KR101319500B1 - Methed for manufacturing of stator and electric motor having thereof, electric vechile having electric motor - Google Patents

Abstract

The present invention relates to a method for manufacturing a stator and an electric vehicle having the same, and an electric vehicle having the motor. The present invention can increase the mass productivity of a stator having a hairpin coil by standardizing a step of manufacturing the hairpin coil and a step of inserting the coil into the stator core and then connecting the coil. In addition, in manufacturing the hairpin coil, it is possible to prevent damage to the insulation layer at the bent portion in advance, thereby reducing the failure rate of the coil and increasing the performance of the electric motor and the electric vehicle employing the same.

Description

Method of manufacturing stator, electric motor having same and electric vehicle provided with the same {METHED FOR MANUFACTURING OF STATOR AND ELECTRIC MOTOR HAVING THEREOF, ELECTRIC VECHILE HAVING ELECTRIC MOTOR}

The present invention relates to a method for manufacturing a stator, an electric motor having the same, and an electric machine having an electric motor.

As is well known, generators and electric motors (hereinafter referred to as "electric machines"), such as alternators or generators, may be constructed with stators and movers that move relative to the stators.

The stator of the electric machine may have a stator core having a plurality of slots and a stator winding wound around the slot.

The stator winding may be constructed by a method of winding a relatively thin diameter wire (coil) a plurality of times inside the slot of the stator core.

However, in the conventional stator winding method as described above, since the ratio of the occupied area (cross-sectional area) of the conductor (coil) to the slot is relatively small, the operation efficiency may be reduced.

In consideration of this point, a segment conductor (hereinafter, referred to as a coil) having a substantially "U" shape, is inserted from one side to the other in the slot of the stator core along the axial direction. ALTERNATOR FOR AN AUTOMOTIVE VEHICLE, which connects the end of the coil protruding to the other side of the stator core in a preset manner, is disclosed in US Patent Publication No. US 6,198,190 (published date: 2001.03.06). Is disclosed.

In the conventional stator winding method including the above-described "automotive alternator", the coils are sequentially inserted from one side of the stator core to the other side, and the ends of the coils protruding to the other side of the stator core extend in the axial direction of the stator core. It was bending and connecting to each other.

An object of the present invention is to prepare a stator manufacturing method of manufacturing a stator core that manufactures a hairpin-shaped coil and inserts it into a stator core, and then performs an insulation process, and to increase the mass productivity. It is to provide an electric vehicle equipped.

In order to achieve the object of the present invention, the first step of forming the bending of the intermediate portion of each coil; Inserting the primary formed coils into the slots of the stator; Forming a secondary by bending both ends of the coils inserted into the slots of the stator; And connecting both ends of the secondary-formed coils, respectively.

In addition, an enclosure; A stator disposed inside the enclosure; And a rotor rotatably disposed with respect to the stator, wherein the stator is provided with an electric motor manufactured by the manufacturing method described above.

In addition, a vehicle body; A battery provided in the vehicle body; And an electric motor provided at the vehicle body and connected to the battery to provide a driving force to the vehicle body, wherein the electric motor is provided with an electric vehicle having a stator manufactured by the manufacturing method described above.

The manufacturing method of a stator according to the present invention, an electric motor having the same, and an electric vehicle provided with the motor, standardize a process of manufacturing a hairpin coil and a process of inserting the coil into a stator core and then connecting the coil to a stator having a hairpin coil. Mass production can be improved. In addition, in manufacturing the hairpin coil, it is possible to prevent damage to the insulation layer at the bent portion in advance, thereby reducing the failure rate of the coil and increasing the performance of the electric motor and the electric vehicle employing the same.

1 is a schematic view showing an electric vehicle according to an embodiment of the present invention;
2 is a cross-sectional view showing the electric motor of FIG.
3 is a yab perspective view showing a stator of the electric motor of FIG.
4 is a perspective view showing the coil of FIG.
5 is a schematic view for explaining a connection state of the stator winding of the electric motor of FIG.
Figure 6 is a block diagram showing an example of the manufacturing process of the stator according to the present invention,
7 is a schematic view showing the configuration of a twister for secondary forming in the manufacturing process according to FIG.
8 is a block diagram showing another embodiment of the manufacturing process of the stator according to the present invention.

Hereinafter, an embodiment of a stator manufacturing method according to the present invention, an electric motor having the same, and an electric vehicle having an electric motor will be described in detail with reference to the accompanying drawings.

As shown in FIG. 1, an electric vehicle having an electric motor according to an embodiment of the present invention includes a vehicle body 110, a battery 125 provided in the vehicle body 110, and the vehicle body ( It may include an electric motor 140 provided in the 110 to provide a driving force to the vehicle body (110).

A boarding space (not shown) may be provided in an upper region of the vehicle body 110, and a plurality of wheels 115 may be provided at both sides of the front and rear regions of the vehicle body 110 to enable driving. In addition, a suspension device 120 may be provided between the vehicle body 110 and the wheel 115 to mitigate vibration and shock generated during driving.

The vehicle body 110 may be provided with a battery 125 for supplying power. The battery 125 may be configured as a secondary battery to be charged.

The vehicle body 110 may include an electric motor 140 providing a driving force to the wheel 115, and an inverter device 130 connected to the battery 125 and the electric motor 140, respectively.

The inverter device 130 may convert the DC power provided from the battery 125 into driving power suitable for driving the motor 140, and then provide the driving power to the motor 140.

As shown in FIG. 2, the electric motor 140 includes an enclosure 141 for forming a receiving space therein and a stator of an electric machine according to an embodiment of the present invention disposed in the enclosure 141. 160 and a rotor 150 rotatably disposed with respect to the stator 160.

The enclosure 141 may be configured, for example, in a cylindrical shape with both sides open.

Covers or brackets 145 may be provided at both ends of the enclosure 141. The bracket 145 may be detachably coupled to an end of the enclosure 141. The bracket 145 may be provided with a bearing 147 rotatably supporting the rotating shaft 157 of the rotor 150.

The rotor 150 may include a rotor core 151 and a magnet 155 provided in the rotor core 151.

A shaft hole 154 may be formed in the rotor core 151 to allow the rotation shaft 157 to be coupled thereto. In addition, the rotor core 151 may be configured by, for example, insulating stacking a plurality of electrical steel plates 152 on which the shaft holes 154 are formed.

The magnet 155 may be provided on an outer surface of the rotor core 151. Here, the rotor 150 may be configured such that a magnet (not shown) is inserted into the rotor core 151 in the axial direction.

The stator 160 of the electric machine may include a stator core 161 having a plurality of slots 165 and a stator winding 170 wound around the slot 165.

A rotor accommodating space 164 is formed in the stator core 161 so that the rotor 150 can be rotatably accommodated, and a plurality of slots 165 along the circumferential direction of the rotor accommodating space 164. ) And a tooth 166 may be provided.

The slot 165 and the tooth 166 may be alternately arranged.

The stator core 161 may be formed by, for example, insulating lamination of the electrical steel plate 162 on which the rotor accommodating space 164, the slot 165, and the teeth 166 are formed.

On the other hand, the stator windings 170, as shown in Figures 3 to 4, a plurality of coils are inserted in the axial direction in the slot 165 on one side of the stator core 161 is connected at both ends on the other side 171. Although not shown in the drawings, the coil may be provided with a connecting conductor interposed between both ends of the coil 171 at the other side of the stator core 161 to connect the two ends.

The coils 171 may be formed of conductors having a rectangular cross section, respectively. The coil 171 includes a conductor 171a made of copper wire and an insulating layer 171b coated with a varnish on the outer circumferential surface of the conductor 171a.

As illustrated in FIG. 4, the coil 171 may include two legs 173 disposed to be spaced apart from each other at a predetermined interval, and a connection part 175 connecting the two legs 173 to each other.

The two legs 173 of the coil 171 may be formed to have a length that is inserted from one side along the axial direction of the stator core 161 (or the longitudinal direction of the rotation shaft 157) and protrudes from the other side.

The two legs 173 of the coil 171 may be formed to be spaced apart from each other at a predetermined interval. For example, an interval between two legs of the coil 171 may be formed by a three slot interval (pitch) of the stator core 161. That is, when the leg 173 of one side of the coil 171 is inserted into the first slot, the leg 173 of the other side may be inserted and coupled to the fourth slot, which is the third slot. Here, the spacing between the two legs 173 of the coil 171 may be appropriately adjusted.

The coils 171 may be accommodated spaced apart from each other along the radial direction of the stator core 161 in the same slot 165 of the stator core 161.

The stator 160 of the electric machine according to the present embodiment exemplifies a case in which an even number of coils 171 are inserted into the slot 165. For example, as shown in FIG. 5, an even, specifically four coils 171 are inserted into the respective slots 165 of the stator core 161, respectively, and are spaced apart from each other along the radial direction. A case of forming the layer to the fourth layer will be described.

The two legs 173 of the coils 171 may be arranged on different circumferences along the radial direction of the stator core 161. In detail, the leg 173 of one side of the coil 171 may be disposed in the first layer of the first slot, and the leg 173 of the other side may be disposed in the second layer of the fourth slot.

Ends of the two legs 173 of the coils 171 may be welded and connected to each other.

On the other hand, the manufacturing method of the stator according to the present embodiment as described above is as follows.

That is, as shown in FIG. 6, first, the coil 171 is formed by coating an insulating layer 171b such as a varnish on the outer circumferential surface of the conductor 171a of the rectangular cross-section copper wire (S11). The conductor 171a may be immersed in a container containing the varnish solution for a predetermined time so that the insulating solution is coated on the conductor.

Next, the coil 171 coated with the insulating layer 171b is cut into a predetermined length. (S12) Here, the coil 171 is set to a predetermined length using a stopper (not shown), and a rail (not shown). After moving the coil 171 by using a cutter (not shown) using a cutter to cut the coil 171. The use of rails allows the coil to move in a straight line without being twisted.

Next, both ends of the cut coil 171 are put in a jig (not shown) to strip the insulating layer 171b by a predetermined length. (S13) A jig is provided with a square band cutter to the square band cutter. The insulating layer 171b may be peeled off while inserting the coil by a predetermined depth.

Next, both ends of the coil 171 from which the insulating layer 171b has been stripped are removed using a brushing machine (not shown) to remove burrs generated during stripping or grind the edges smoothly. S14) The brushing process may be performed simultaneously with the stripping process.

Next, the coil 171 is placed on the fixed side hairpin jig and pressed with the movable side hairpin jig so that the intermediate portion of the coil is firstly bent in two dimensions. (S15) At this time, the bending portion of the coil The reference groove provided in the fixed side hairpin jig can be used.

Next, the first bent coil 171 is placed in a press jig (not shown), and the ends of the coil 171 are twisted in three dimensions in two dimensions (S16). Both ends (ie, primary bent portions) are bent to be located on different circumferential phases (or different layers).

Next, a surge test may be performed to determine whether the insulating layer 171b of the bent portion of the coil 171 is damaged.

Next, the insulating paper 190 is inserted into the coil 171 after the surge test in the axial direction, and then the respective coils 171 are sequentially inserted into the slots 165 of the stator core 161. (S18 to S19) At this time, it is preferable to insert the insulating paper 190 in the direction in which the burr of the stator core 161 is formed to remove the burr. The insulating paper 190 is first inserted into the coil 171 and then inserted into the slot 165 of the stator core 161 with the insulating paper 190 inserted, or the insulating paper 190 is inserted into the stator core 161. First, the coil 171 may be inserted into the slot 165.

Next, in the state in which the coil 171 is inserted into the slot 165 of the stator core 161, a part of the coil 171 bends the second end so as to be connected to a lead wire (not shown). Perform a part of the forming work (S110).

Next, a roll insulating paper (not shown) is inserted between the ends of the coils 171. (S111) The roll insulating paper may be formed in a roll shape to be inserted by turning in the circumferential direction of the stator 160.

Next, the two ends of the coils 171 are pulled by three slots to the left and right, and thus connected to each other, that is, the second twisting that is the remainder of the second forming operation is performed.

To this end, a twister 200 as shown in FIG. 7 may be used. That is, the twister 200 is installed in the center of the base 210 so that the twist jig 220 capable of pulling the end of the coil 171 by the slot may move in the vertical direction. do. In addition, a cam stopper 240 is annularly installed at the edge of the base 210 so that the cam roller 230 can move to constantly twist the coil 171. A body 250 having a cam roller 230 is installed at an upper side of the cam stopper 240, and a finger unit for holding the stator core 161 in the body 250 to move in the left and right directions of the drawing. (finger unit) 260 is installed. In addition, a jig fixing part 280 having a fixing jig 270 is provided on the upper side of the stator core 161 to restrain the stator core 161 in an upward direction.

5 to 7, in the twister 200 as described above, the fixing jig 270 is first brought into close contact with the stator core 171 to support the upward direction. And the coil unit 171 is caught using the finger unit 260. After setting the cam stopper 240 on a single row basis, the position of the twist jig 220 is adjusted to the lead wire side coil. The twister 200 is operated to rotate the coil 171 in one row (ie, the first layer and the second layer) by three slots in the clockwise direction. At this time, the protective film that was sandwiched between the coils 171 is removed. After replacing the cam stopper 240 with two rows (ie, the third layer and the fourth layer), the position of the twist jig 220 is aligned with the lead wire side coil, and the two row coils are simultaneously cut. Rotate clockwise by 3 slots and remove the protective film from the coil.

Next, the both ends of the coil 171 after the torsional molding is cut to a predetermined length and trimmed.

Next, both ends of the trimmed coil 171 are connected by welding, and the connected portions are insulated by additional coating with varnish or epoxy, and then final inspection is completed to finish the manufacturing process of the stator. (S114 to S115)

On the other hand, if there is another embodiment of the manufacturing method of the stator according to the present invention is as follows.

That is, in the above-described embodiment, a coil was formed by coating an insulating layer on the conductor, and then the coil was cut to an appropriate length to be bent and formed. It is intended to prevent the insulating layer from being damaged during the forming process by forming a “shaped” shape and then coating the insulating layer.

8 is a block diagram showing another embodiment of the manufacturing process of the stator according to the present embodiment.

As shown therein, the conductor 171a is bent into a predetermined shape to complete the primary forming. (S21) At this time, the conductor is melted in a mold (not shown) having a cavity having a “three-dimensional U” shape. Forming by injecting may be preferable in consideration of mass productivity.

Next, the conductor 171a formed in the “three-dimensional U” shape is immersed in a container containing an insulating liquid so that the insulating layer 171b is coated (S21).

Next, the process of stripping the coil (S23), coil brushing (S24) and the like proceeds as in the above-described embodiment.

Next, in the above-described embodiment, the coil brushed coil 171 is primarily formed and subjected to a surge test. However, in the present embodiment, since the insulation layer is coated on the primary-formed conductor in the mold, a separate coil surge There is no need to test. Therefore, the coil 171 after the coil brushing process (S24) is immediately inserted into the insulating paper (S25), coil insertion (S26), secondary forming (secondary bending) (S27), insulating paper roll insertion (S28), secondary forming ( Secondary bending (S29), coil trimming (S210), coil connection (S211), varnish or epoxy additional coating (S212), the final test (S213) and the like can be carried out in the same manner as in the above-described embodiment have.

In this way, a "U" shaped coil called a hairpin is inserted into the slot of the stator core from one side to the other side along the axial direction, and the end of the coil protruding to the other side of the stator core is connected in a predetermined manner to manufacture the stator. By standardizing the mass productivity of the stator of the motor applied to the electric vehicle can be improved.

In addition, since the coil is first formed in the mold and then inserted into the slot of the stator core, the second forming is performed, thereby reducing the damage of the insulating layer during the forming of the coil and reducing the defective rate of the coil. The performance of the motor can be improved.

110: vehicle body 115: wheel
120: suspension 125: battery
130: inverter device 140: electric motor
141: enclosure 150: rotor
151: rotor core 155: magnet
157: rotating shaft 160: stator
161: Stator core 165: Slot
167: Teeth 170: stator winding
171: segment conductor (coil) 171a: conductor
171b: insulation layer 173,183: leg
175: connection section 190: insulating paper
200: twister

Claims (13)

Primary forming each of the intermediate portions of the coils by bending;
Inserting the primary formed coils into the slots of the stator;
Forming a secondary by bending both ends of the coils inserted into the slots of the stator; And
Connecting the both ends of the secondary-formed coils, respectively. The method of claim 1,
And the coil is formed by coating an insulating layer on the outer surface of the conductor before primary forming. 3. The method of claim 2,
A method of manufacturing a stator in which the primary foaming is performed by cutting a coil coated with an insulating layer on the conductor to a predetermined length. The method of claim 3,
In the first forming step, the middle portion of the coil is firstly bent in two dimensions, and the first bent coil is twisted in three dimensions so that both ends of the first bent coil are positioned in different layers. Manufacturing method of stator. The method of claim 1,
The coil is formed by first forming a conductor and then coating an insulating layer on an outer surface of the conductor. The method of claim 5,
And the coil is formed by cutting the conductor to a predetermined length and then performing primary forming. The method of claim 1,
A method for manufacturing a stator, wherein the coil is formed by performing primary forming with a mold. The method of claim 7, wherein
And the coil is formed by coating an insulating layer on an outer surface of a conductor primarily formed of a mold. The method of claim 1,
And inserting a plurality of coils into the slot after inserting the insulating paper into the coil or the slot before inserting the primary formed coil into the slot of the stator. The method of claim 1,
And inserting insulating paper between the coils before connecting both ends of the secondary formed coil. The method of claim 1,
After connecting both ends of the coil and the connected portion is a method of manufacturing a stator. Enclosure;
It is disposed inside the enclosure, and on the inner circumferential surface constituting the rotor accommodating space has a stator core alternately formed with a plurality of slots and teeth along the circumferential direction and a stator winding wound around the slot; A stator manufactured by the method of manufacturing a stator of any one of claims; And
And a rotor rotatably disposed with respect to the stator. Vehicle body;
A battery provided in the vehicle body; And
And an electric motor provided in the vehicle body and connected to the battery to provide a driving force to the vehicle body.

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