KR20180028767A - method for winding hairpin coil with cap and winding structure thereof - Google Patents

Abstract

The present invention relates to a method for winding a hairpin coil with a cap, and a winding structure thereof. The method comprises: a bare copper line preparing step of making a plurality of bare copper lines by unwinding a steel line from a bobbin winding the steel line without a coating layer to cut the steel line at predetermined length; a hairpin forming step of bending the bare copper line to form a hairpin which can be coupled to a stator core of a motor and has no coating layer; a mounting step of hanging a free end unit of the hairpin with a gripper to mount the hairpin on the gripper so that a bending unit of the hairpin is positioned at a downward position; a step of inserting the hairpin hung on the gripper into a coating tub containing an insulating liquid to form the coating layer on the surface of the hairpin except the free end unit with an insulating liquid component; and a step of coating metal powder having relatively higher conductivity than that of a body material of the hairpin on the free end unit of the hairpin without the coating layer after drying the coating layer.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a hairpin winding method having a cap,

The present invention relates to a hairpin winding method having a cap and a winding structure thereof, and more particularly, to a hairpin winding method having a cap and a capillary for manufacturing a high quality hairpin, A hairpin winding method and a winding structure thereof.

In accordance with the international requirements for greenhouse gas reduction regulation and automobile fuel economy improvement, research and development and practical use of environmentally friendly automobile parts are actively being carried out in the field of automobile industry.

As a part of eco-friendly automobile related parts, technologies are being developed that use electric motors to exert driving force. Especially, motor efficiency and motor productivity are required.

 Manufacturers and eco-friendly parts manufacturers apply a hairpin to a driving motor as part of the development of technology to reduce the weight and volume of eco-friendly parts in order to reduce the weight of the vehicle or eco-friendly car and secure the interior space.

The conventional hairpin applying drive motor according to the related art can increase the dropping rate of the motor for driving the vehicle and thus can be advantageous in terms of efficiency and power density but is extremely difficult to manufacture and maintain.

According to the method of manufacturing a driving motor for a hairpin applying method according to the related art, a coil or a round wire having a generally rectangular cross-section, unlike a general motor for winding a coil, can be inserted into a slot of a stator core Or formed into a hairpin. The prior art hair pin is inserted into the slot of the stator core in the motor axial direction. The end of the hairpin protruding out of the slot of the stator core is twisted to be physically contactable. The end twisted portion of the hairpin is electrically connected by welding, and then an additional insulating resin is applied to the welded portion.

That is, the conventional hairpin winding driving method of a conventional hairpin applying driving motor is a method of winding a hairpin end of a formed hairpin, a hairpin inserting process into a slot of a stator core, a process of inserting an insulating paper (For example, No. 108), a welding process for a twisted region, and an insulating resin application process. Therefore, the manufacturing method or the winding method itself is complicated and difficult.

Further, the conventional hairpin winding method has a disadvantage in that a process of additionally inserting a portion where the coil is welded and the peeled portion of the coated film after the welding is required is required.

For example, the applicant of the present invention has developed a technology for connecting a hair pin by a welding method through the respective copper wire winding method of a motor for a vehicle of Korean Patent Application No. 10-2015-0127176 after development of the disclosed technology as disclosed in the following patent documents There is one.

However, each of the copper wire winding method or the hairpin winding method of the prior art is disadvantageous in terms of the writing because the hairpin winding is often burned due to welding defect. That is, when the slots of the stator core are 54 slots, the number of times of welding must be 108 since four turns are made per slot. In addition, the part where the insulating film is lost by welding is further dried after insulation, and the process time is increased because the impregnation must be performed again.

Further, in the conventional hairpin winding method, inter-phase insulating paper is inserted into a part of the end coil to improve the insulation performance. Since the inter-phase insulating paper requires not only cutting of the insulating paper but also inserting it while fitting one side at the time of inserting, there is a difficult time and inserting. Therefore, there is a urgent need for a technology to maximize the quality of the hair- It is a situation that is required.

Korean Patent Publication No. 10-2016-0051408

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a process for removing a process related to a welding process and related parts (for example, a welding rod, an additional insulating resin material after welding, Which can reduce the investment cost and material cost due to the cap, and improve the coil insulation performance by the cap.

Another object of the present invention is to provide a cap having a conductor bar which is covered by a coil end portion of a hairpin and which can conduct electrically and externally insulation, thereby simplifying the manufacturing process of the motor by eliminating the welding process during the hairpin winding In addition, the present invention provides a hairpin winding structure having a cap capable of maximizing the quality of a hairpin product because the clip portion can strengthen the external vibration and simplify the process.

According to an aspect of the present invention, there is provided a method of winding a hairpin having a cap, the method including: removing a coil end portion of a hairpin for a motor formed to be installed in a plurality of slots of a stator core; Inserting a hairpin from which the coil ends have been removed into respective slots of a nose core; Twisting the coil ends of the hairpins passing through the slots of the stator core to come close to each other; And assembling a cap having a seating groove portion into which the one end of the one coil and the other end of the coil are inserted in the coil end portion of the coiled hairpin, have.

The step of peeling the coil end portion may include a step of peeling off the film from the one end of the coil and the end of the other coil in a direction in which the one end of the coil and the end of the other coil can face each other in the seating groove, And the other end of the coil is formed.

The step of assembling the cap includes inserting the one end coil end portion and the other end coil end portion of each of the film peeling portions into the seating recess portion formed on the bottom surface of the cap and electrically conducting through the film peeling portion.

Wherein the step of assembling the cap includes a step of inserting a conductor bar formed in the seating groove of the cap between the one end of the one coil and the end of the other coil inserted into the seating groove of the cap, The negative film peeling portion is brought into contact with the surface of the conductor bar so as to be energized.

The step of assembling the cap directly contacts the inner surface of the one coil end portion and the outer coil end portion of the cap inserted into the seating groove portion of the cap so as to be energizable in the seating groove portion of the cap.

Wherein the twisting step includes bending the end portions of the one coil and the other coil so that the film unwinding portions are closely contacted with each other so that one coil side slope portion and the other side coil slope portion of the hairpin, The first body bending portion and the second body bending portion corresponding to the lower side of the one side coil inclination portion and the other side coil inclining portion after the first bending are spaced apart from each other and parallel to each other Bend inward in relation to the second bending point.

According to another aspect of the present invention, there is provided a winding structure made by a hairpin winding method with a cap, wherein a coil end portion of a hairpin for a motor formed to be installed in each of a plurality of slots of a stator core is peeled off, The hairpin is inserted into each slot of the nose core and twisted so that the coil end portions of the hairpins passing through the slots of the stator core come close to each other and the cap is assembled to the end portions of the coils close to each other, Wherein the cap has a first coil end portion and a second coil end portion except for the film stripping portion and a second coil end portion except for the film stripping portion, A seating groove portion surrounding the surface of the portion; And an insulating body portion formed around the seating groove portion such that the seating groove portion is opened with respect to an insertion direction of the coil end portion.

The insulating body further includes an integral bulkhead formed of the same insulating material as the material of the insulating body between the seating recesses to isolate one or more seating recesses formed on the bottom surface of the insulating body from each other.

Wherein the seating groove portion is fixed to the ceiling face of the seating groove portion with respect to an intermediate position of the seating groove portion so as to be interposed between the one end coil end portion and the other coil end portion inserted in the seating groove portion, And a tapered surface is formed at a lower end of the conductive bar.

The seating groove portion may further include a clip portion formed on an inner wall surface of the seating groove portion so as to be coupled to a clip groove portion formed at the end portion of one coil and the end portion of the other coil.

The hairpin winding method and the winding structure of the cap with the cap according to the present invention can improve the performance by performing the hairpinning connection by the cap having the conductor bar corresponding to the holder including the conductor without welding, The contact resistance is reduced, the copper loss is reduced, and the efficiency can be improved.

In addition, the present invention has an advantage in that it can maximize the space utilization rate as well as improving the insulation performance because it covers the nose portion (for example, the coil end portion with the film removed) with the insulating material of the cap.

Further, the present invention further has a clip part, which has the advantage that the fastening force between the cap and the hairpin can be further improved.

In addition, from the viewpoint of improving the convenience, the present invention does not require a separate environment (for example, temperature and humidity) management for improving the welding quality and requires only general parts assembly environment, thereby providing relatively excellent manufacturing convenience.

In addition, the present invention is advantageous in that, in order to simplify the process, fixing for holding the two coil portions of the hairpin in order to perform the hairpin winding is eliminated, and fixing for inserting the insulating paper between phases is eliminated.

Further, the present invention has an advantage in that parts in accordance with existing welding processes such as a welding rod, an additional insulating resin material after welding, an inter-phase insulating paper and the like can be deleted from the viewpoint of reducing the number of parts.

In addition, the present invention has the effect of reducing the investment cost by eliminating the expensive special welding equipment from the viewpoint of the cost reduction, reducing the cost due to elimination of the insulating paper between phases and reducing the coil stripping length for welding (for example, There is an advantage that the hairpin raw material can be efficiently used.

Further, the present invention corresponds to a method of assembling between a cap and a hairpin in terms of environmental friendliness, thereby solving the problem that the gas generated during welding contaminates the environment inside the workplace.

Further, in another aspect of the present invention, it is possible to reduce the end coil height by eliminating the length of the coil end portion which is peeled off for welding, and the commercialization and quality of the hairpin application drive motor There is an advantage that improvement can be realized.

1 is a flow diagram of a hairpin winding method with a cap according to an embodiment of the present invention;
FIG. 2 is a perspective view of a winding structure produced by the method shown in FIG. 1; FIG.
Fig. 3 is a perspective view of the hairpin wiring cap shown in Fig. 2; Fig.
FIG. 4 is a cross-sectional view illustrating a state where a hairpin is coupled to a cap cut along a line AA in FIG. 3;
5 is a cross-sectional view showing an application example of the hairpin wiring cap shown in Fig.
Fig. 6 is a cross-sectional view showing another application example of the hairpin wiring cap shown in Fig. 3; Fig.
7 is an exploded cross-sectional view showing another application example of the hairpin wiring cap shown in Fig.
8 is a cross-sectional view showing a state where the hairpin and the cap shown in Fig. 7 are coupled to each other.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention, and the manner of achieving them, will be apparent from and elucidated with reference to the embodiments described hereinafter in conjunction with the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. And is provided to fully illustrate the scope of the invention to those skilled in the art, and the invention is defined by the claims. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. In the present specification, the singular form includes plural forms unless otherwise specified in the specification. It is noted that " comprises, " or "comprising," as used herein, means the presence or absence of one or more other components, steps, operations, and / Do not exclude the addition.

In the description of the present embodiment and claims, the hairpin refers to a hairpin coil or a hairpin conductor that is wrapped with a coating of an insulating material on all surfaces except for a film peeling portion, which may be abbreviated as a hairpin for ease of explanation.

In the following description, according to the stator core for a motor, a plurality of stator core slots (hereinafter abbreviated as 'slots') are formed along the circumferential direction of the stator core, and two slots The hair pin can be coupled in an insertion manner corresponding to a predetermined motor winding arrangement standard.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a flow chart of a hairpin winding method with a cap according to an embodiment of the present invention.

Referring to Fig. 1, a hairpin winding method with a cap according to the present embodiment discloses a series of methods for connecting a hairpin to a slot of a stator core and electrically connecting the hairpin to the stator core.

That is, the method of the present embodiment includes a step S110 of removing the coil end portion of the formed hairpin for a motor so as to be respectively installed in a plurality of slots of the stator core.

Here, the step of removing the end portion of the coil (S110) refers to a process of forming the skin strips (13, 14) on the coil end portions (11, 12) as shown in FIG.

That is, the skin removing skins 13 and 14 are areas including both the end surfaces of the coil end portions 11 and 12 and the side surfaces bounding the end surface of the coil end portions 11 and 12, May refer to an area corresponding to a part of the surfaces of the coil end portions 11 and 12 facing each other in the seating groove portion 110 of the rotor. At this time, the exfoliation area of the film removing skins 13 and 14 is set such that at least the film removing skins 13 and 14 are disposed in the accommodating space inside the seating groove 110 of the cap 100 and can not be exposed to the outside And can be determined within the numerical range of the degree of

Further, in the subsequent step, a step S120 of inserting the hairpin from which the coil end is molten into each slot of the core core is performed.

7 or 8, between the step S110 of removing the coil end portion and the step S120 of inserting the coil into the slot, a step of forming a clip groove at the end of the coil (S115) may be further included.

After the inserting step S120, a step S130 of twisting the coil end portions of the hairpin passing through the slots of the stator core to come close to each other and a step S140 of assembling the caps to the coil end portions may be performed .

The step (S130) of twisting is performed by a general hairpin twisting device, which means that the coil end portion and the portion connected to the hairpin are deformed such that they are twisted, and that the coil end portions are bent or closely contacted with each other. That is, the coil end portions 11 and 12 of the hairpin 10 before the twisting shown in FIG. 2 and the lower portion connected thereto are twisted (S130) And can be machined to have a protruded and twisted shape Q above the slot 2.

According to the step S140 of assembling the cap to the end of the coil, the cap is formed with a seating groove portion for physically and electrically connecting the coil ends adjacent to each other.

One hairpin is formed with two coil end portions extending in two bifurcations with respect to the U-shaped bent portion, that is, one end coil end portion and the other end end portion.

As described later in detail, the seating groove portion of the cap is positioned at a position where one end of the coil and the other end of the coil are inserted into a pair of coil end portions of the hairpin removed by the step S110 of removing the coil end portion, And may refer to a groove-like structure corresponding to the position.

2 is a perspective view showing a winding structure manufactured by the method shown in FIG.

2, the winding structure of the present embodiment includes a coil end portion 11 of a hairpin 10 for a motor that is formed so as to be installed in each of a plurality of slots 2 of the stator core 1 as mentioned above And the hairpin 10 from which the coil end portions 11 and 12 have been removed is inserted into each slot 2 of the core block 1 and the slot 10 of the stator core 1 12 of the hairpin 10 which has passed through the coil ends 2 and 2 are brought close to each other and the cap 100 is assembled to the coil end portions 11 and 12 close to each other Made, or manufactured.

The cap 100 can be fixed to the coil end portions 11 and 12 of the hair pin 10 by frictional force. The cap 100 may be prevented from separating from the coil end portions 11 and 12 because the cap 100 can be supported by frictional force or a cover or an inner insulating part of the motor not shown.

Since the hairpin 10 is connected using the cap 100, the connection process by welding is not necessary, and all the problems related to the welding mentioned above can be solved.

The plurality of caps 100 may be manufactured as many as the number of the slots 2. Each cap 100 may be manufactured by injection molding using a homogeneous plastic insulating material or by dual injection molding using different materials (e.g., plastic and metal).

Here, according to the use position of the transfer material, a metal (for example, a conductor bar) is used only in a region where energization is required, and only plastic, which is an insulating material, is used at locations where the energization is not performed . At least the insulating material or the insulating material may be any material selected from a group of synthetic resins or polymers having excellent molding properties, durability and electrical insulation properties as an electrical article.

FIG. 3 is a perspective view of the cap for wiring the hairpin shown in FIG. 2, and FIG. 4 is a cross-sectional view for explaining a state where the cap is cut along the line A-A of FIG. 3.

Referring to FIGS. 3 and 4, the cap 100 includes a seating groove 110 and an insulating body 120.

The seating groove portion 110 is opened downward from the bottom surface of the cap 100, that is, the bottom surface of the insulating body portion 120.

The seating grooves 110 may be provided in one or a plurality (for example, two).

The seat groove 110 is formed in a space between the coil end portions 11 and 12 of the pair of coil end portions 11 and 12 of the removed hair pin 10 and the skin strips 13 and 14 of the other coil end portions 12, And covers the surfaces of one coil end portion 11 and the other coil end portion 12 except for the skin strips 13 and 14 so as to be electrically energized. The skin removing skins 13 and 14 may refer to a part of the hair pin 100 through which electrical conduction is performed through step S110 of removing the coil end portion where machining is performed.

The cap 100 is capable of some elastic deformation due to its material properties.

Therefore, the seating groove 110 formed in the cap 100 is not loosely coupled to the one-end coil end 11 and the other-end coil end 12 with the restoring force of the elastic deformation together with the cap 100, So as to realize a coupling capable of generating a force as a function of overlap. That is, the numerical values of the volume and shape standard of the seating groove portion 110 show the adhesion force in a state in which the one-end coil end portion 11 and the other-end coil end portion 12 are inserted, And can be appropriately determined within a range.

The insulating body 120 is formed in a shape such that the seating groove 110 opens on the basis of the insertion direction of the coil end portions 11 and 12 (for example, the downward direction from the bottom surface of the cap 100) Respectively. The material of the insulating body 120 may be the same as the insulating material or insulating material of the cap 100 mentioned above.

At this time, since the motor winding standard to be used in this embodiment uses two hair pins for four-turn winding per slot, one or more (e.g., two seating grooves 110) are formed on the bottom surface of the insulating body portion 120 .

At this time, the insulation body portion 120 is formed with an integral type of partition wall 130 (see FIG. 1) formed of the same insulating material as the material of the insulation body portion 120 between the seating recess portions 110 so as to isolate the two seating recess portions 110 from each other ) May be formed.

Since the height of the barrier ribs 130 is the same as the height of the barrier ribs 121 forming the outer edges of the caps 100 of the insulation body 120, Of the bottom surface of the base plate.

Each of the seating grooves 110 according to the present embodiment further includes a conductor bar 140. The conductor bar 140 is a metal part made of a conductor such as a bus bar or the like and a part of the conductor bar 140 can be integrally incorporated into the seating groove part 110 and the other part of the conductor bar 140 is seated May protrude toward the receiving space for the coil end portions (11, 12) of the groove portion (110).

Here, the conductor bar 140 is disposed at a position corresponding to the intermediate position of the seating groove 110 so as to be interposed between the one end coil 11 and the other coil end 12 inserted in the seating groove 110 And is fixed to the ceiling surface of the seating groove portion 110 and extends along the groove opening direction of the seating groove portion 110.

The tapered surface 141 or the inclined surface for the insertion guide is formed at the lower end of the conductor bar 140 so that the conductor bar 140 can be easily inserted between the one coil end 11 and the other coil end 12, It is possible to physically connect the coil end portions 11 and the coil end portions 12 of the other coil end portions 13 and 14 physically or in contact with each other or electrically connect the coil end portions 11 and 14 during the insertion process.

The conductive bar 140 is longer than the height of the partition wall 130 or the edge wall 121 and is formed to have a protruded height H greater than the bottom surface of the cap 100.

That is, when the cap 100 is moved toward the coil end portions 11 and 12 of the hairpin 10 in order to assemble the cap 100, the lower end portion of the conductive bar 140 having the tapered surface 141, The cap 100 and the hair pin 10 can be more smoothly assembled by contacting the coil ends 11 and 12 before the coil 100 and dividing the spaces between the coil ends 11 and 12. [ .

5 is a cross-sectional view showing an application example of the hairpin wiring cap shown in FIG.

In the cap 100a according to the application example, the seating groove portion 110, the insulating body portion 120, and the partition 130 are formed without the conductor bar described above.

According to this application example, the size of the cap 100a can be relatively reduced, and the motor can be made to be relatively lightweight.

1 and 5, the step S110 of removing the coil end portions 11 and 12 may be performed such that the one coil end portion 11 and the other coil end portion 12 are separated from the seating groove portion 110, (13, 14) capable of causing electrical conduction are formed on the one-end coil end portion (11) and the other-end coil end portion (12), respectively, It can refer to the processing process.

The step S140 of assembling the caps 100 and 100a is carried out in such a manner that the one end coil end 11 and the other end coil end 12 of the cap 100 100a may be inserted into the seating groove 110 formed on the bottom of the conductive bars 140a and 100a and electrically connected to the conductive bars 140 or the skin strips 13 and 14. [

4, the conductive bar 140 formed in the seating groove 110 of the cap 100 may be inserted into the seating groove of the cap 100 (step S140) 110 between the one end coil 11 and the other end 12 of the other coil.

Accordingly, the uncoated skins 13, 14 of the one end coil 11 and the other end 12 of the coil can be brought into contact with the surface of the conductive bar 140 in a conductive manner.

5, according to the step S140 of assembling the cap 100a according to the application example, the one-side coil end portion 11 and the other-side coil end portion 12 of the hairpin 10 are inserted into the seating groove portion The skin removing skins 13 and 14 of the one coil end 11 and the other coil end 12 of the coil 100a are inserted into the seating groove 110 of the cap 100a, Can be contacted.

Here, since the surface of the hairpin 10 except for the film strips 13 and 14 is formed of the insulating film formed at the time of coil fabrication, the mutual contact between the insulating films, i.e., the surfaces of the hairpins 10, It may not be electrically connected.

5, the current flowing through the hairpin 10 is applied to the skin removing skins 13 and 14 of each hairpin 10 which are in close contact with each other by the cap 100a So that it can be energized.

6 is a cross-sectional view showing another application example of the hairpin wiring cap shown in FIG.

6, the cap 100b according to another application example is designed to perform energization by direct contact between the skin strips 13, 14 of the coil end portions 11, 12 of the respective hair pins 10 The sectional shapes of the partition wall 130a and the rim wall 121a of the cap 100b are formed so as to correspond to the coil end portions 11 and 12 corresponding to the bent shapes of the coil end portions 11 and 12, So that it can be hermetically contacted with the bent vertical surface or the inclined surface of the light guide plate.

That is, referring to FIGS. 1 and 6, the twisting step 130 may further include the following detailed bending process.

For example, the twisting step 130 firstly bends the one end coil 11 and the other end end 12 of the coil so that the film strips 13 and 14 come in close contact with each other.

At this time, in the twisting step 130, the one-side coil inclined portion 15 and the other-side coil inclined portion 16 of the hairpin 10 corresponding to the lower portion of the film strip 13, Bending in the outward direction with respect to the bending point 17 is included.

In the twisting step 130, after the first bending, one body portion 18 of the hair pin 10 corresponding to the one side coil inclined portion 15 and the lower side of the other side coil inclined portion 16, The bending process is performed in an inner direction (e.g., a direction in which one body portion 18 and the other body portion 19 are brought closer to each other) with respect to the secondary bending point 20 so that the body portions 19 are spaced apart from each other .

Therefore, the one-side coil end portion 11 and the other-side coil end portion 12 of the hairpin 10 to be connected to each other can be energized by direct contact of the skin 13, 14, It is possible to achieve a state in which they are separated from each other by the bending one side coil inclined portion 15 and the other side coil inclined portion 16 or the one side body portion 18 and the other side body portion 19 spaced from each other, The posture degree of the hair pin 10 in the slot of the stator core can be facilitated.

FIG. 7 is an exploded cross-sectional view showing another application example of the hairpin wiring cap shown in FIG. 3, and FIG. 8 is a cross-sectional view showing a state where the hairpin and cap shown in FIG.

Referring to FIGS. 7 and 8, the cap 100c according to another application provides a seating groove portion 110 having a pair of clip portions 150. FIG.

Each of the seating grooves 110 has a clip part 150 formed on the inner wall surface of the seating groove part 110 so as to be fastened to the clip groove part 30 formed on one coil end part 11 and the other coil end part 12, ).

One end of the clip unit 150 can be fixed to the inner wall surface of the seat unit 110 through the double injection while the clip unit 150 is inclined and the other end of the clip unit 150 is elastically deformed It is a free end that can act as a restoring force.

A recess portion 122 is formed on the inner wall surface of the seating groove portion 110 on the basis of the periphery of the other end portion of the free end clip portion 150 so as to secure an elastic clearance, Can be guaranteed.

In addition, a clip groove portion 30 is formed by grooving on the positions of the one coil end portion 11 and the other coil end portion 12 facing the climbing portion 150. The clip groove portion 30 functions as a fixing jaw for receiving the other end portion of the clip portion 150.

Therefore, when the pair of one-side coil end portions 11 and the other-side coil end portions 12 are inserted into the seating groove portion 110, the other end of the clip portion 150 is elastically fastened to the clip groove portion 30 So that the connection state of the cap 100c and the hair pin 10 can be more firmly and stably maintained.

The cap 100c may also include the partition 130 or the conductor bar 140 described above. In this case, as described above, the one end coil 11 and the other coil end end The cap 100c may be formed in the shape described above so that the connection between the cap 100c and the cap 12c can be performed. The deformed shape of the cap 100c can be directly connected to the one coil end portion 11 and the other coil end portions 12 without the conductor bar 140 while the clip portion 150 is provided .

The foregoing description is merely illustrative of the technical idea of the present invention and various changes and modifications may be made without departing from the essential characteristics of the present invention. Therefore, the embodiments described in the present invention are not intended to limit the scope of the present invention, but are intended to be illustrative, and the scope of the present invention is not limited by these embodiments. The scope of protection of the present invention should be construed according to the following claims, and all technical ideas which are equivalent or equivalent thereto should be interpreted as being included in the scope of the present invention.

10: hairpin 11, 12: coil end
13, 14: skin depression 30: clip groove
100, 100a, 100b, 100c: cap 110:
120: insulated body part 130: partition wall
140: conductor bar 150: clip portion

Claims (10)

Removing a coil end portion of the formed hairpin for a motor so as to be installed in a plurality of slots of the stator core;
Inserting a hairpin from which the coil ends have been removed into respective slots of a nose core;
Twisting the coil ends of the hairpins passing through the slots of the stator core to come close to each other; And
And assembling a cap having a seating groove portion into which the end portions of one coil and the other end of the coil are inserted in a coil end portion of the coiled hairpin, which are separated from each other,
A hairpin winding method with an in cap.
The method according to claim 1,
Wherein the step of removing the coil end portion comprises:
A film peeling portion capable of causing electrical conduction is formed in the one end of the one coil and the other end of the other coil in reference to a direction in which the one end of the coil and the end of the other end of the other coil are opposed to each other in the seating groove that
A hairpin winding method with an in cap.
The method according to claim 1,
The step of assembling the cap includes:
Wherein the one coil end portion and the other coil end portion each having the film peeling portion are inserted into the seating groove portion formed on the bottom surface of the cap and electrically energized through the film peeling portion
A hairpin winding method with an in cap.
The method of claim 3,
The step of assembling the cap includes:
A conductor bar formed in the seating groove of the cap is interposed between the end of the one coil and the end of the other coil inserted into the seating groove of the cap,
Wherein the one-sided coil end portion and the non-coating portion of the other-side coil end portion are brought into contact with the surface of the conductor bar so as to be energizable
A hairpin winding method with an in cap.
The method of claim 3,
The step of assembling the cap includes:
Wherein the uncoated portions of the one end coil and the other end coil of the one coil inserted into the seating groove of the cap are in direct contact with each other so as to be energized in the seating groove of the cap
A hairpin winding method with an in cap.
6. The method of claim 5,
Wherein the twisting comprises:
The one end of the one coil and the end of the other coil are bent so that the film stripping portion is in close contact with each other,
Bending one of the side coil inclination portions and the other side coil inclination portions of the hairpin corresponding to the lower portion of the film detachment portion in the outward direction with respect to the first bending point,
After the first bending, bending in the inward direction with respect to the secondary bending point such that one body portion and the other body portion of the hairpin corresponding to the one side coil inclined portion and the other side coil inclined portion are spaced apart from each other and arranged in parallel
A hairpin winding method with an in cap.
The hairpin of the formed hairpin is peeled off so as to be installed in a plurality of slots of the stator core, the hairpin from which the end of the coil is removed is inserted into each slot of the core core, A winding structure made by twisting a coil end portion of a hairpin to come close to each other and assembling a cap at an end portion of the coil close to each other,
The cap
And the other end of the one coil and the other end of the other coil are electrically connected to each other in the coil end portions of the separated hairpins, ; And
And an insulating body portion formed around the seating groove portion such that the seating groove portion is opened with respect to an insertion direction of the coil end portion
A winding structure made by a hairpin winding method with an in cap.
8. The method of claim 7,
Wherein the insulating body portion comprises:
And an integral bulkhead formed of the same insulating material as the material of the insulating body part between the seating recesses so as to isolate one or more seating recesses formed on the bottom surface of the insulating body part from each other
A winding structure made by a hairpin winding method with an in cap.
9. The method of claim 8,
The seating groove portion,
And is fixed to the ceiling surface of the seating groove portion and extends along the groove opening direction of the seating groove portion with reference to an intermediate position of the seating groove portion interposed between the one end coil end portion and the other coil end portion inserted in the seating groove portion Further comprising a conductor bar,
And a tapered surface is formed at the lower end of the conductor bar
A winding structure made by a hairpin winding method with an in cap.
10. The method of claim 9,
The seating groove portion,
And a clip portion formed on an inner wall surface of the seating groove portion so as to be fastened to a clip groove portion formed in the one end coil portion and the other coil end portion
A winding structure made by a hairpin winding method with an in cap.

Images