WO2014065026A1 - 電気機械用電機子巻線に用いられる巻線体の製造方法 - Google Patents
電気機械用電機子巻線に用いられる巻線体の製造方法 Download PDFInfo
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- WO2014065026A1 WO2014065026A1 PCT/JP2013/074125 JP2013074125W WO2014065026A1 WO 2014065026 A1 WO2014065026 A1 WO 2014065026A1 JP 2013074125 W JP2013074125 W JP 2013074125W WO 2014065026 A1 WO2014065026 A1 WO 2014065026A1
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- winding
- bulging
- forming step
- winding body
- manufacturing
- Prior art date
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
- H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0435—Wound windings
- H02K15/0442—Loop windings
- H02K15/045—Form wound coils
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/06—Embedding prefabricated windings in machines
- H02K15/062—Windings in slots; salient pole windings
- H02K15/065—Windings consisting of complete sections, e.g. coils, waves
- H02K15/066—Windings consisting of complete sections, e.g. coils, waves inserted perpendicularly to the axis of the slots or inter-polar channels
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
Definitions
- the present invention relates to a method for manufacturing a winding body used for an armature winding for an electric machine such as a rotary electric machine such as an electric motor or a generator, or a linear motion machine such as a linear motor.
- a winding formed by winding a conductor wire in two slots separated by two or more slots is a distributed winding.
- the distributed winding is a winding that is wound a plurality of turns so that a conductor wire extending from one slot enters another slot across two or more consecutive teeth.
- the present invention has been made in order to solve the above-described problems, and can provide an armature for an electric machine that can be manufactured at a low cost with a simple mechanism by winding a conductor wire in a spiral shape with a set number of turns. It aims at obtaining the manufacturing method of the coil used for winding.
- a continuous conductor wire having insulation coating and having no connection portion is spirally wound m times (where m is a natural number of 2 or more), and m wires are arranged in each row in two rows.
- the linear ends that are arranged and the coil ends that connect the ends of the linear portions between the rows are provided, and each of the coil ends connects the bulging portion, the bulging portion, and the linear portion.
- a pair of inclined portions, and a crank portion that is formed at a central portion of the bulging portion and that displaces the linear portions connected by the coil ends by an amount set in the arrangement direction of the linear portions.
- a method of manufacturing a winding body used for an armature winding for an electric machine includes a bulging portion forming step of bending the bulging portion at a pitch set to the conductor wire, and a central portion of the bulging portion.
- a crank part forming process for bending the crank part, a bulging part forming process After the crank part forming step is completed, the bulging part is formed at a set pitch, and the crank part is a linear part that bends and forms the linear part on the conductor wire formed on each of the bulging parts.
- an inclined portion forming step of bending the inclined portion on both sides of the bulging portion of the conductor wire is provided prior to the forming step and the linear portion forming step.
- the mechanism of the device can be simplified, Can be reduced in size and cost.
- the bulging portion is formed at a set pitch by the bulging portion forming step and the crank portion forming step, and the crank portion is producing a conductor wire formed on each of the bulging portions, the bulging portion A winding body with a set number of turns can be produced simply by changing the number of moldings. Therefore, the step of joining the set number of coil strands becomes unnecessary, and the manufacturing cost is reduced.
- FIG. 1 It is a half sectional view which shows the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the principal part of the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the stator applied to the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the iron core block which comprises the stator iron core applied to the rotary electric machine which concerns on Embodiment 1 of this invention. It is a perspective view which shows the coil
- FIG. 1 It is a perspective view which shows the coil
- FIG. 3 is an end view of a main part when a state in which two winding bodies in the rotary electric machine according to Embodiment 1 of the present invention are mounted on a stator core sharing one slot is viewed from one end side in the axial direction. It is the expanded view which looked at the state by which three winding bodies in the rotary electric machine which concerns on Embodiment 1 of this invention were continuously mounted
- FIG. 1 is a half sectional view showing a rotating electrical machine according to Embodiment 1 of the present invention
- FIG. 2 is a perspective view showing a main part of the rotating electrical machine according to Embodiment 1 of the present invention
- FIG. 3 is an embodiment of the present invention.
- FIG. 4 is a perspective view showing a stator block applied to the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 5 is a perspective view showing an iron core block constituting the stator core applied to the rotary electric machine according to Embodiment 1 of the present invention.
- FIG. 4 is a perspective view showing a stator block applied to the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 5 is a perspective view showing an iron core block constituting the stator core applied to the rotary electric machine according to Embodiment 1 of the present invention.
- FIG. 6 is a perspective view showing a winding assembly constituting a stator winding of a stator applied to the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 6 is a winding in the rotary electric machine according to Embodiment 1 of the present invention
- 7 is a perspective view showing a winding body constituting the wire assembly
- FIG. 7 is a front view showing the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 9 is a perspective view of the winding body constituting the winding assembly in the rotary electric machine according to Embodiment 1 of the present invention as seen from the front and obliquely above
- FIG. FIG. 11 is an end view of the main part of the state in which two winding bodies in the rotating electrical machine according to the first embodiment share one slot and are attached to the stator core when viewed from one end side in the axial direction
- FIG. 12 is a developed view of the state in which three winding bodies in the rotating electrical machine according to the first embodiment are continuously mounted in the same slot group of the stator core in the circumferential direction, as viewed from one end side in the axial direction.
- a rotating electric machine 100 as an electric machine includes a housing 1 having a bottomed cylindrical frame 2 and an end plate 3 that closes an opening of the frame 2, and a state in which the rotating electric machine 100 is fitted in a cylindrical portion of the frame 2.
- the stator 10 as an armature fixed to the rotor and the rotating shaft 6 rotatably supported on the bottom of the frame 2 and the end plate 3 via the bearing 4 are rotated to the inner peripheral side of the stator 10.
- a rotor 5 arranged in a possible manner.
- the rotor 5 is arranged with a rotor core 7 fixed to the rotary shaft 6 inserted in the axial center position, and arranged at a pitch set in the circumferential direction embedded in the outer peripheral surface side of the rotor core 7.
- the rotor 5 is not limited to a permanent magnet type rotor, and a squirrel-cage rotor in which a non-insulated rotor conductor is housed in a slot of a rotor core and both sides are short-circuited by a short-circuit ring, or an insulated conductor. You may use the winding-type rotor which attached the wire to the slot of the rotor core.
- the stator 10 includes a stator core 11 and a stator winding 20 as an armature winding attached to the stator core 11.
- the number of poles of the rotor 5 is 8
- the number of slots of the stator core 11 is 48
- the stator winding 20 is a three-phase winding. That is, the slots 13 are formed in the stator core 11 at a rate of two per phase per phase.
- the number of slots per phase per pole is 2.
- the core block 12 is obtained by dividing the annular stator core 11 into 48 equal parts in the circumferential direction, and is produced by laminating and integrating a set number of electrical steel sheets as shown in FIG. Core back portion 12a and teeth 12b extending radially inward from the inner peripheral wall surface of the core back portion 12a.
- the stator core 11 is formed by aligning and integrating the 48 core blocks 12 in the circumferential direction, with the teeth 12b facing inward in the radial direction, but with the side surfaces in the circumferential direction of the core back portion 12a facing each other. It is configured in an annular shape.
- the slots 13 constituted by the iron core blocks 12 adjacent in the circumferential direction are arranged at an equiangular pitch in the circumferential direction so as to open to the inner circumferential side.
- the teeth 12b are formed in a tapered shape in which the circumferential width gradually decreases inward in the radial direction, and the cross section of the slot 13 is rectangular.
- the circumferential direction corresponds to the arrangement direction of the slots 13.
- the stator winding 20 is configured by performing a connection process on a winding assembly 21 mounted on the stator core 11.
- the winding assembly 21 is formed by arranging winding bodies 22 accommodated in pairs of slots 13 located on both sides of six consecutive teeth 12b in the circumferential direction at a pitch of one slot. Is done.
- Winding ends 22g described later extend in the axial direction, and are arranged in the circumferential direction at a pitch of 1 slot on the inner diameter side of the winding assembly 21.
- winding ends 22h described later extend in the axial direction in the same direction as the winding end 22g, and are arranged in the circumferential direction at a one-slot pitch on the outer diameter side of the winding assembly 21.
- the winding body 22 includes, for example, a conductor wire 25 having a rectangular cross section made of continuous copper wire, aluminum wire, or the like that is insulation-coated with enamel resin and has no connection portion.
- the plane composed of the long sides of the rectangular cross section is opposed to each other, and a gap d substantially equal to the short side length of the rectangular cross section is secured between the opposed planes, and is spirally wound four times in a substantially hexagonal shape. This is a tortoiseshell shaped coil.
- the winding bodies 22 configured in this way are arranged in two rows at 6-slot angular intervals.
- the first and second windings 22 are arranged in four rows in the short-side direction of the rectangular cross section with a gap d in each row.
- First and second coil ends 22c and 22d that alternately connect one end and the other end in the length direction between the two straight portions 22a and 22b and the first and second straight portions 22a and 22b. It is equipped with.
- the 6-slot angular interval is an interval between the slot centers of the slots 13 on both sides of the six consecutive teeth 12b.
- the first coil end 22c has an inclination set from one end of the first straight portion 22a in the center and the first top portion 22e in the center between the first and second straight portions 22a and 22b, and the other row.
- the two straight portions 22b side, and first and second linear portions 22a an inclined portion 22c 1 connected to the first top 22e extending in the longitudinal direction outwardly of 22b, setting the first top 22e of Is extended to the second straight line portion 22b side of the other row and inward in the longitudinal direction of the first and second straight line portions 22a and 22b, and connected to one end of the second straight line portion 22b of the other row.
- the first top portion 22e is formed by bending an inverted U-shaped bulging portion 22e 1 connecting between the end portions of the inclined portions 22c 1 and 22c 2 and a central portion of the bulging portion 22e 1 into a crank shape.
- a crank portion 22e 2 that displaces the portions 22c 1 and 22c 2 by a distance d in the arrangement direction of the first and second linear portions 22a and 22b is provided.
- the second coil end 22d is inclined from the second top 22f at the center between the rows of the first and second straight portions 22a and 22b and the other end of the second straight portion 22b in the other row.
- an inclined portion 22d 1 extending to the first straight portion 22a side of one row and extending outward in the length direction of the first and second straight portions 22a, 22b and connected to the second top portion 22f,
- a slope set from the top portion 22f extends to the first straight portion 22a side of one row and inward in the length direction of the first and second straight portions 22a and 22b, and the first straight portion 22a of one row.
- an inclined portion 22d 2 connected to the other end of the.
- Second apex portion 22f includes an inclined portion 22 d 1, inverted U-shaped bulging portion 22f 1 that connects between the ends of the 22 d 2, it is formed by bending the central portion of the bulge portion 22f 1 into a crank shape, inclination the part 22 d 1, 22 d 2 the first and second straight portions 22a, and a crank portion 22f 2 for displacing the arrangement direction of 22b by distance d.
- the first and second linear portions 22a and 22b and the first and second coil ends 22c and 22d are each configured by the long side of the rectangular cross section of the conductor wire 25.
- the flat surfaces are opposed to each other, and are arranged at a pitch approximately twice (2d) the short side length in the short side direction of the rectangular cross section of the conductor wire 25.
- the first straight portion 22a and the second straight portion 22b connected via the first top portion 22e and the second top portion 22f are shifted by a gap d in the arrangement direction.
- the winding body 22 includes a winding end 22g extending in the length direction from the other end of the first linear portion 22a located at one end in the arrangement direction of one row, and the other end in the arrangement direction of the other row. And a winding end 22h extending in the length direction from the other end of the second linear portion 22b located at the center.
- FIG. 10 shows a state in which two winding bodies 22 are wound around two consecutive pairs of pairs of slots 13 that straddle six consecutive teeth 12b, and FIG. 11 and FIG. Each of the winding bodies 22 is wound around three consecutive pairs of slots 13 that straddle six consecutive teeth 12b.
- the first coil end 22c extending from the first straight portion 22a of the first layer to the one end side in the axial direction from the slot opening side of one slot 13 has an inclination angle ⁇ Extends to the other slot 13 side in the circumferential direction, shifted by a distance d radially outward at the crank portion 22e 2 of the first top portion 22e, and then toward the other slot 13 side in the circumferential direction at a reverse inclination angle ⁇ . It extends and is connected to the second straight portion 22b of the second layer from the slot opening side of the other slot 13.
- the second coil end 22d extending from the slot opening side of the other slot 13 to the other axial end side from the second linear portion 22b of the second layer is inclined toward the one slot 13 side in the circumferential direction at an inclination angle ⁇ . extends, is crank portion 22f 2 in radially outward by a distance d shift of the second top 22f, then extends one slot 13 side at an inclination angle opposite ⁇ in the circumferential direction, the slot opening side of one of the slots 13 To the first straight portion 22a of the third layer.
- the circumferential interval between the first and second straight portions 22a and 22b of the winding body 22 is directed outward in the radial direction so as to match the slot shape of the pair of slots 13 straddling the six consecutive teeth 12b. Gradually getting wider.
- the radial direction corresponds to the slot depth direction.
- the first straight portion 22a of the first layer, the third layer, the fifth layer, and the seventh layer of the one slot 13 and the second layer, the fourth layer, the sixth layer, and the eighth layer of the other slot 13 are obtained.
- the second linear portion 22b of the layer is spirally connected by the first and second coil ends 22c and 22d, respectively.
- Inclined portions 22c 1 , 22c 2 , 22d 1 , 22d 2 extending from the ends of the first and second straight portions 22a, 22b to the first and second top portions 22e, 22f are formed in an arc shape when viewed from the axial direction. Has been.
- the curvatures of the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 are larger as the inclined portion is located on the outer diameter side.
- the first and second straight portions 22a and 22b of the two winding bodies 22 have the long side of the rectangular cross section of the conductor wire 25 facing in the circumferential direction. In the radial direction, they are stored alternately in a line.
- the first and second coil ends 22 c and 22 d are located radially outward from the tip of the teeth 12 b of the stator core 11 and radially inward from the bottom of the slot 13. positioned.
- FIG. 13 is a diagram for explaining a flow of a manufacturing process of a winding body used for the stator winding according to the first embodiment of the present invention
- FIG. 14 is used for the stator winding according to the first embodiment of the present invention.
- FIG. 15 is a perspective view for explaining a configuration of a coil end molding machine in a method for manufacturing a wound body
- FIG. 15 is a coil end molding machine in a method for manufacturing a winding body used for a stator winding according to Embodiment 1 of the present invention.
- FIG. 16 is a diagram for explaining a bulging portion forming step in the method of manufacturing a winding body used in the stator winding according to Embodiment 1 of the present invention
- FIG. FIG. 18 is a diagram for explaining a bulging portion forming step in the method of manufacturing a winding body used for the stator winding according to Embodiment 1
- FIG. 18 is a winding used for the stator winding according to Embodiment 1 of the present invention.
- FIG. 19 is a view for explaining a bulging portion forming step in the method of manufacturing the winding body used for the stator winding according to the first embodiment of the present invention
- FIG. 20 is a diagram illustrating the fixing according to the first embodiment of the present invention.
- FIG. 21 is a diagram for explaining a crank part forming step in a manufacturing method of a winding body used for a child winding, and FIG. 21 is a coil end in the manufacturing method of the winding body used for the stator winding according to Embodiment 1 of the present invention.
- FIG. 22 is a front view showing a conductor wire that has been bent by a forming machine, and FIG. 22 shows a bending process performed by a coil end forming machine in the manufacturing method of the winding body used in the stator winding according to Embodiment 1 of the present invention.
- FIG. 21 is a diagram for explaining a crank part forming step in a manufacturing method of a winding body used for a child winding
- FIG. 21 is a coil end in the manufacturing method of the winding body used for the stator winding according to Embodiment 1 of the present invention.
- FIG. 22 is a front view showing
- FIG. 23 is a perspective view showing an inclined part / linear part forming machine in the method of manufacturing a winding body used in the stator winding according to Embodiment 1 of the present invention
- FIG. 26 is a process diagram for explaining an inclined portion forming step in the method of manufacturing a winding body used for the stator winding according to the first embodiment, and FIG. 26 is used for the stator winding according to the first embodiment of the present invention.
- FIG. 27 is a process diagram for explaining the linear part forming step in the winding body manufacturing method, and FIG. 27 is an intermediate winding body manufactured by the winding body manufacturing method used for the stator winding according to Embodiment 1 of the present invention.
- FIG. 28 is a top view showing an intermediate winding body manufactured by the method of manufacturing a winding body used in the stator winding according to Embodiment 1 of the present invention
- FIG. 29 is an embodiment of the present invention
- FIG. 30 is a top view showing a winding body manufactured by the method of manufacturing a winding body used in the stator winding according to Embodiment 1
- FIG. 30 shows the winding used in the stator winding according to Embodiment 1 of the present invention. It is a figure explaining the circular arc part formation process in the manufacturing method of a wire.
- the method of manufacturing the winding body 22 includes a bulging portion forming step 710, a crank portion forming step 720, an inclined portion / linear portion forming step 810, and an arc portion forming step 910. .
- the coil end molding machine 700 used in the bulging part forming process and the crank part forming process is fixed base 701 movably in the axial direction X of the fixed base 701 and the conductor wire 25 having a rectangular cross section.
- crank part molding right-angle slide clamper 705 installed in the cylinder, and a crank part molding die disposed so as to be movable in the axial direction X and the vertical direction It includes a 06, a.
- the crank part forming die 706 has a coil forming part 706 a that matches the shapes of the crank part forming axis slide clamper 704 and the crank part forming right angle slide clamper 705.
- the conductor wire 25 is fed in an amount set in the axial direction X, and the bulging portion forming axis slide mold 702 and the bulging portion forming right angle are fed. It is arranged between the slide mold 703. Subsequently, the right-angle slide mold 703 for forming the bulging part is operated on the side of the bulging part forming axis slide mold 702. Accordingly, as shown in FIG. 17, the conductor wire 25 is sandwiched between the bulging portion forming axis slide mold 702 and the bulging portion forming right angle slide mold 703, and the inverted U-shaped bulging portion. 22e 1 is molded.
- the right-angle slide mold 703 for forming the bulging part is operated in a direction away from the axis-sliding mold 702 for forming the bulging part, and the opened conductor wire 25 is fed by an amount set in the axial direction X.
- the crank part forming right angle slide clamper 705 is operated on the crank part forming axis slide clamper 704 side, and as shown in FIG. 18, the bulging part 22e 1 is formed with the crank part forming axis slide clamper 704 and the crank part forming part. It is clamped by a right angle slide clamper 705 for use.
- crank part forming axis slide clamper 704 is moved in the axial direction X to a position where the distance from the bulging part forming axis slide mold 702 is longer than the final forming target distance. Thereby, the bulging part 22e1 is positioned.
- the stop position in the axial direction X of the crank part forming axis slide clamper 704 is the length and circumferential interval of the first and second straight portions 22a and 22b of the winding body 22 which is the final formed body, and the first position.
- the reduction of the conductor wire 25 in the axial direction X due to the formation of the bulging portions 22e 1 and 22f 1 and the formation of the crank portions 22e 2 and 22f 2 is considered. Is set.
- the stop position in the axial direction X of the crank portion forming axial slide clamper 704 is such that the circumferential interval between the first and second straight portions 22a and 22b of the winding body 22 which is the final formed body is directed radially outward.
- the bulge portion forming axis slide mold 702 is controlled so as to gradually become wider. In this way, the bulging portions 22e 1 and 22f 1 serve as reference points, and the pitch for bending the next bulging portions 22e 1 and 22f 1 is managed.
- the bulging portion for molding a right angle slide mold 703 is operated to the shaft bulging portion molding line slide mold 702 side, as shown in FIG. 19, an inverted U-shaped protruding portion 22f 1 is formed .
- the crank portion forming mold 706 is run down, as shown in FIG. 20, bending by the coil-forming part 706a is applied to the bulging portion 22e 1, the crank portion 22e 2 is bulging portion 22e 1 Is formed at the central portion (crank portion forming step 720).
- the crank part molding die 706 is operated upward, and the crank part molding right angle slide clamper 705 is operated in a direction away from the crank part molding axis slide clamper 704, and the bulging part molding right angle slide mold 703 is operated. Is operated in a direction away from the bulging portion forming axis slide mold 702, and the conductor wire 25 is opened.
- the crank portion 22e 2 and the bulge portion 22f 1 of the bulging part 22e 1 and the crank portion 22f 2 formed is formed of the conductor wires 25 Intermediate conductor wires 26 that are alternately formed at a pitch set in the axial direction X are manufactured.
- the bulging part forming step 710 only the bulging part forming right-angle slide mold 703 is operated to form the bulging parts 22e 1 and 22f 1.
- the bulging portions 22e 1 and 22f 1 may be molded by operating the mold 702 and the bulging portion forming right-angle slide mold 703.
- the crank part forming step 720 only the crank part forming right-angle slide clamper 705 is operated to fix the bulged parts 22e 1 and 22f 1 , but the crank part forming axis slide clamper 704 and the crank part are fixed.
- the bulging portions 22e 1 and 22f 1 may be fixed by operating the right-angle slide clamper 705 for molding.
- the inclined portion / linear portion forming machine 800 used in the inclined portion / linear portion forming step 810 is stepped through step portions 801a corresponding to the crank portions 22e 2 and 22f 2.
- a coil end molding fixed mold 801 having a back surface portion 801b formed thereon, a coil end molding movable mold 802 having a bulging portion 802a for positioning the bulging portions 22e1, 22f1, and a back surface portion.
- Bending portions 803a and 803b are attached to the coil end forming fixed die 801 so as to be rotatable around an axis orthogonal to 801b, and bend and form the first and second linear portions 22a and 22b.
- the bulging portion 22e 1 of the conductor wire 25 is aligned with the bulging portion 22e 1 of the coil end forming movable mold 802, and the conductor wire 25 is positioned. To do. At this time, the bulging portion 22e 1 of the conductor wire 25 is positioned at the stepped portion 801a, and the portions on both sides of the bulging portion 22e 1 of the conductor wire 25 are in contact with the back surface portion 801b.
- the coil end molding movable mold 802 is operated to the coil end molding fixed mold 801 side, and the conductor wire 25 is pressed against the coil end molding fixed mold 801.
- the conductor lines 25 are pressurized and nipped between the coil end forming fixed die 801 and the coil end molding movable die 802, the bulging portion 22e 1 becomes a reference point, the inclined portions 22c 1, 22c 2 is bent on both sides of the bulge portion 22e 1.
- the bent portions 803a and 803b are operated to extend the conductor wire 25 that is pressure-clamped between the coil end molding fixed mold 801 and the coil end molding movable mold 802. Bend the protruding part.
- the bulging portion 22e 1 serves as a reference point, and the first and second straight portions 22a and 22b are bent.
- the inclined portion / linear portion forming step 810 is repeated to form inclined portions 22c 1 , 22c 2 , 22d 1 , 22d 2 on both sides of the bulging portions 22e 1 , 22f 1 , and the first and second linear portions 22a,
- the intermediate winding body 22A is manufactured by molding 22b.
- the intermediate winding body 22A has inclined portions 22c 1 , 22c 2 , 22d 1 , 22d 2 having first and second straight portions 22a, 22b and bulging portions 22e 1 , 22f. It is manufactured in the same manner as the winding body 22 except that it is formed so as to be linearly connected to 1 .
- the next bulge portion is formed with the bulge portions 22e 1 and 22f 1 previously bent and formed as reference points.
- the pitch for bending and forming 22e 1 and 22f 1 is managed. Therefore, by changing the molding pitch of the bulging portions 22e 1 and 22f 1 , the length of the first and second straight portions 22a and 22b of the winding body 22 and the row of the first and second straight portions 22a and 22b The interval between them can be easily changed, and it is possible to respond to changes in the axial length and diameter of the stator core 11. Furthermore, it is possible to easily cope with a change in the number of turns of the winding body 22 by changing the number of the bulging portions 22e 1 and 22f 1 formed.
- first and second top portions 22e and 22f of the first and second coil ends 22c and 22d are formed separately in the bulging portion forming step 710 and the crank portion forming step 720, a two-dimensional complicated shape is formed.
- the first and second top portions 22e and 22f can be bent with a simple mechanism, and the apparatus can be reduced in size and cost. Since it is divided into a bulging portion forming step 710, a crank portion forming step 720, an inclined portion / linear portion forming step 810, and an arc portion forming step 910, adjustment of tact time and production management are facilitated.
- the bulged portion forming process 710 the bulging portion 22e 1 that is bent along the first, the 22f 1 as a reference point, since the bending a next bulging portion 22e 1, 22f 1, the bulging part 22e 1 , 22f 1 can be accurately formed.
- the bulged portions 22e 1 and 22f 1 formed by bending are fed out by a set amount and sandwiched between the crank portion forming axis slide clamper 704 and the crank portion forming right angle slide clamper 705, and the crank portion is formed.
- the part forming axis slide clamper 704 After the part forming axis slide clamper 704 is moved in the axial direction X and the crank part forming axis slide clamper 704 (the bulging portions 22e 1 and 22f 1 ) is positioned at the set position, the next bulging portions 22e 1 and 22f are moved. 1 is bent. Therefore, not only the feed amount of the conductor wire 25 but also the bulging portions 22e 1 and 22f 1 serving as reference points are positioned at the set positions, so that the bulging portions 22e 1 and 22f 1 can be bent and formed with high accuracy.
- the inclined portion, the linear portion forming process 810 as a reference point the bulging portion 22e 1, 22f 1, the inclined portions 22c 1 on both sides of the bulging part 22e 1, 22f 1, 22c 2 , 22d 1, 22d 2 and the Since the first and second straight portions 22a and 22b are bent, the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 and the first and second straight portions 22a and 22b can be bent and formed with high accuracy.
- the inclined portions 22c 1 , 22c 2 , 22d 1 , and 22d 2 of the intermediate winding body 22A manufactured by the inclined portion / linear portion forming step 810 are bent into an arc shape.
- the winding body 22 having the arc-shaped inclined portions 22c 1 , 22c 2 , 22d 1 , and 22d 2 that have been bent with high accuracy. can be produced.
- FIGS. 31 to 36 are perspective views for explaining a method of assembling the winding assembly in the rotary electric machine according to the first embodiment of the present invention
- FIGS. 37 to 39 are diagrams for the rotary electric machine according to the first embodiment of the present invention. It is a schematic diagram explaining the procedure of incorporating the 48th winding body in the assembly method of a winding assembly.
- the winding bodies 22 are referred to as a winding body 22 1 , a winding body 22 2 , a winding body 22 3 , a winding body 22 47 , and a winding body 22 48 in the assembling order.
- the first and second winding bodies 22 1 and 22 2 are adjacent to each other in the circumferential direction with their axial height positions aligned.
- the second first straight portion 22a of the winding 22 2 inserted between the second linear portion 22b having a first winding 22 1 of the gap d.
- the second winding body 22 2 is moved in the circumferential direction.
- the two winding bodies 22 1 and 22 2 are assembled as shown in FIG. In the assembly of the two winding bodies 22 1 and 22 2 , the conductor wire 25 of the winding body 22 2 enters the gap between the conductor wires 25 of the winding body 22 1 and overlaps in the radial direction, thereby increasing the rigidity.
- the third winding body 22 3 is adjacent to the assembly of the winding bodies 22 1 and 22 2 in the circumferential direction with the axial height position aligned.
- the first linear portion 22a of the third winding body 22 3 is inserted between the second linear portions 22b of the winding bodies 22 1 and 22 2 .
- the first linear portion 22a of the third winding body 22 3 is located at a position spaced apart from the first linear portion 22a of the second winding body 22 2 by one slot pitch (angle between one slot)
- the third winding body 22 3 is moved in the circumferential direction.
- the subassembly 24 including the three winding bodies 22 1 , 22 2 , and 22 3 is assembled as shown in FIG.
- the winding body 22 is sequentially aligned in the axial direction and moved in the circumferential direction, and is assembled to the 47th winding body 2247.
- the assembly 23 in which the 47 winding bodies 22 1 to 22 47 are assembled is expanded in diameter, as shown in FIG. 37, the first winding body 22 1 and the 47th winding body 22 47. Is formed in a C-shape that is wider than the circumferential width of the 48th winding body 2248.
- FIG. 38 assembling the 48 th winding body 22 48 47 th winding body 22 47 side.
- FIG. 39 it closes the opening of the C-shaped assembly 23, the first winding 22 1 and assembled and 48th windings 22 48, annular shown in FIG.
- the winding assembly 21 is assembled.
- eight first and second linear portions 22a and 22b arranged in a row in the radial direction are arranged in 48 rows in the circumferential direction at a one-slot pitch.
- FIGS. 40 to 43 are views for explaining a method of mounting the winding assembly on the stator core in the rotary electric machine according to Embodiment 1 of the present invention.
- FIGS. 40 and 41 are diagrams before mounting of the winding assembly. 42 shows a state after the winding assembly is mounted, and FIG. 43 shows an enlarged state after the winding assembly is mounted. 41 to 43, the winding assembly 21 is represented by only the first and second linear portions 22a and 22b for convenience.
- the 48 iron core blocks 12 are arranged so that each of the teeth 12b is in the radial direction between the adjacent first and second linear portions 22a, 22b of the winding assembly 21. They are arranged at a substantially equiangular pitch in the circumferential direction so as to be located outward.
- the iron core blocks 12 arranged in the circumferential direction are simultaneously moved radially inward. Thereby, each of the teeth 12b of the iron core block 12 is inserted between adjacent rows of the first and second straight portions 22a and 22b, and the side surfaces in the circumferential direction of the adjacent iron core blocks 12 are abutted to each other.
- the winding assembly 21 is attached to the stator core 11.
- eight first and second straight portions 22 a and 22 b are stored side by side aligned in a row in the radial direction with the long side of the rectangular cross section facing the circumferential direction. .
- the first and second straight portions 22a and 22b arranged unevenly in the radial direction can be obtained.
- the teeth 12b of the adjacent iron core blocks 12 are aligned by a movement that narrows. Further, the gap between the first and second linear portions 22a and 22b aligned in the radial direction is reduced and eliminated by the movement of the core block 12 toward the inner diameter side of the core back portion 12a. Thereby, the space factor of the conductor wire 25 in the slot 13 can be improved.
- the conductor wire 25 in the slot 13 and the iron core block 12 are in contact with each other and the heat transfer performance from the winding assembly 21 serving as a heating element to the stator iron core 11 when energized can be improved, the winding assembly.
- the temperature rise of 21 can be suppressed and the increase in electrical resistance can be suppressed.
- the iron core block 12 is inserted so that the space
- crank portions 22e 1 and 22f 1 of the first and second top portions 22e and 22f are configured to shift in the radial direction by a gap d substantially equal to the radial dimension of the first and second linear portions 22a and 22b. Therefore, one winding body 22 is moved to the other one winding body 22 side in the circumferential direction by aligning the height position in the axial direction with the other one winding body 22 without interference. Thus, the assembly of the winding assembly 21 can be improved.
- the tapered teeth 12b of the first and second straight portions 22a, 22b are inserted. Since it is inserted from the outer diameter side into each of the rows and moved inward in the radial direction, the winding assembly 21 has the stator in a state where the first and second straight portions 22a and 22b are aligned in one row. Mounted on the iron core 11.
- the rotating electrical machine 100 using the stator 10 configured as described above operates as an 8-pole, 48-slot inner rotor type three-phase motor by supplying AC power set to the stator winding 20. .
- the row of the first straight portions 22a and the row of the second straight portions 22b of the winding body 22 are described as being separated by a 6-slot angular interval.
- the spacing is not limited to 6 slot angular spacing.
- the interval between the first straight line portion 22a and the second straight line portion 22b is defined as a three-slot angular interval. In this way, a stator winding having a distributed winding structure with a full-pitch winding can be obtained.
- FIG. FIG. 44 is a front view showing a conductor wire bent by a coil end forming machine in the method for manufacturing a winding body in a rotary electric machine according to Embodiment 2 of the present invention.
- the shapes of the bulging portion forming axis slide mold 702 and the bulging portion forming right angle slide mold 703 in the coil end molding machine are changed, and the bulging portions 22e 1 and 22f 1 and the inclined portion are changed. 22c 1 , 22c 2 , 22d 1 , 22d 2 are bent at the same time. Therefore, the inclined portion forming step is included in the bulging portion forming step, and as shown in FIG. 44, the bulging portions 22e 1 and 22f 1 and the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 are connected to the conductor wire. An intermediate conductor wire 27 formed at a pitch set to 25 is produced.
- the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 are simultaneously bent when the bulging portions 22e 1 and 22f 1 are bent, the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 can be accurately molded.
- FIG. FIG. 45 is a front view showing a conductor wire that has been bent by a coil end forming machine in the method of manufacturing a wound body in a rotary electric machine according to Embodiment 3 of the present invention.
- the shapes of the bulging portion forming axis slide mold 702 and the bulging portion forming right angle slide mold 703 in the coil end molding machine are changed, and the bulging portions 22e 1 and 22f 1 and the inclined portion are changed. 22c 1 , 22c 2 , 22d 1 , 22d 2 are bent at the same time. Therefore, the inclined portion forming step is included in the expanded portion forming step, and as shown in FIG. 45, the expanded portions 22e 1 and 22f 1 and the inclined portions 22c 1 , 22c 2 , 22d 1 , and 22d 2 are connected to the conductor wire. An intermediate conductor wire 28 formed at a pitch set to 25 is produced.
- the inclined portions 22c 1 , 22c 2 , 22d 1 and 22d 2 are simultaneously bent when the bulging portions 22e 1 and 22f 1 are bent, the inclined portions 22c 1 , 22c 2 and 22d are formed. 1 and 22d 2 can be accurately molded.
- the winding body is formed by winding the conductor wire spirally for four turns.
- the number of turns of the conductor wire is not limited to four times, and may be two times or more. I just need it.
- the winding body is manufactured using a conductor wire having a rectangular cross section, but the winding body may be manufactured using a conductor wire having a circular cross section. In this case, bending of the conductor wire is facilitated.
- the stator winding is described as the armature winding.
- the same effect can be obtained even when applied to the rotor winding.
- the electric machine to which the present application can be applied is not limited to a rotating electric machine such as an electric motor and a generator, and a linear motion machine such as a linear motor. Even if it is applied to, the same effect can be obtained.
- the inclined portion of the coil end of the winding body is not bent into an arc shape but is linear, and the interval between the first linear portion row and the second linear portion row is constant. It has become.
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Abstract
Description
また、膨出部成形工程およびクランク部成形工程により、膨出部が設定されたピッチで形成され、クランク部が膨出部のそれぞれに形成された導体線を作製しているので、膨出部の成形個数を変えるだけで、設定されたターン数の巻線体を作製できる。そこで、設定された個数のコイル素線を接合する工程が不要となり、製造コストの低下が図られる。
図1はこの発明の実施の形態1に係る回転電機を示す片側断面図、図2はこの発明の実施の形態1に係る回転電機の要部を示す斜視図、図3はこの発明の実施の形態1に係る回転電機に適用される固定子を示す斜視図、図4はこの発明の実施の形態1に係る回転電機に適用される固定子鉄心を構成する鉄心ブロックを示す斜視図、図5はこの発明の実施の形態1に係る回転電機に適用される固定子の固定子巻線を構成する巻線アッセンブリを示す斜視図、図6はこの発明の実施の形態1に係る回転電機における巻線アッセンブリを構成する巻線体を示す斜視図、図7はこの発明の実施の形態1に係る回転電機における巻線アッセンブリを構成する巻線体を示す正面図、図8はこの発明の実施の形態1に係る回転電機における巻線アッセンブリを構成する巻線体を示す側面図、図9はこの発明の実施の形態1に係る回転電機における巻線アッセンブリを構成する巻線体を正面斜め上方から見た斜視図、図10はこの発明の実施の形態1に係る回転電機における2つの巻線体が1つのスロットを共有して固定子鉄心に装着された状態を軸方向一端側から見た要部端面図、図11はこの発明の実施の形態1に係る回転電機における3つの巻線体が固定子鉄心の同一スロット群に周方向に連続して装着された状態を軸方向一端側から見た展開図、図12はこの発明の実施の形態1に係る回転電機における3つの巻線体が固定子鉄心の同一スロット群に周方向に連続して装着された状態を径方向外方から見た展開図である。なお、図11では、便宜上、コイルエンドを直線的に示している。
ついで、クランク部成形用金型706が下方に稼働され、図20に示されるように、コイル成形部706aによる曲げ加工が膨出部22e1に施され、クランク部22e2が膨出部22e1の中央部に成形される(クランク部成形工程720)。ついで、クランク部成形用金型706が上方に稼働され、クランク部成形用直角スライドクランパ705がクランク部成形用軸線スライドクランパ704から離反する方向に稼動され、膨出部成形用直角スライド金型703が膨出部成形用軸線スライド金型702から離反する方向に稼働され、導体線25が開放される。
また、クランク部成形工程720では、クランク部成形用直角スライドクランパ705のみを稼働して、膨出部22e1,22f1を固定するものとしているが、クランク部成形用軸線スライドクランパ704とクランク部成形用直角スライドクランパ705とを稼働して膨出部22e1,22f1を固定してもよい。
膨出部成形工程710、クランク部成形工程720、傾斜部・直線部成形工程810、および円弧部成形工程910に分けられているので、タクトタイムの調整および生産管理が容易となる。
膨出部成形工程710では、曲げ成形された膨出部22e1,22f1を設定された量送り出してクランク部成形用軸線スライドクランパ704とクランク部成形用直角スライドクランパ705とに挟持させ、クランク部成形用軸線スライドクランパ704を軸線方向Xに移動させ、クランク部成形用軸線スライドクランパ704(膨出部22e1,22f1)を設定位置に位置決めした後、次の膨出部22e1,22f1を曲げ成形している。そこで、導体線25の送り量だけでなく、基準点となる膨出部22e1,22f1を設定位置に位置決めしているので、膨出部22e1,22f1を高精度に曲げ成形できる。
傾斜部・直線部成形工程810により製造された中間巻線体22Aの傾斜部22c1,22c2,22d1,22d2を円弧状に曲げ成形している。つまり、高い加工精度が要求される円弧部成形工程910が最終工程となるので、高精度の曲げ加工された円弧状の傾斜部22c1,22c2,22d1,22d2を有する巻線体22を作製できる。
ついで、図38に示されるように、48番目の巻線体2248を47番目の巻線体2247側に組み付ける。さらに、図39に示されるように、C字状の組立体23の開口を閉じ、1番目の巻線体221と48番目の巻線体2248とを組み付け、図5に示される円環状の巻線アッセンブリ21が組み立てられる。このように組み立てられた巻線アッセンブリ21では、径方向に1列に並んだ8本の第1および第2直線部22a,22bが、1スロットピッチで周方向に48列配列される。
図44はこの発明の実施の形態2に係る回転電機における巻線体の製造方法においてコイルエンド成形機により曲げ加工が施された導体線を示す正面図である。
図45はこの発明の実施の形態3に係る回転電機における巻線体の製造方法においてコイルエンド成形機により曲げ加工が施された導体線を示す正面図である。
また、上記各実施の形態では、巻線体が導体線を螺旋状に4ターン巻回して構成されているものとしているが、導体線のターン数は4回に限定されず、2回以上であればよい。
また、上記各実施の形態では、長方形断面の導体線を用いて巻線体を作製しているが、円形断面の導体線を用いて巻線体を作製してもよい。この場合、導体線の曲げ加工が容易となる。
また、上記各実施の形態では、本願を電動機に適用した場合について説明しているが、本願を発電機に適用しても、同様の効果を奏する。
また、上記各実施の形態では、本願を電動機に適用した場合について説明しているが、本願が適用できる電気機械は、電動機、発電機などの回転電機に限定されず、リニアモータなどの直動機に適用しても、同様の効果を奏する。この場合、巻線体のコイルエンドの傾斜部は円弧形に曲げ成形されず、直線状となっており、第1直線部の列と第2直線部の列との間の間隔は、一定となっている。
Claims (8)
- 絶縁被覆された、かつ接続部のない連続した導体線を螺旋状にm回(但し、mは2以上の自然数)巻回して構成され、各列にm本並んで2列に配列された直線部、および列間で該直線部の端部間を連結するコイルエンドを有し、
上記コイルエンドのそれぞれは、膨出部と、該膨出部と上記直線部とを連結する一対の傾斜部と、該膨出部の中央部に形成されて、該コイルエンドにより連結された該直線部を該直線部の配列方向に設定された量だけ変位させるクランク部と、を備えた、電気機械用電機子巻線に用いられる巻線体の製造方法において、
上記導体線に設定されたピッチで上記膨出部を曲げ成形する膨出部成形工程と、
上記膨出部の中央部に上記クランク部を曲げ成形するクランク部成形工程と、
上記膨出部成形工程および上記クランク部成形工程の完了後、上記膨出部が設定されたピッチで形成され、上記クランク部が該膨出部のそれぞれに形成された上記導体線に、上記直線部を曲げ成形する直線部成形工程と、
上記直線部成形工程に先立って、上記導体線の上記膨出部の両側に上記傾斜部を曲げ成形する傾斜部成形工程と、を備えていることを特徴とする電気機械用電機子巻線に用いられる巻線体の製造方法。 - 上記膨出部成形工程において、曲げ成形された上記膨出部を基準点として次の上記膨出部を曲げ成形する上記ピッチを管理することを特徴とする請求項1記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 次の上記膨出部を曲げ成形するのに先立って、基準点となる上記膨出部を把持して上記導体線送り方向に移動し、次の上記膨出部を曲げ成形する上記ピッチが設定されたピッチとなるように、基準点となる上記膨出部を位置決めすることを特徴とする請求項2記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 基準点となる上記膨出部が位置決めされた後、上記クランク部成形工程を実施され、上記クランク部が位置決めされた上記膨出部の中央部に曲げ成形されることを特徴とする請求項3記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 上記直線部成形工程において、上記膨出部を基準点として、上記直線部が該膨出部の両側に曲げ成形されることを特徴とする請求項1から請求項4のいずれか1項に記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 上記直線部が上記膨出部の両側に曲げ成形されるのに先立って、上記傾斜部成形工程が実施され、上記傾斜部が、上記膨出部を基準点として、上記導体線の該膨出部の両側に曲げ成形されることを特徴とする請求項5記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 上記膨出部成形工程が上記傾斜部成形工程を含み、上記膨出部と該膨出部の両側の上記傾斜部とが上記導体線に設定されたピッチで同時に曲げ成形されることを特徴とする請求項1から請求項5のいずれか1項に記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
- 上記直線部成形工程の完了後、上記傾斜部を円弧状に曲げ成形する工程を備えていることを特徴とする請求項1から請求項7のいずれか1項に記載の電気機械用電機子巻線に用いられる巻線体の製造方法。
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EP4264795A1 (fr) * | 2020-12-17 | 2023-10-25 | Nidec PSA Emotors | Bobine destinée à être insérée dans des encoches d'un stator d'une machine électrique tournante |
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US10971979B2 (en) | 2017-08-04 | 2021-04-06 | Odawara Engineering Co., Ltd. | Coil segment forming apparatus, coil segment forming method and manufacturing apparatus of electrical rotating machine |
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Also Published As
Publication number | Publication date |
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CN104737427B (zh) | 2017-06-13 |
CN104737427A (zh) | 2015-06-24 |
US9680358B2 (en) | 2017-06-13 |
DE112013005097T5 (de) | 2015-08-06 |
JPWO2014065026A1 (ja) | 2016-09-08 |
JP5924711B2 (ja) | 2016-05-25 |
US20150288262A1 (en) | 2015-10-08 |
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