WO2010131319A1

WO2010131319A1 - Method for manufacturing stator, and stator

Info

Publication number: WO2010131319A1
Application number: PCT/JP2009/058751
Authority: WO
Inventors: 三元井ノ口
Original assignee: トヨタ自動車株式会社
Priority date: 2009-05-11
Filing date: 2009-05-11
Publication date: 2010-11-18
Also published as: JP5093362B2; JPWO2010131319A1

Abstract

Provided is a method for manufacturing a stator wherein heat generated in a coil can be radiated efficiently to a stator core, and thermal energy required for molding an insulator can be used effectively. A method for manufacturing a stator having a split stator equipped with a split core (16), an insulator (15), and an edgewise coil (11) of a concentrated winding coil comprises a molding step of molding the insulator (15) by inserting the edgewise coil (11), and a shrink fitting step of shrink fitting the edgewise coil (11), in which the insulator (15) is molded, to a tooth portion (16a) of the split core (16) by attaching the edgewise coil (11), in which the insulator (15) is molded, to a tooth portion (16a) of the split core (16), while keeping the edgewise coil (11) at a predetermined temperature (at 150°C in the embodiment) or more and then cooling the edgewise coil (11).

Description

Stator manufacturing method and stator

The present invention relates to a stator manufacturing method for manufacturing a stator having a split stator including a split core, an insulator, and a concentrated winding coil.

The present applicants have proposed a method of manufacturing a split stator in Patent Documents 1 and 2. That is, an insulator having a thickness of 0.2 to 0.3 mm is formed on the tooth portion of the split core. Next, an edgewise coil is mounted on the insulator. Resin molding is performed by inserting the split core on which the edgewise coil is mounted via the insulator. Thereby, a split stator can be manufactured.
According to this manufacturing method, since the resin mold enters the gap between the edgewise coils, a stator excellent in heat dissipation can be manufactured.

JP 2009-072055 A JP 2008-160938 A

However, the techniques of Patent Documents 1 and 2 have the following problems.
(1) When an edgewise coil is mounted on an insulator, a gap is formed between the insulator and the edgewise coil. Since this gap is small, when resin molding is performed, the resin cannot enter and an air layer is formed. When used as a stator, heat is generated in the edgewise coil. The generated heat is released to the core through the insulator. However, if an air layer exists between the insulator and the edgewise coil, there is a problem that the efficiency of heat transfer is significantly deteriorated.
(2) Further, since the resin is heated and cooled to mold the insulator, the heated energy is discarded as it is, and there is a problem that it cannot contribute to energy saving and carbon dioxide reduction.

The present invention is for solving the above-described problems, and can efficiently dissipate heat generated in the coil to the stator core, and can effectively use the heat energy necessary to mold the insulator. An object of the present invention is to provide a stator manufacturing method that can be used.

In order to achieve the above object, a stator manufacturing method according to an aspect of the present invention has the following configuration.
(1) In a stator manufacturing method for manufacturing a stator having a split stator including a split core, an insulator, and a concentrated winding coil, a molding step for forming the insulator by inserting the concentrated winding coil, and the insulator While the formed concentrated winding coil is kept at a predetermined temperature or more, it is attached to the teeth portion of the split core and cooled, whereby a shrink fitting process for shrink fitting the concentrated winding coil formed with the insulator into the teeth portion, Have.
(2) In the stator manufacturing method described in (1), it is preferable that the insulator is formed only at a location where the coil faces the split core.
(3) In the stator manufacturing method described in (1), it is preferable that the insulator is formed to cover the entire circumference of the coil.
(4) In the stator manufacturing method described in (3), it is preferable that a gap is formed between the outer peripheral surface of the insulator and the insulator outer peripheral surface of the split core adjacent to the split core.

(5) In any one of the stator manufacturing methods described in (1) to (4), the concentrated winding coil is an edgewise coil, and a positioning mechanism that positions the edgewise coil in a molding die It is preferable to have.
(6) In the stator manufacturing method described in (5), it is preferable that the positioning mechanism is a convex portion formed by inserting an edgewise coil in advance.
(7) Preferably, the stator is manufactured by any one of the stator manufacturing methods described in (1) to (6).

Next, the stator manufacturing method having the above-described configuration, and the operation and effect of the stator will be described.
(1) In a stator manufacturing method for manufacturing a stator having a split stator including a split core, an insulator, and a concentrated winding coil, a molding step for forming the insulator by inserting the concentrated winding coil, and the insulator While the formed concentrated winding coil is kept at a predetermined temperature or more, it is attached to the teeth portion of the split core and cooled, whereby a shrink fitting process for shrink fitting the concentrated winding coil formed with the insulator into the teeth portion, Have.
When the insulator is molded by inserting the coil into the cavity, the insulator and the coil are heated to a temperature of 150 ° C. or higher. The coil with the insulator formed on the inner peripheral surface or the like is still at a predetermined temperature (for example, 150 ° C.) or more, that is, immediately after the insulator is formed, it is attached to the tooth portion of the split core, and the split core is used as cold metal. Since the insulator and the coil are cooled, the insulator and the coil are cooled and contracted, so that the insulator and the coil are shrink-fitted to the teeth portion of the split core. Thereby, the clearance gap (existence of an air layer) between an insulator and a teeth part can be almost eliminated. In addition, since the heat energy used to form the insulator can be used as it is in the shrink-fitting process of the insulator and the coil, it can contribute to energy saving and carbon dioxide reduction.

(2) In the stator manufacturing method described in (1), since the insulator is formed only at a location where the coil faces the split core, the insulator is formed into a coil, and the remaining heat immediately after the molding Thus, the coil can be shrink-fitted into the split core.
(3) In the stator manufacturing method described in (1), the insulator is formed so as to cover the entire circumference of the coil. Therefore, the insulator includes an insulator and a resin mold of Patent Document 1. Therefore, the resin molding step can be omitted and the production efficiency can be improved.
(4) In the stator manufacturing method described in (3), a gap is formed between the outer peripheral surface of the insulator and the outer peripheral surface of the insulator of the split core adjacent to the split core. When the cooling oil is applied to the stator and used in the hybrid vehicle, the cooling oil enters the gap and the coil can be further cooled.

(5) In the stator manufacturing method described in (1), the concentrated winding coil is an edgewise coil, and has a positioning mechanism for positioning the edgewise coil in a molding die. The insulator can be formed with a predetermined thickness on the inner peripheral surface of the edgewise coil. The insulator formed on the inner peripheral surface of the edgewise coil has a thickness of about 0.2 to 0.3 mm. This is because sufficient insulation can be secured with such a thickness, and by reducing the thickness, the efficiency of heat transfer from the coil to the core is increased. However, the thickness of the insulator needs to be surely ensured to be 0.2 mm, and therefore a positioning mechanism is required.

(6) In the stator manufacturing method described in (5), since the positioning mechanism is a convex portion formed by inserting an edgewise coil in advance, the edgewise coil is inserted. By performing the pre-molding, a convex portion can be formed at a necessary portion of the edgewise coil. When the edgewise coil in which the convex portion is formed is inserted into the insulator molding die, the convex portion comes into contact with the inner surface of the die and is positioned. By forming in this state, the thickness of the insulator formed on the inner peripheral surface of the edgewise coil can be made constant. Here, since the convex portion is formed of the same material as the insulator, the convex portion also constitutes a part of the insulator.

It is sectional drawing which shows the upper mold | type of 1st Example, a lower mold | type, and the edgewise coil to insert. In FIG. 1, it is a figure which shows the state which inserted the edgewise coil. In FIG. 2, it is a figure which shows the state which closed the upper mold | type. In FIG. 3, it is a figure which shows the state which inject | emitted resin and shape | molded the insulator. It is a figure which shows the relationship between the edgewise coil immediately after shape | molding an insulator, and a division | segmentation core. It is a figure which shows the state which mounted | wore the tooth part of a split core with the edgewise coil immediately after shape | molding an insulator. It is a perspective view of an edgewise coil. It is a perspective view of a stator assembly. It is a figure which shows the edgewise coil in which the positioning convex part of 2nd Example was formed. It is sectional drawing explaining the method to shape | mold the positioning convex part of 2nd Example. It is a figure which shows the state which inserted the edgewise coil in which the positioning convex part of FIG. 9 was formed in the lower mold | type, and closed the upper mold | type. In FIG. 11, it is a figure which shows the state which inject | emitted resin and shape | molded the insulator. It is a figure which shows the relationship between the edgewise coil immediately after shape | molding an insulator, and a division | segmentation core. It is a figure which shows the state which mounted | wore the tooth part of a split core with the edgewise coil immediately after shape | molding an insulator. It is sectional drawing which shows the edgewise coil in which the insulator with which the adjacent teeth part of 3rd Example was mounted | worn was formed.

Hereinafter, a stator manufacturing method according to an embodiment of the present invention will be described in detail with reference to the drawings. 1 to 4 show a process of forming an insulator by inserting an edgewise coil into a mold. FIG. 7 is a perspective view of the edgewise coil 11. The edgewise coil 11 has a rectangular cross section with a thickness of 1 to 2 mm and a width of 8 to 10 mm, and a conductive wire having an enamel layer formed on the outer periphery is wound into a rectangular shape, and the length of the short side of the rectangle is sequentially changed. Thus, the entire cross section is formed into a trapezoidal shape.

Terminal portions

11 a and 11 b protrude from the edgewise coil 11.
In FIG. 3, a cavity 14 is constituted by a lower mold 12 that is a fixed mold and an upper mold 13 that is a movable mold. The edgewise coil 11 is inserted into the cavity 14. Although not shown in FIG. 3, the

terminal portions

11 a and 11 b of the edgewise coil 11 shown in FIG. 7 are sandwiched by stepped portions formed on the upper and

lower molds

12 and 13 and protrude out of the cavity 14. Yes. As shown in FIGS. 3 and 4, the lower mold 12 is formed with an injection port 12 a for injecting the resin F.

As shown in FIG. 2, when the edgewise coil 11 is inserted into the lower mold 12, the inner surface 14 a of the cavity 14 comes into contact with the outer peripheral surface 11 c of the edgewise coil 11. Is positioned. In this state, the upper mold 13 is lowered to a position where it comes into contact with the lower mold 12. The state is shown in FIG.
As shown in FIG. 3, a cavity space 14 b for forming the insulator 15 exists on the inner peripheral surface of the edgewise coil 11. Further, a cavity space 14 c exists on the upper end surface of the edgewise coil 11. A cavity space 14 d exists on the lower end face of the edgewise coil 11. A cavity 14 is configured by the

cavity spaces

14b, 14c, and 14d. The injection port 12a communicates with the cavity space 14d through the distribution flow path 12b.

FIG. 4 shows a state in which the resin F for molding the insulator 15 is injected. The resin is a thermoplastic resin and is heated to 150 ° C. or more and melted. The insulator 15 includes a cylindrical portion 15a, a core side portion 15b formed at one end of the cylindrical portion 15a on the divided core main body side, and a teeth tip side portion 15c formed at the other end side of the cylindrical portion 15a. Yes.
The cylindrical portion 15 a is a portion that covers the cylindrical inner surface of the edgewise coil 11. The core side part 15b is a part facing the core main body inner peripheral surface 16b which is an inner peripheral surface other than the teeth part 16a of the split core 16 shown in FIG. The teeth tip side portion 15 c is for holding the edgewise coil 11.

FIG. 5 shows a coil assembly 17 in a state where the edgewise coil 11 is inserted and the insulator 15 is formed. As shown in FIG. 5, the width of the base of the teeth portion is A = 20.000 mm. Further, the inner surface width of the insulator 15 of the coil assembly 17 is set to B = 20−0.013 mm. Both are dimensions at room temperature.
The division | segmentation core 16 is comprised from the laminated steel plate, and is iron. The linear expansion coefficient of iron is 12 * 10 ⁻⁶ . The edgewise coil 11 is made of copper, and the insulator is made of resin. The linear expansion coefficient of copper and insulator resin is 17 * 10 ⁻⁶ .
In FIG. 2, the split core 16 is at room temperature and A = 20 mm. The temperature of the edgewise coil 11 and the insulator 15 is about 150 ° C. because it is just after being taken out of the mold. Therefore, the insulator inner surface width of the coil assembly 17 is thermally expanded, and B = 20 mm.

Thereby, the coil assembly 17 is inserted to the base of the tooth portion 16a of the split core 16, that is, to the position where the outer surface of the core side portion 15b of the insulator 15 is in contact with the core body inner peripheral surface 16b of the split core 16. Can do.
In this state, by cooling the coil assembly 17 to room temperature, B is reduced by 0.013 mm to B = 19.987 mm. As a result, shrink fitting with a tightening margin of 0.013 mm is performed. The state at room temperature is shown in FIG.
The insulator 15 and the edgewise coil 11 are shrink-fitted into the tooth portion 16a, thereby eliminating an air layer existing between the inner peripheral surface of the cylindrical portion 15a of the insulator 15 and the outer peripheral surface of the tooth portion 16a. be able to.
From the state of FIG. 6, the outer side of the edgewise coil 11 is resin-molded to complete the split stator, 18 split stators are arranged in an annular shape, and the shrink fit ring 19 is shrink fit. As shown in FIG. 8, the stator assembly 20 is completed. A stator is completed by attaching a bus bar to the stator assembly 20 and wiring and connecting the terminals of the three phases.

As described above in detail, according to the stator manufacturing method of the present embodiment, a stator having a split stator including the split core 16, the insulator 15, and the edgewise coil 11 that is a concentrated winding coil. In the stator manufacturing method to be manufactured, the edgewise coil 11 is inserted and the insulator 15 is molded, and the edgewise coil 11 on which the insulator 15 is molded has a predetermined temperature (150 ° C. in this embodiment) or higher. The edgewise coil has a shrink fitting process in which the edgewise coil 11 in which the insulator 15 is molded is shrink-fitted into the teeth portion 16a by being mounted on the teeth portion 16a of the split core 16 and being cooled. 11 is inserted into the cavity 14 and the insulator 15 is molded. Shureta 15 and the coil 11 are heated to a temperature of at least 0.99 ° C.. The edgewise coil 11 with the insulator 15 formed on the inner peripheral surface or the like is mounted on the tooth portion 16a of the split core 16 in a state where the temperature is still higher than a predetermined temperature (150 ° C. in this embodiment), that is, immediately after the insulator is formed. Then, the insulator 15 and the edgewise coil 11 are cooled by using the split core 16 as a cold gold. Therefore, since the insulator 15 and the edgewise coil 11 are cooled and contracted, the insulator 15 and the edgewise coil 11 are Then, it is shrink-fitted into the teeth portion 16a of the split core 16. Thereby, the clearance gap (presence of an air layer) between the insulator 15 and the teeth part 16a can be almost eliminated. And the thermal radiation characteristic of a stator can be improved.
Further, since the heat energy used for forming the insulator 15 can be used as it is in the shrink-fitting process of the insulator 15 and the edgewise coil 11, it can contribute to energy saving and carbon dioxide reduction.
Further, since the insulator 15 is formed only at a position where the edgewise coil 11 is opposed to the split core 16, the insulator 15 is formed into the edgewise coil 11, and the edgewise coil is formed by the residual heat immediately after the molding. 11 can be shrink-fitted to the split core 16.

Next, a second embodiment of the present invention will be described.
FIG. 9 shows a state in which four positioning convex portions 21 are formed on the outer periphery of the edgewise coil 11 before the main forming. FIG. 10 shows a method for forming the product in the state shown in FIG. FIG. 10 shows a cross-sectional view of a lower mold 22 that is a fixed mold in which the edgewise coil 11 is inserted, and an upper mold 23 that is a movable mold. The cross section shows a lower mold 22 and an upper mold 23 corresponding to the AA cross section in FIG.
A flow path 24 through which resin passes is formed in the lower mold 22. The flow path 24 is connected to a nozzle 25 for supplying resin. FIG. 9 shows a state where the resin is injected and the positioning convex portions 21 are formed at four locations. As a result, the one shown in FIG. 9 is obtained. This is a preliminary process before the main molding.

Next, the main forming process will be described. FIG. 11 shows a state in which the edgewise coil 11 formed with the positioning convex portion 21 shown in FIG. 9 is inserted into the cavity 28 of the lower mold 26 which is a fixed mold, and the upper mold 27 which is a movable mold is closed. Indicates. A resin flow path 33 is formed in the lower mold 26.
As shown in FIG. 11, the edgewise coil 11 is positioned with four positioning convex portions 21 in contact with the inner peripheral surface of the cavity 28 of the lower mold 26. The edgewise coil 11 is in contact with the lower die 26 and the upper die 27 only through the four positioning convex portions 21, and the other portions are in a state of floating in the cavity 28. Since the inner surface of the cavity 28 of the lower mold 26 becomes narrower as it goes down, the edgewise coil 11 is positioned by the four positioning protrusions 21.
A cavity 28 a is formed on the upper surface side of the edgewise coil 11 in the drawing, a cavity 28 b is formed on the left side, a cavity 28 c is formed on the lower side, and a cavity is formed on the right side except for the positioning convex portion 21. 28d is formed.

FIG. 12 shows a state where the resin F is injected and the insulator 29 is molded. The flow path 33 is connected to a nozzle 36 for injecting the resin F.
The edgewise coil 11 is covered with an insulator 29 around the entire circumference. Since the positioning convex portion 21 and the resin injected in FIG. 12 are the same resin, the positioning convex portion 21 also constitutes the insulator 29 together with the newly injected resin F. The insulator 29 according to the present embodiment includes the insulator 15 according to the first embodiment and a resin mold.
The resin F is a thermoplastic resin and is heated to 150 ° C. or more and melted.
FIG. 13 shows a coil assembly 30 in a state where the edgewise coil 11 is inserted and the insulator 29 is formed. As shown in FIG. 13, the width of the base of the tooth portion is set to A = 20.000 mm. Further, the inner surface width of the insulator 29 of the coil assembly 30 is set to B = 20−0.013 mm. Both are dimensions at room temperature.
The division | segmentation core 16 is comprised from the laminated steel plate, and is iron. The linear expansion coefficient of iron is 12 * 10 ⁻⁶ . The edgewise coil 11 is made of copper, and the insulator is made of resin. The linear expansion coefficient of copper and insulator resin is 17 * 10 ⁻⁶ .
In FIG. 13, the split core 16 is at room temperature and A = 20 mm. The temperature of the edgewise coil 11 and the insulator 29 is about 150 ° C. because it is just after being taken out of the mold. Therefore, the insulator inner surface width of the coil assembly 30 is thermally expanded, and B = 20 mm.

Thereby, the coil assembly 30 is inserted to the base of the tooth portion 16a of the split core 16, that is, to the position where the outer surface of the core side portion 29b of the insulator 29 is in contact with the core body inner peripheral surface 16b of the split core 16. Can do.
In this state, by cooling the coil assembly 30 to room temperature, B is reduced by 0.013 mm to B = 19.987 mm. As a result, shrink fitting with a tightening margin of 0.013 mm is performed. FIG. 14 shows the state at room temperature.
The insulator 29 and the edgewise coil 11 are shrink-fitted to the tooth portion 16a, thereby eliminating an air layer existing between the inner peripheral surface of the tubular portion 29a of the insulator 29 and the outer peripheral surface of the tooth portion 16a. be able to.
As shown in FIG. 8, the stator assembly 20 is completed by arranging 18 split stators in the state of FIG. 14 in an annular shape and shrink-fitting the shrink-fitting ring 19. A stator is completed by attaching a bus bar to the stator assembly 20 and wiring and connecting the terminals of the three phases.

As described above, according to the stator manufacturing method of the second embodiment, the insulator 29 is formed so as to cover the entire circumference of the edgewise coil 11. Since the insulator and the resin mold of Document 1 are integrally formed, the resin molding step can be omitted and the production efficiency can be increased.
Moreover, since it has the positioning mechanism which positions the edgewise coil 11 in a shaping die, the insulator 29 can be shape | molded by the predetermined | prescribed thickness to the internal peripheral surface of the edgewise coil 11. FIG. The insulator 29 formed on the inner peripheral surface of the edgewise coil 11 has a thickness of about 0.2 to 0.3 mm. This is because sufficient insulation can be secured with such a thickness, and by reducing the thickness, the efficiency of heat transfer from the edgewise coil 11 to the core is increased. However, the thickness of the insulator 29 needs to be surely ensured by 0.2 mm, and thus a positioning mechanism is required.

Further, since the positioning mechanism is the positioning convex portion 21 formed by inserting the edgewise coil 11 in advance, the edgewise coil can be obtained by inserting the edgewise coil 11 and performing preliminary molding. The positioning convex part 21 can be formed in 11 necessary places. When the edgewise coil 11 on which the positioning convex portion 21 is formed is inserted into the lower mold 26 that is an insulator molding die, the positioning convex portion 21 comes into contact with the inner surface of the lower mold 26 and is positioned. By forming in this state, the thickness of the insulator 29 formed on the inner peripheral surface of the edgewise coil 11 can be made constant. Here, since the positioning convex portion 21 is formed of the same material as the insulator 29, the positioning convex portion 21 also constitutes a part of the insulator 29.

Next, a third embodiment of the present invention will be described. In the third embodiment, only the shape of the insulator 29 is different from that of the second embodiment, and other configurations and the like are the same as those of the second embodiment. The explanation of the part is omitted.
FIG. 15 shows the shape of the insulator 34 of the third embodiment. The edgewise coil 11 and the insulator 34 attached to the adjacent split core 16 are shown in cross section.
As shown in FIG. 15, a gap S is formed between the outer surfaces of adjacent insulators 34.
As for this gap S, 18 gaps S are formed between 18 divided stators. In a hybrid vehicle, cooling oil may be applied to the stator in order to cool the stator. In that case, since the clearance S exists, the cooling oil flows through the clearance S, and the edgewise coil 11 can be efficiently cooled.

In addition, this invention is not limited to the said embodiment, A part of structure can also be changed suitably and implemented in the range which does not deviate from the meaning of invention.
For example, in the present embodiment, the positioning mechanism of the edgewise coil 11 is performed by forming the positioning convex portion 21 by preforming. However, the positioning mechanism is provided with a sliding member protruding into the cavity by the biasing means. You may go by providing. According to this method, the edgewise coil 11 is positioned in the cavity at the tip of the sliding member. By shaping, the thickness of the insulator 15 formed on the inner peripheral surface of the edgewise coil 11 can be made constant. Here, in the state where the resin is filled in the cavity, since the internal pressure of the resin exceeds the force of the urging means, the sliding member is retracted into the mold to form an insulator having a predetermined thickness. it can.

11 Edgewise coils 12, 22, 26

Lower mold

13, 23, 27 Upper mold 14

Cavities

15, 29, 34 Insulator 16 Split core 16a Teeth 16b Core body inner

peripheral surface

17, 30 Coil assembly 20 Stator assembly 21 Positioning Convex part 28 Cavity

Claims

In a stator manufacturing method of manufacturing a stator having a split stator including a split core, an insulator, and a concentrated winding coil,
A molding step of inserting the concentrated winding coil and molding an insulator;
The concentrated winding coil in which the insulator is molded is attached to the teeth portion of the split core while being kept at a predetermined temperature or more, and is cooled, whereby the concentrated winding coil in which the insulator is molded is attached to the teeth portion. The shrink fitting process for shrink fitting,
A stator manufacturing method comprising:
In the stator manufacturing method according to claim 1,
The stator manufacturing method, wherein the insulator is formed only at a position where the coil faces the split core.
In the stator manufacturing method according to claim 1,
The method for manufacturing a stator, wherein the insulator is formed to cover the entire circumference of the coil.
In the stator manufacturing method according to claim 3,
A stator manufacturing method, wherein a gap is formed between an outer peripheral surface of the insulator and an insulator outer peripheral surface of a split core adjacent to the split core.
In any one of the stator manufacturing methods described in Claim 1 thru | or 4,
The concentrated winding coil is an edgewise coil;
Having a positioning mechanism for positioning the edgewise coil in a molding die;
The stator manufacturing method characterized by these.
In the stator manufacturing method according to claim 5,
The stator manufacturing method, wherein the positioning mechanism is a convex portion formed by inserting an edgewise coil in advance.
A stator manufactured by any one of the stator manufacturing methods according to claim 1.