, slot numbers 4, 10 Slot groups #, 94, slot numbers 5, 11, 95, slot numbers 6, 12, 96, and 96 slot groups, respectively. The conductor segments 15 are similarly connected to produce a winding for six phases.

The number of slots recommended for slot groups 1, 7, ..., 91, the number of slots recommended for slot groups 3, 9, ..., 93, and slot number No. 5, 11, ..., 95 recommended slot group is connected to the neutral point N, Y connection (AC connection), slot number 2, 8, ..., slot 92 Recommended winding for slots, slot number 4, 10, ..., 94, slot group Recommended for slot number 6, 12, ..., 96 slot group The windings are similarly connected in Y, two sets of three-phase AC windings are produced, and the stator 10 is obtained as shown in Figs. 1, 2 and 6 (c). In addition, these two three-phase AC windings constitute a stator winding 12.

In the stator winding 12 configured as described above, the slot accommodating portion 16a having a rectangular cross section is brought into close contact with the flat surface through the insulator 13 to the side wall surface of each slot 11a. They are arranged side by side in.

Then, in each of the pair of slots 11a spaced six slots apart, the slot accommodating portion 16a housed in addresses 1 and 2 in both slots 11a on the first end face side of the stator core 11 in the axial direction. ) Is connected in series by a connecting portion 17 having a circular cross section, and the slot accommodating portions 16a stored at addresses 3 and 4 in both slots 11a are connected in series by a connecting portion 17 having a circular cross section. Is connected. Here, the connection part 17 is comprised by the turn part 17a, the pair of meandering part 17b which connects each slot accommodating part 16a, and the turn part 17a, and becomes a 1st coil end. Then, two first coil ends are arranged in the circumferential direction at one slot pitch to constitute the first coil end group 12a. For this reason, the 1st coil ends are arrange | positioned and arranged in the circumferential direction, mutually spaced apart in the radial direction and the circumferential direction.

Similarly, in each of the pair of slots 11a spaced six slots apart, the slot accommodating portion 16a housed in addresses 2 and 1 in both slots 11a on the second end face side of the stator core 11 in the axial direction. ) Are connected in series to the straight sides 16 and the slot accommodating sides 16a stored in the 4th and 3rd addresses in both slots 11a are connected to the straight sides 16. They are connected in series with each other. Here, the second coil end formed by joining the directing sides of the straight portions 16 is a joining portion 18 for joining the end portions 16c of the straight portions 16 to each slot accommodating portion 16a and a joining portion ( It consists of a pair of meandering part 16b which connects 18). The two second coil ends are arranged in the circumferential direction at one slot pitch to form the second coil end group 12b. As a result, the second coil ends are arranged so as to be spaced apart from each other in the radial and circumferential directions.

Thus, according to this Embodiment 1, since the slot accommodating part 16a of the conductor segment 15 is formed in rectangular cross section, the droplet ratio of the conductor in the slot 11a can be enlarged. Moreover, the slot accommodating part 16a stored in the other address in the slot 11a which is 6 slots apart from the both ends of the stator core 11 is connected in series with two 1st and 2nd coil ends, respectively, Since the first and second coil ends 12a, 12b are arranged by circumferentially arranging the first and second coil ends at a single slot pitch, the first and second coil ends 12a, 12b. ) Alignment and density are achieved. As a result, a stator capable of realizing small high power is obtained.

Moreover, since the connection part 17 corresponded to a 1st coil end is formed in circular cross section, when the copper wire 21 is bent in a U shape, the stress which arises in the turn part 17a (bending part) of the connection part 17 becomes small. The damage of the insulating film 14 coated on the turn part 17a can be suppressed, and the insulation can be improved.

In addition, since the connecting portion 17 is formed in a circular cross section, the connecting portions 17 (first coil ends) are separated from each other by vibration generated during assembling the stator winding 12 or during operation of the actual machine on which the stator 10 is mounted. Even if they interfere with each other, damage to the insulating film 14 can be suppressed and insulation can be improved.

Moreover, since the lead line O and the neutral point N of the stator winding 12 are formed in circular cross section, removal of the insulating film 14 becomes easy. Therefore, when mounting the stator 10 to an alternator, the connection between the lead wire O of the stator 10 and the rectifier can be carried out easily and reliably.

Moreover, although Embodiment 1 demonstrated using the stator winding 12 comprised by the wave winding winding, even if it is applied to the stator winding comprised by the overwinding winding, the same effect is acquired.

In the first embodiment, the conductor segments 15 are inserted into pairs of slots 11a spaced 6 slots apart, but the conductor segments 15 inserted into pairs of slots 11a spaced 6 slots apart. The number of is not limited to this, but may be three or more. However, the number of the slot accommodating parts 16a accommodated in the slot 11a becomes even.

In the first embodiment, the conductor segment 15 is inserted into a pair of slots 11a spaced apart by six slots, but the present invention is not limited thereto. When the number of slots per pole is 1, the conductor segment ( 15 is inserted into a pair of slots 11a spaced three slots apart.

In the first embodiment, the center portions of the copper wires 21 are deformed in a circular cross section by the press jig 20 one by one, but the central portions of the plurality of copper wires 21 are collectively pressed by the press jig 20. You may make it deform | transform into circular cross section. In this case, the manufacturing process can be simplified and the manufacturing time can be shortened.

Embodiment 2.

In the second embodiment, the stator winding is formed by combining the conductor segment 15 and the release conductor segment 22. And the release conductor segment 22 is used in the place which connects the four wave winding windings which comprise each winding in series. As shown in FIG. 9, this release conductor segment 22 presses the one end side of the short copper wire material which has a rectangular cross section by which the insulating film 14 was coat | covered using the press jig 20, and deform | transforms into circular cross section, It is made.

Referring to FIG. 8, the deformed conductor segment 22 includes the first and third slots 11a of 55 and the first and fourth slots 11a of the slot 11a of 61 and the slot 11a of 67. It is installed at 2 and 4 of respectively. Each release conductor segment 22 is then inserted into the slot 11a and bent as indicated by the arrow in FIG. 9. In addition, the conductor segment 15 is inserted in the pair of the other slots 11a as in the first embodiment. In addition, the deformed conductor segment 22 has a meandering portion 32b and an end portion 23c which are equivalent to the meandering portion 16b and the end portion 16c of the conductor segment 15 by bending at the distal end side of the spherical cross section 23. The remaining part of the spherical cross section 23 becomes the slot accommodating part 23a. The circular cross section 24 is bent so as not to interfere with the connecting portion 17 of the conductor segment 15.

Then, at the second end surface side, at the end 23c of the release conductor segment 22 directed from the first and third addresses of the slot 11a of No. 55 and the second and fourth addresses of the slot 11a of the 49th. The end 16c of the conductor segment 15 is joined. Also, the end 23c of the release conductor segment 22 which is produced at the first and third addresses of the slot 11a of 61 and the conductor segment 15 which is produced at the second and fourth addresses of the slot 11a of the 55th slot 11a. The end 16c is joined. In addition, the end 23c of the release conductor segment 22 which is produced at 2nd and 4th of the slot 11a of 61 and the conductor segment 15 which is produced at 1st and 3rd of the slot 11a of the 67th The end 16c is joined. In addition, the end 23c of the release conductor segment 22 produced at the 2nd and 4th positions of the slot 11a of 67 and the conductor segment 15 of the 1st and 3rd positions of the slot 11a of the 73th slot 11a It joins with the edge part 16c.

Subsequently, at the first cross-section side, the release member is directed to the first cross-section side at the end 24a of the release conductor segment 22 and the fourth cross-section of the slot 11a 61 at the 55th slot 11a. The end 24a of the conductor segment 22 is joined and directed at the end 24a of the release conductor segment 22 and the 4th slot 11a of 67 to be produced at the 3rd slot 55a. The end 24a of the release conductor segment 22 is joined to produce at the 1st position of the 61st slot 11a. At the end 24a of the release conductor segment 22 and the 2nd position of the 61st slot 11a. The ends 24a of the release conductor segment 22 are joined.

Thus, as in the first embodiment, a winding of one phase is obtained in which four one-turn wave winding windings are connected in series. The end of the release conductor segment 22 extending to the first cross-section side at the 2nd slot 11a of the 67th slot and the release conductor segment 22 extending to the first cross-section side at the 3rd slot 11a of the 61st slot 11a. The end part 24a becomes the leader line O and the neutral point N of the winding of one phase, respectively.

Moreover, it is comprised similarly about the winding of another 5 phases.

Therefore, according to this Embodiment 2, since the release conductor segment 22 is used, it is not necessary to cut | disconnect the conductor segment 15 when connecting the four wave winding windings which comprise the winding of each phase in series, and it connects. Sex is improved.

Embodiment 3.

In the third embodiment, the center and both ends of the short copper wire having a rectangular cross section coated with the insulating coating 14 are pressed by the press jig 20 to be deformed into a circular cross section, and then the center of the copper wire is bent to U. The conductor segment 25 shape | molded in magnetic shape is used. As shown in Fig. 10, the conductor segment 25 has a slot accommodating portion 25a formed into a rectangular cross section, a connecting portion 25b constituting the first coil end has a circular cross section, and constitutes a second coil end. The meandering portion 25c and the end portion 25d are formed in a circular cross section. Moreover, it is comprised like the said Embodiment 1 except the conductor segment 25 being used instead of the conductor segment 15. As shown in FIG.

According to the third embodiment, since the second coil end is composed of a conductor having a circular cross section, the second coil ends are insulated even when the second coil ends interfere with each other by vibration generated during assembling the stator windings or during operation of the actual machine equipped with the stator. Damage to the coating 14 is suppressed. Therefore, damage to the insulating film 14 in the first coil end group and the second coil end group is suppressed, and excellent insulation is obtained.

Embodiment 4.

In this Embodiment 4, as shown in FIG. 11, the both ends of the short copper wire material 26 which has a circular cross section by which the insulating film 14 was coat | covered are pressed by the press jig 20A, and it shape | molds to rectangular cross section, After that, the central portion of the copper wire material 26 is bent to produce a U-shaped conductor segment.

Moreover, it is comprised like the said Embodiment 1 except the copper wire material 26 which manufactures a conductor segment has a circular cross section.

Therefore, according to the fourth embodiment, since the conductor segment is manufactured using a copper wire member having a circular cross section, it is cheaper than the copper wire member 21 having a rectangular cross section, and the stator can be manufactured at a low cost.

Moreover, since the slot accommodating part is press-molded, the hardness of a slot accommodating part becomes high with respect to a connection part. Therefore, the connecting portion as the first coil end is easily deformed, and even if the connecting portions interfere with each other, damage to the insulating film 14 is less likely to occur, and the insulation is improved.

In the fourth embodiment, the slot accommodating portion is formed by pressing to increase the hardness. However, the means for increasing the hardness of the slot accommodating portion with respect to the hardness of the connecting portion is not limited thereto.

Embodiment 5.

In this Embodiment 5, as shown in FIG. 12, the insulating film 14 is coat | covered first, and the short copper wire material 27 which has a circular cross section which made the center part large diameter is produced, and then the copper wire material is continued. The site | part except the center part of (27) is pressed, and it deform | transforms into a rectangular cross section. Thereafter, the center portion of the copper wire material 27 is bent to form a U-shaped conductor segment 28 connected by a pair of straight portions 30. The conductor segment 28 has a large cross-sectional area of the connecting portion 30 with respect to the cross-sectional area of the straight portion 29.

Moreover, it is comprised like the said Embodiment 1 except that the conductor segment 28 is used instead of the conductor segment 15. As shown in FIG.

According to the fifth embodiment, the cross-sectional area of the first coil end constituted by the connecting portion 30 is largely formed with respect to the cross-sectional area of the slot accommodating portion constituted by the straight portion 29. Here, since the heat generation amount at the first coil end is suppressed when the stator is mounted on the alternator, the cooling fan equipped to cool the coil end group can be downsized, and the alternator can be downsized.

Embodiment 6.

In the sixth embodiment, as shown in Fig. 13, the meandering portions 17b adjacent to the circumferential direction of the first coil end group 12a are arranged in contact with the circumferential direction, and the main portion of the second coil end group 12b is arranged. The meandering parts 16b adjacent in the direction are arranged in contact with the main direction. Moreover, the other structure is comprised like the said 1st Embodiment.

According to the sixth embodiment, since the meandering portions 16b and 17b adjacent in the circumferential direction are arranged without gaps, the inclination with respect to the axial direction of the stator core 11 of the meandering portions 16b and 17b becomes large. , The axial heights of the first and second coil end groups 12a and 12b are lowered. As a result, when mounted on the alternator, the ventilation resistance in the first and second coil end groups 12a and 12b is reduced. As a result, the air volume of the cooling wind by a cooling fan increases, the 1st and 2nd coil end groups 12a and 12b are cooled efficiently, the temperature rise of a stator is suppressed, and high output of an alternator can be caused. .

Embodiment 7.

Fig. 14 is a perspective view showing the main parts of a stator of the vehicular alternator according to Embodiment 7 of the present invention, and Fig. 15 is a winding of one phase in the stator winding of the stator of the vehicular alternator according to Embodiment 7 of the present invention. 16 is a cross-sectional view illustrating a wiring state of a wiring assembly of a stator winding of a stator of an automotive alternator according to a seventh embodiment of the present invention, and FIG. 18 is a view illustrating a method of manufacturing a winding assembly applied to a stator winding of a stator of a vehicular alternator according to Embodiment 7; FIG. 18 is a winding assembly applied to a stator winding of a stator of a vehicular alternator according to Embodiment 7 of the present invention; 19 is a view for explaining a manufacturing method of the stator winding of the stator of the automotive alternator according to Embodiment 7 of the present invention. Fig. 20 is a perspective view illustrating the winding structure of the winding assembly applied to the stator winding of the stator of the vehicular alternator according to Embodiment 7 of the present invention, and Fig. 21 is an embodiment of the present invention. It is process sectional drawing explaining the manufacturing method of the stator of the automotive alternator which concerns on the form 7.

In Fig. 15, the solid line indicates the connection state of the first end face of the stator iron core, the dotted line indicates the connection state of the second end face side of the stator iron core, and the black circle indicates the junction part. 13 indicates a slot number.

In FIG. 14, the stator 35 is made of a laminated iron core formed in a cylindrical shape, and a plurality of stator iron cores 11 are formed with a predetermined pitch in the circumferential direction so that the slot 11a extending in the axial direction opens to the inner circumferential side; It consists of the stator winding 36 formed by recommending many continuous conductor wires to the slot 11a, and the insulator 13 attached to each slot 11a.

In the stator winding 36, a single conductor wire 40 is returned outside the slot 11a on the first and second cross-sectional sides of the stator core 11 to form an inner layer in the slot depth direction in the slot 11a every six slots. There are a number of windings recommended for wave windings to alternate between the outer and outer layers.

Here, the conductor wire 40 uses the copper wire material by which the insulating film was coat | covered. One slot (slot accommodating portion) of the conductor wire 40 stored in the slot 11a has a rectangular cross section, and one slot is spaced 6 slots away from the first and second end faces of the stator core 11. The connection part 41 of the conductor wire 40 which connects the slot accommodating part of the inner layer in 11a and the slot accommodating part of the outer layer in the other slot 11a in series has a circular cross section. This connection part 41 is comprised from the turn part 41a, the pair of meandering parts 41b which connect each slot accommodating part, and the turn part 41a, and becomes a 1st and 2nd coil end, respectively.

Next, the winding structure of the winding 37 of one phase constituting the stator winding 36 will be described in detail with reference to FIG.

The winding 37 of one phase is comprised from the 1st-4th windings 51-54 which consist of one conductor wire 40, respectively. The first winding 51 is configured by wave winding so that one conductor wire 40 alternately adopts 1 and 2 in the slot 11a every 6 slots from 1 to 91. The second winding 52 is constituted by wave winding the conductor wire 40 so as to alternately adopt addresses 2 and 1 in the slot 11a every 6 slots from 1 to 91. The third winding 53 is configured by wave winding the conductor wire 40 so as to alternately adopt the addresses 3 and 4 in the slot 11a at positions 1 to 91 every six slots. The fourth winding 54 is configured by wave winding the conductor wire 40 to alternately adopt the 4th and 3th addresses in the slot 11a every 6 slots from 1st to 91th. In the slot 11a, four slot accommodating portions 42 of the conductor wire 40 are arranged side by side in the longitudinal direction along the longitudinal direction of the rectangular cross section.

Then, the winding end 52a of the second winding 52 which is produced at the second address of the first slot 11a on the first end face side of the stator iron core 11 and the third address of the slot 11a of the 91st number. The winding end 54b of the fourth winding 54 to be produced by TIG is welded, and the winding starting end 54a of the fourth winding 54 to be produced at the fourth address of the first slot 11a, and 91 The winding end portion 52b of the second winding 52, which is produced at the first address of the first slot 11a, is TIG-welded to form two turns of winding.

The winding start end 51a of the first winding 51 directed at the first end of the slot 11a on the second end face side of the stator core 11 and the fourth end of the slot 11a on the 91st side. The winding end 53b of the third winding 53 to be joined is joined, and the winding starting end 53a of the third winding 53 to be produced at the third address of the first slot 11a and the slot 91 The winding end portion 51b of the first winding 51, which is produced at the second address 11a, is joined to form a winding of two turns.

The connecting portion 41 of the conductor wire 40 of the third winding 53 extending from the third address of the slot 11a and the fourth address of the slot 11a to the first end face of the stator iron core 11. ) Is cut and the conductor wire 40 of the fourth winding 54 directed from the third address of the slot 11a of the 67th and the fourth end of the stator iron core 11 from the fourth address of the slot 11a of 73. The connection part 41 is cut | disconnected. Then, one end of the four turns obtained by joining the cutting end 53c of the third winding 53 and the cutting end 54c of the fourth winding 54 to connect the first to fourth windings 51 to 54 in series. The winding 37 of an upper part is formed.

In addition, the cutting end 53d of the third winding 53 and the cutting end 54d of the fourth winding 54 become the leader line O and the neutral point N, respectively.

Similarly, the winding 37 for 6 phases is formed by pushing the slot 11a which the conductor wire 40 recommends by 1 slot.

And the winding 37 recommended for the slot group of slots 1, 7 and 91, the winding 37 recommended for the slot group of slots 3, 9 and 93, The winding 37 recommended for the slot group of slot number 5, 11, 95 is joined to the Y by connecting the neutral points N. Similarly, the slot number 2, 8, 92, etc. Winding 37 recommended for the slot group, the slot 37 recommended for the slot group 4, 10, ... slot number, slot group 6, 12 ... 96 slot number The winding 37 recommended in the above is bonded to the neutral points N and connected to Y to form two sets of three-phase AC windings, and the stator 35 is obtained. In addition, these two three-phase AC windings constitute a stator winding 36.

In the stator 35 configured as described above, the slot accommodating portion 42 having a rectangular cross section adheres the flat surface to the side wall surface of each slot 11a through the insulators 13 in the slot depth direction in each slot 11a. They are arranged side by side.

Then, in the pair of slots 11a spaced apart from each other, the first and second end faces of the stator iron core 11 in the slot 11a and the second slot accommodating portion 42 accommodated in the second slot 11a are circular. Connected in series by the connection part 41 which has a cross section, the slot accommodating part 42 accommodated in addresses 3 and 4 in both slots 11a is connected in series by the connection part 41 which has a circular cross section. have. These two connecting portions (first coil ends) are arranged apart from each other in the radial direction. As a result, the first coil ends are arranged so as to be spaced apart from each other in the radial direction and the main direction at one slot pitch in the circumferential direction, and constitute the first coil end group 36a.

Similarly, in the pair of slots 11a spaced six slots apart, the slot accommodating portion 42 accommodated in addresses 1 and 2 in both slots 11a on the second end face side of the stator core 11 in the axial direction is provided. Connected in series by the connection part 41 which has a circular cross section, and the slot accommodating part 42 accommodated in addresses 3 and 4 in both slot 11a is connected in series by the connection part 41 which has a circular cross section. It is. These two connection parts (2nd coil end) are mutually spaced apart in the radial direction. As a result, the second coil ends are arranged in a radial direction and in the circumferential direction to be aligned with one slot pitch in the circumferential direction to constitute the second coil end group 36b.

Therefore, in the seventh embodiment, the area ratio of the conductors in the slot 11a can be increased, and the alignment and density of the first and second coil end groups 36a and 36b can be increased, resulting in a small high output. A stator is obtained that can be realized.

Moreover, since the connection part 41 which comprises the 1st and 2nd coil end is formed in circular cross section, the stress which arises in the turn part 41a when bending the conductor wire 40 and forming the turn part 41a of the connection part 41 is formed. Is less, damage to the insulating film coated on the turn part 41a is suppressed, and insulation can be improved.

Moreover, since the connection part 41 is formed in circular cross section, the connection part 41 (1st and 2nd coil end) by the vibration which generate | occur | produces at the time of assembling the stator winding 36, or during the operation of the actual machine in which the stator 35 is mounted. ) Even if they interfere with each other, damage to the insulating film can be suppressed and insulation can be improved.

Moreover, since the lead wire O and the neutral point N of the stator winding 36 are formed in circular cross section, the insulation coating coat | covered at the edge part of the lead wire O and the neutral point N becomes easy to remove. Therefore, when the stator 35 is mounted on the alternator, the connection between the lead wire O of the stator 35 and the rectifier can be easily and securely performed.

In the seventh embodiment, the first and second coil ends are arranged so as to be spaced apart in the circumferential direction. However, the meandering portions of the first and second coil ends may be arranged in the circumferential direction. In this case, the ventilation resistance of the 1st and 2nd coil end groups becomes small, and the effect similar to Embodiment 6 is acquired.

Subsequently, the assembling method of the stator 35 will be described in detail with reference to FIGS. 16 to 21.

First, 12 consecutive conductor lines 39 are arranged side by side in a slot pitch on a plane. Subsequently, as shown in FIG. 16, the twelve conductor lines 39 are returned together at a predetermined pitch (position of the two-dot and dashed lines), and as shown in FIG. ) Also forms a strip-shaped winding unit 43 wound spirally. The conductor wire 39 is made of a copper wire material having a circular cross section coated with an insulating coating.

Then, a pair of pin groups 44 are inserted between the conductor lines 39 on the surface side of the winding unit 43 at positions away from the distance D with respect to the width direction of the winding unit 43. Similarly, a pair of pin groups 44 are inserted between the conductor lines 39 on the rear surface side of the winding unit 43 at positions away from the distance D with respect to the width direction of the winding unit 43. Moreover, the position control pin group 45 is inserted between each conductor wire 39 in the width direction edge part of the winding unit 43. As shown in FIG. In this way, the pin groups 44 and 45 are set as shown in FIG. Here, the distance D substantially coincides with the groove direction length (axial length of the stator iron core 11) of the slot 58a of the laminated iron core 58 described later.

Here, a pair of pin groups 44 inserted between the conductor lines 39 on the surface side of the winding unit 43 are moved in the opposite directions in the longitudinal direction of the winding unit 43 as indicated by the solid line arrows in FIG. 17. . Similarly, a pair of pin groups 44 inserted between the conductor lines 39 on the back side of the winding unit 43 are moved in the opposite direction in the longitudinal direction of the winding unit 43 as indicated by the dotted arrows in FIG. 17. . At this time, since the position control pin group 45 is inserted between the conductor lines 39, the conductor line 39 is prevented from being disturbed.

Thus, the portion of each conductor wire 39 located between the pair of pins 44 is deformed to be orthogonal to the longitudinal direction of the winding unit 43. As a result, the straight portions 56a deformed to be perpendicular to the longitudinal direction of the winding unit 43 are paired in the display direction of the winding unit 43 to form a pair, and one slot pitch in the longitudinal direction of the winding unit 43 is 96 Pairs are arranged. And the site | part of each conductor wire 39 located in the outer side of a pair of pin 44 becomes a connection part which connects between the linear parts 56a which are 6 slots apart. The strip-shaped winding unit 56 manufactured as described above has a winding structure equivalent to the winding assembly 57 described later in FIG. 19 except that the straight portion 56a has a circular cross section. That is, the winding unit 56 is arranged at a six-slot pitch by connecting the straight portions 56a by the connecting portions, and the width of the conductor wire 39 on both sides of the thickness direction by the adjacent straight portions 56a by the connecting portions. (w) Two pairs of conductor lines 39 formed in a pattern shifted alternately by 6 slot pitches are shifted from each other, and the pair of conductor lines 39 formed by overlapping the linear portions 56a are deferred by one slot pitch, and the six phases are delayed. It is arranged and arranged.

Subsequently, the strip-shaped winding unit 56 is set in the press jig 46. As shown in Fig. 18, the press jig 46 is composed of a mold 47 in which the press groove 48 is arranged at one slot pitch, and a pressing tool 49 in which the press bar 49a is arranged at one slot pitch. have. And each press groove 48 is formed in the groove direction length substantially equal to the groove direction length (axial length of the stator core 11) of the slot 58a of the laminated iron core 58 mentioned later, and a conductor A second press having a groove width that is equal to the wire diameter of the line 39, and is continuously formed in the first press groove 48a and narrower than the groove width of the first press groove 48a. It is comprised by the groove | channel 48b. In addition, the press rod 49a has a length substantially equal to the length of the groove direction of the press groove 48, and has a width substantially equal to the groove width of the second press groove 48b.

Thus, the strip-shaped winding unit 56 has a mold 47 so that each pair of straight portions 56a is received in the first press groove 48a of each press groove 48, as shown in FIG. Is set. Then, the pressing mechanism 49 is set to position each press rod 49a in the first press groove 48a of the press groove 48, and moves downward in FIG. 18A.

Thereby, each pair of linear part 56a is pressed, it pushes into the 2nd press groove 48b from the 1st press groove 48a, and plastically deforms, and finally touches the bottom of the 2nd press groove 48b. Then, each pair of straight portions 56a is further pressed by the pressing mechanism 49 to form a slot accommodating portion 42 having a rectangular cross section as shown in Fig. 18B. Thereafter, the pressing mechanism 49 is pulled out, the strip-shaped winding unit 56 is taken out of the mold 47, and the winding assembly 57 shown in FIG. 19 is obtained.

In the winding assembly 57 produced as described above, 96 pairs of slot accommodating portions 42 overlapping each other in the direction orthogonal to the ground of Fig. 19 (corresponding to the width direction of the winding assembly 57) are arranged in a slot pitch of 96 pairs. The connecting portion 41 is connected to the slot accommodating portion 42 on the other side of the slot accommodating portion 42 of the pair of slot accommodating portions 42 in the width direction one of the slot accommodating portions 42 of the pair. Are connected by).

That is, as shown in FIG. 20, the slot accommodating part 42 is connected by the connection part 41, and is arrange | positioned at 6 slot pitch, and the adjacent slot accommodating part 42 is connected to both sides of the width direction by the connection part 41. As shown in FIG. The two conductor wires 40 formed in the pattern pushed alternately by the width w of the conductor wire 40 are 6 slot pitches apart from each other, and the slot accommodating parts 42 are overlapped and arranged in a pair. The pair of conductor wires 40 configured as described above are arranged in six pairs by pushing the slot pitches one by one to form the winding assembly 57.

Subsequently, as shown in FIG. 21A, an insulator 13 is mounted in each slot 58a of the laminated core 58. The laminated iron core 58 is formed of a rectangular parallelepiped by stacking a plurality of magnetic steel sheets, and 96 slots 58a are formed. Then, as shown in Fig. 21B, two winding assemblies 57 are overlapped and mounted on the laminated core 58 on the opening side of the slot 58a. As a result, the winding assembly 57 is accommodated in the slot 58a with four slot receiving portions 42 aligned in the slot depth direction in the longitudinal direction of the spherical cross-section, and aligned in the slot depth direction, so that the laminated core 58 )

Thereafter, as shown in FIG. 21C, the laminated core 58 on which the two winding assemblies 57 are mounted is bent in an annular manner to fit both ends of the laminated iron core 58 that is bent in an annular manner, and the fitting portion is laser-welded. do. Then, the laminated iron core 58 integrated by welding both ends becomes the stator iron core 11.

Thus, according to this Embodiment 7, the slot accommodating part 42 is connected by the connection part 41, and it arrange | positions in 6 slot pitch, and the adjacent slot accommodating part 42 is the width direction by the connection part 41. The conductor wire 40 formed by overlapping the slot accommodating portion 42 by arranging two conductor wires 40 formed in a pattern pushed alternately by the width (w) of the conductor wire 40 on both sides of the slot by pushing the slot accommodating portion 42. Since the pair uses a winding assembly 57 formed by being arranged in six phases by one slot pitch, the joining operation on the second end face side is remarkable compared to the above embodiment using the U-shaped conductor segment 15. It reduces, and the assembly property of a stator improves.

In addition, since the press jig 46 is used to collectively press the 96 pairs of the linear portions 56a of the winding unit 56 to produce the winding assembly 57, all the linear portions 56a are fired in a rectangular cross section at one time. It is deformed and the manufacturing process of the winding assembly 57 is simplified, and manufacturing time can be shortened.

Moreover, since the slot accommodating part 42 press-forms the linear part 56a of a circular cross section, and is formed in the rectangular cross section, the hardness of the slot accommodating part 42 becomes high with respect to the meandering part 41b of the connection part 41. As shown in FIG. . Therefore, the connection part 41 as a 1st and 2nd coil end becomes easy to deform | transform, and even if the connection part 41 mutually interferes, damage to the insulating film 14 hardly arises and insulation improves.

Moreover, since the press groove 48 of the metal mold | die 47 is comprised by the 1st press groove 48a with a wide groove width, and the 2nd press groove 48b with a narrow groove width, the linear part 56a of the winding unit 56 is carried out. ) Is easily attached to the press groove 48, and press workability is improved. Moreover, since the linear part 56a is pressed by the press rod 49a and plastically deform | transforms and pushes in the 2nd press groove 48b from the 1st press groove 48a, the linear part 56a which has a circular cross section is simplified. It can be deformed into a rectangular cross section. At this time, since the straight portion 56a extends in the press groove direction, the insulating film on the long side of the slot accommodating portion 42 also extends and becomes thin. And since the long side (flat part) of the slot accommodating part 42 is in close contact with the side wall surface of the slot 11a through the insulator 13, the heat which generate | occur | produced in the slot accommodating part 42 is efficiently carried out to the stator iron core 11; Delivered. As a result, heat generated in the slot accommodating portion 42 of the stator winding 36 is radiated from the stator iron core 11 having a large heat dissipation area, so that the temperature rise of the stator 35 is suppressed.

Embodiment 8.

In the seventh embodiment, one winding unit 56 is pressed by the press jig 46. In the eighth embodiment, two windings are shown as shown in Figs. 22A and 22B. The unit 56 is collectively pressed by the press jig 46.

Therefore, according to the eighth embodiment, the number of presses of the winding unit 56 ends in one cycle, and the number of manufacturing labor is reduced.

In the eighth embodiment, it is explained that the two winding units 56 are collectively pressed by the press jig 46, but the number of the winding units 56 that are collectively pressed by the press jig 46 is It is not limited to two. For example, when there are three winding assemblies 57 recommended for the stator iron core 11, the three winding units 56 may be collectively pressed by the press jig 46.

Embodiment 9

In the seventh embodiment, the winding unit 56 is pressed by the press jig 46 to produce the winding assembly 57. In the ninth embodiment, the winding assembly 57 is formed by press molding. After fabrication, the second insulating film 14a is coated on the slot accommodating portion 42 deformed into a rectangular cross section of the winding assembly 57.

That is, the straight portion 56a of the winding unit 56 made of the conductor line 39 having a circular cross section has a circular cross section as shown in Fig. 23A. When the winding unit 56 is pressed by the press jig 46, the straight portion 56a is deformed into a rectangular cross section as shown in FIG. 23B to become the slot accommodating portion 42. Subsequently, the second insulating film 14a is coated on the slot accommodating portion 42. As a result, the slot accommodating portion 42 has a two-layer structure of the insulating film 14 and the second insulating film 14a, as shown in FIG.

In the seventh embodiment, when the winding assembly 57 is manufactured by the press jig 46, the copper wire 60 of the straight portion 56a is plastically deformed, and the insulating film 14 is coated on the long side of the rectangular cross section. ) Also extends and becomes thinner. As a result, cracks in the insulating coating 14 occur at the long sides and the respective portions of the slot accommodating portion 42, which causes a poor insulation.

However, according to the ninth embodiment, after the winding assembly 57 is manufactured by press molding, the second insulating film 14a is coated on the slot accommodating portion 42 deformed into a rectangular cross section of the winding assembly 57. Since the insulating coating coated on the slot accommodating portion 42 has a two-layer structure between the insulating coating 14 and the second insulating coating 14a, cracks generated in the insulating coating 14 are the second insulating coating. It is clogged by 14a and insulation improves.

Here, the material of an insulating film is demonstrated.

Since the insulating resin 14 coated on the copper wire 60 is press-molded, excellent adhesion is required. For this reason, it is preferable to use adhesive reinforcement resin, such as polyester imido resin, for the insulating film 14, for example.

In addition, since press molding is not performed to the 2nd insulating film 14a, it is preferable to use heat resistant resin, such as a polyamide-imide resin, for example.

In addition, even when the same resin is used for the insulating film 14 and the second insulating film 14a, the insulating film has a two-layer structure, whereby cracks formed in the insulating film 14 by press molding are applied to the second insulating film 14a. It is clogged, and the effect which can improve insulation is acquired. When the adhesive reinforcing resin is used for the insulating coating 14 and the heat resistant resin is used for the second insulating coating 14a, cracks during press forming are less likely to occur. Softening is suppressed, insulation is always more.

Embodiment 10.

In this tenth embodiment, as shown in FIG. 24, the winding assembly 57 is superimposed in three layers and is recommended for the stator iron core 11. That is, the winding of each phase of the stator winding is formed of 6 turns of wave winding windings. In each slot 11a, six slot accommodating parts 42 are arranged in a line with the longitudinal direction of the rectangular cross section coinciding in the radial direction.

Here, the inner peripheral side end surface of the slot accommodating part 42a located in an innermost peripheral layer is shape | molded in circular arc shape, and the outer peripheral side end surface of the slot accommodating part 42b located in an outermost peripheral layer is shape | molded in circular arc shape. That is, the slot accommodating parts 42a and 42b located in an innermost circumferential layer and an outermost circumferential layer are shape | molded in a shot shape.

The other configuration is configured as in the seventh embodiment.

According to the tenth embodiment, since the slot accommodating portion 42b located at the outermost circumferential layer is formed in a shot shape, the winding assembly 57 is radially inserted into the slots 58a and 11a of the laminated core 58. The winding assembly 57 can be inserted smoothly when mounting from the inside of the. In addition, damage to the insulating film 14 due to friction between the tip end of the slot accommodating portion 42b and the side wall surface of the slot 58a is suppressed, and the insulation is improved.

Moreover, since the slot accommodating part 42a located in an innermost periphery layer is shape | molded in a shot shape, when bending the laminated iron core 58 annularly, the blade part of the tooth parts 58b and 11b of the laminated iron core 58 ( 58c) and 11c and interference with the slot accommodating part 42a are suppressed. Thereby, the damage of the insulating film 14 resulting from the interference of the tip part of the slot accommodating part 42a and the blade part 58c of the tooth part 58b is suppressed, and insulation is improved.

Here, the slot accommodating portions 42a and 42b are formed by contacting the bottom of the second press groove 48b with the pair of straight portions 56a as shown in FIG. It can be formed by stopping the pressing force by the press rod 49a before the contact surface with the bottom part of the 2nd press groove 48b becomes flat.

Moreover, the slot accommodating part 42a does not need to form the whole inner peripheral side cross section in circular arc shape, and if the curvature radius of the inner peripheral part of the slot accommodating part 42a is formed larger than the curvature radius of the outer peripheral part, do. Similarly, the slot accommodating part 42b does not need to form the entire outer peripheral side end surface circularly, and at least the curvature radius of the outer peripheral part of the slot accommodating part 42b should be larger than the curvature radius of the inner peripheral part. .

Moreover, in each said embodiment, although the slot accommodating part is connected by the connection part which has a circular cross section, the cross-sectional shape of a connection part is not limited to a circular cross section, What is necessary is just a non-flat cross-sectional shape. Here, the non-flat cross-sectional shape is a cross-section having substantially the same diameter throughout the entire direction, and is a cross-sectional shape such as a circle, a square, or a regular polygon. In addition, a slot accommodating part should just be flat cross-sectional shape, and cross-sectional shapes, such as rectangular shape, a race track shape, and a shot shape, are used.

Since this invention is comprised as mentioned above, there exists an effect as described below.

According to the present invention, in a stator of an automotive alternator having a stator winding formed by recommending a stator iron core having a plurality of slots and a conductor wire coated with an insulating coating to the slot,

The stator windings are stored in the plurality of slots by 2n (n: integers), each formed in a flat cross-sectional shape, and the flat surfaces are brought into close contact with the sidewall surfaces of the slots, and are arranged side by side in the slot depth direction in each slot. Non-flat cross section of each of the arranged slot housing portions and the slot receiving portions stored at different addresses with respect to the slot depth direction in both slots on the first end face side in the axial direction of the stator core in each of the slot pairs separated by a predetermined number of slots. N first coil ends connected in series by a continuous conductor line having a plurality of slots, and in each of the pair of slots spaced apart from each other by the predetermined slot number, with respect to the slot depth direction in the slot on the second end face side in the axial direction of the stator iron core. And n second coil ends for serially connecting the slot accommodating parts stored at different addresses,

On the first end face side of the stator iron core, the n first coil ends connecting the slot accommodating parts stored at different addresses with respect to the slot depth direction in the two slots in series are arranged at one slot pitch in the circumferential direction, 1 coil end group which constitutes one coil end group and connects in series the slot accommodating parts housed at different addresses with respect to the slot depth direction in both slots on the second end face side of the stator iron core is one in the main direction. Since the second coil end group is arranged at the slot pitch, the stator of the vehicular alternator can be obtained while improving the compactness and high output of the vehicular alternator.

Moreover, since the said 2nd coil end is formed by the continuous conductor line which has a non-flat cross section, the damage of the insulating film by the contact of 2nd coil ends is suppressed, and insulation is improved.

In addition, since the cross-sectional area of the coil end having the non-flat cross section is larger than the cross-sectional area of the slot accommodating portion, the stator of the vehicle AC generator is larger than the cross-sectional area of the slot accommodating portion. have.

The slot accommodating portion accommodated in the outermost address in the slot is formed in a cross-sectional shape in which the radius of curvature of the corner portions of the radial direction is larger than the radius of curvature of the corner portions of the radial direction. Interference between the conductor wire and the slot is suppressed, damage to the insulating film is suppressed, and insulation is improved.

Further, since the curvature radius of each corner portion in the radial direction is formed in a cross-sectional shape than the curvature radius of the corner portions in the radial direction, the slot accommodating portion and the slot accommodating portion housed in the innermost address in the slot are formed. The damage of the insulating film resulting from interference with is suppressed and insulation is improved.

The slot accommodating part has a heat dissipation area having a large heat dissipation area in the slot accommodating part since the insulating film of the flat surface which is in close contact with the side wall surface of the slot is formed thinner than the insulating film of the outer and inner portions in the radial direction. The heat is rapidly transmitted to the heat sink, and heat is radiated from the surface of the stator core, and the temperature increase of the stator winding is suppressed.

In addition, since the insulating film is covered with two layers of the slot accommodating portion, damage to the insulating film of the slot accommodating portion is suppressed and the insulation is improved.

In addition, since the insulating film is composed of a lower insulating film made of an adhesive reinforcement resin and an upper insulating film made of a heat resistant resin, damage of the insulating film caused by bending is suppressed, and the insulating film caused by heat generation in the stator winding is suppressed. Softening is suppressed and excellent insulation is obtained.

Further, the first and second coil end groups have a meandering portion in which the first and second coil ends are inclined with respect to the axial direction of the stator iron core positioned between the rising part and the top part from the slot accommodating part. Since the arrangement is arranged in contact with each other, the amount of directing from the cross section of the stator iron core of the first and second coil end groups is reduced, and the ventilation resistance in the first and second coil end groups can be reduced when mounted on the vehicle alternator. Can be.

Further, since the slot housing portion is formed to have a higher hardness than the meandering portion located between the rising portion and the top portion from the slot receiving portion inclined with respect to the axial direction of the stator iron core in the coil end having a non-flat cross section. The meandering part of an end becomes easy to deform | transform, and even if coil end mutually interferes, it is hard to produce damage to an insulating film, and insulation property improves.

Moreover, since the lead wire of the stator winding produced by one of the first and second coil end groups has a circular cross section, the connection work between the lead wire and the rectifier becomes easy.

In addition, the straight portions are connected by a connecting portion and arranged at a predetermined slot pitch, and the adjacent straight portions are formed in a pattern pushed by the connecting portion to alternately adopt the inner layer and the outer layer in the slot depth direction, and the insulating film is coated. A strip-shaped winding unit configured by arranging two conductor wires having a non-flat cross-sectional shape by one slot pitch in a pair of conductor wires which are delayed by the predetermined slot pitch with each other and arranged in such a manner that the straight line portions are superposed. A process of manufacturing, a step of manufacturing the winding assembly by pressing the straight portion of the winding unit into a flat cross-sectional shape, and inserting the straight portion of the winding assembly from the slot opening side of the laminated iron core of the rectangular parallelepiped, and inserting the winding assembly into the laminated iron core. Mounting process and bending the laminated iron core on which the winding assembly is mounted Matdae the section between the iron core and the iron core of the multilayer hayeoteumeuro a step of welding and integrating the cross-section between the bonding locations in the stator core end surface significantly reduced, the manufacturing method of the stator of the automotive alternator having excellent productivity can be obtained.

Further, in the manufacturing process of the winding assembly, the first press groove having a groove width equal to or greater than the width of the linear portion, and the first press groove having a groove width narrower than the width of the linear portion, and continuously speaking in the groove depth direction to the first press groove. Using a die provided with a press groove, the straight portion of the winding unit is accommodated in the first press groove, and then the straight portion is pressed on the first press groove side and the straight portion is pressed into the second press groove. By deforming the portion to a flat cross section, the winding unit can be easily set to a die, and the press workability can be improved, and the straight portion can be deformed into a simple flat cross section.

Further, in the winding assembly attached to the laminated core, the straight portion accommodated at the deepest position in the slot depth direction in the slot has a cross section in which the radius of curvature of the corner portion of the slot bottom is larger than the radius of curvature of the corner portion of the slot opening side. Since it is formed in the shape, the winding assembly can be smoothly mounted on the laminated iron core, the damage of the insulating film caused by the interference between the straight portion and the slot is suppressed, and the insulation is improved.

Further, in the winding assembly attached to the laminated core, the straight portion accommodated at the lowest position in the slot depth direction in the slot has a radius of curvature greater than the curvature radius of each corner portion of the slot opening side. Since it is formed in a cross-sectional shape, when bending the laminated iron core in an annular manner, interference of the blade edge and the straight portion of the tooth tip of the laminated iron core is suppressed, and the damage of the insulating film caused by the interference between the blade portion and the straight portion is suppressed. Insulation is improved.

Further, in the manufacturing process of the winding assembly, all the linear parts of the winding unit are press-molded collectively, so that the product process can be simplified and the manufacturing time can be shortened.

Further, in the manufacturing process of the winding assembly, all the linear parts of the plurality of winding units are press-molded in a batch so that the manufacturing process can be further simplified to shorten the manufacturing time.

Moreover, since it has a process of apply | coating and forming a 2nd insulating film in the linear part of the said winding assembly, even if a crack generate | occur | produces in the insulating resin at the time of press molding of a linear part, this crack is prevented by the 2nd insulating film, and insulation property improves.

In addition, since the insulating film is an adhesive reinforcement resin and the second insulating film is a heat resistant resin, cracking of the insulating film during press forming of the linear part is suppressed, and softening of the second insulating film due to heat generation in the stator winding is suppressed. It is suppressed and insulation improves.

BRIEF DESCRIPTION OF THE DRAWINGS The perspective view which looked at the principal part of the stator of the vehicular alternator which concerns on Embodiment 1 of this invention from the 1st cross section side of an axial direction.

Fig. 2 is a perspective view of the main part of the stator of the vehicular alternator according to Embodiment 1 of the present invention, as viewed from the second cross-sectional side in the axial direction;

3 is a perspective view showing a conductor segment applied to a stator winding of a stator of a vehicular alternator according to Embodiment 1 of the present invention;

4 is a perspective view for explaining a method of forming a conductor segment shown in FIG. 3;

FIG. 5 is a perspective view for explaining a method of attaching a conductor segment to a stator core of a stator of an automotive alternator according to Embodiment 1 of the present invention; FIG.

FIG. 6 is a process chart for explaining a method for manufacturing a stator of a vehicular alternator according to Embodiment 1 of the present invention; FIG.

FIG. 7 is a view for explaining the arrangement of conductor segments in the slots of the stator cores in the stator of the vehicular alternator according to Embodiment 1 of the present invention; FIG.

8 is a cross-sectional view illustrating a connection state of a winding of one phase in a stator winding of a stator of an automotive alternator according to Embodiment 1 of the present invention;

9 is a perspective view showing a conductor segment applied to a stator winding of a stator of a vehicular alternator according to Embodiment 2 of the present invention;

10 is a perspective view showing a conductor segment applied to a stator winding of a stator of a vehicular alternator according to Embodiment 3 of the present invention;

11 is a perspective view for explaining a method of forming a conductor segment applied to a stator winding of a stator of a vehicular alternator according to Embodiment 4 of the present invention;

12 is a perspective view for explaining a method of forming a conductor segment applied to a stator winding of a stator of a vehicular alternator according to Embodiment 5 of the present invention;

13 is a plan view of the main part of the stator of the vehicular alternator according to Embodiment 6 of the present invention, as viewed from the inner diameter side thereof;

14 is a perspective view showing main parts of a stator of the vehicular alternator according to Embodiment 7 of the present invention;

FIG. 15 is a cross-sectional view illustrating a connection state of a winding of one phase in the stator winding of the stator of the vehicular alternator according to Embodiment 7 of the present invention; FIG.

FIG. 16 is a view for explaining a method of manufacturing a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 7 of the present invention; FIG.

FIG. 17 is a view for explaining a method for manufacturing a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 7 of the present invention; FIG.

FIG. 18 is a view for explaining a method for manufacturing a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 7 of the present invention; FIG.

19 is a side view showing a winding assembly applied to a stator winding of a stator of a vehicular alternator according to Embodiment 7 of the present invention;

20 is a perspective view illustrating a winding structure of a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 7 of the present invention;

21 is a cross-sectional view illustrating the manufacturing method of the stator of the vehicular alternator according to Embodiment 7 of the present invention;

FIG. 22 is a view explaining a press step of a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 8 of the present invention; FIG.

23 is a cross-sectional view illustrating a method of manufacturing a winding assembly applied to a stator winding of a stator of a vehicular alternator according to Embodiment 9 of the present invention;

24 is a cross-sectional view for explaining an arrangement state of conductor lines in a slot in the stator of the vehicular alternator according to Embodiment 10 of the present invention;

25 is a view for explaining a press step of a winding assembly applied to a stator winding of a stator of an automotive alternator according to Embodiment 10 of the present invention;

Fig. 26 is a sectional view showing the main parts of a stator of a conventional automotive alternator;

Fig. 27 is a perspective view showing conductor segments constituting a stator winding of a stator of a conventional automotive alternator.

<Description of the symbols for the main parts of the drawings>

10, 35: stator, 11: stator core,

11a: slot, 12, 36: stator windings,

12a, 36a: first coil end group, 12b, 36b: second coil end group,

14: insulating film, 15, 25, 28: conductor segment,

16a, 25a: slot receiving portion, 16b, 25c: meandering portion,

17, 25b, 30: connecting portion, 17b: meandering portion,

29: straight portion, 39, 40: conductor wire,

41: connecting portion, 42: slot receiving portion,

46: press jig, 47: mold,

48: press groove, 48a: first press groove,

48b: second press groove, 56: winding unit,

56a: straight part, 57: winding assembly.

Claims (3)

In the stator of a vehicle alternator having a stator iron core having a plurality of slots and a stator winding formed by recommending a conductor wire coated with an insulating coating to the slot, The stator windings are accommodated in the plurality of slots by 2n (n: integers) and are formed in a flat cross-sectional shape, respectively, and the flat surfaces are arranged in parallel with each other in the slot depth direction by bringing the flat surface into close contact with the side wall surface of the slot. In each of the slot accommodating portions and the slot pairs spaced apart from each other by the predetermined number of slots, the non-flat section of the slot accommodating portion accommodated at different addresses with respect to the slot depth direction in both slots on the first end face side in the axial direction of the stator iron core is shown. In each of the n first coil ends connected in series by a continuous conductor line having a predetermined number of slots, and the slot pairs apart from each other by the predetermined number of slots, the slot depth direction in the slots in both slots is on the second end surface side in the axial direction of the stator core. And n second coil ends for serially connecting the slot accommodating parts stored at different addresses, On the first end face side of the stator iron core, the n first coil ends that connect the slot accommodating parts stored in different addresses in series with respect to the slot depth direction in both slots are arranged at a slot pitch in the circumferential direction, N second coil ends constituting one coil end group and connecting the slot accommodating parts housed in different addresses with respect to the slot depth direction in both slots on the second end face side of the stator iron core in series are main directions. Arranged in a slot pitch to form a second coil end group, The stator of the vehicular alternator, wherein a cross-sectional area of the coil end having the non-flat cross section is larger than that of the slot receiving portion. delete The straight portion is connected by a connecting portion and arranged at a predetermined slot pitch, and the adjacent straight portion is formed in a pattern pushed to alternately adopt the inner layer and the outer layer in the slot depth direction by the connecting portion, and has an uneven cross-sectional shape coated with an insulating film. Manufacturing a strip-shaped winding unit having two conductor wires each having a plurality of pairs equal to the predetermined number of slots by pushing the pair of conductor wires arranged by overlapping the straight portions by pushing the predetermined slot pitches with each other by one slot pitch; A step of forming a winding assembly by press-molding a straight portion into a flat cross section on a winding unit, and inserting the straight portion of the winding assembly into a slot of a laminated iron core of a rectangular body at a slot opening side to mount the winding assembly to the laminated iron core. And bending the laminated iron core on which the winding assembly is mounted in an annular manner. Method for manufacturing a stator of a vehicle AC generator, characterized in that the conformity between the end surface of the laminated iron cores comprising a step of welding integrally the section between the laminated iron core.