WO2014129521A1 - ステータの製造方法及び製造装置 - Google Patents
ステータの製造方法及び製造装置 Download PDFInfo
- Publication number
- WO2014129521A1 WO2014129521A1 PCT/JP2014/053962 JP2014053962W WO2014129521A1 WO 2014129521 A1 WO2014129521 A1 WO 2014129521A1 JP 2014053962 W JP2014053962 W JP 2014053962W WO 2014129521 A1 WO2014129521 A1 WO 2014129521A1
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- WIPO (PCT)
- Prior art keywords
- concentrated winding
- winding coil
- coil
- phase
- stator
- 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
- H02K15/06—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
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/0056—Manufacturing winding connections
- H02K15/0068—Connecting winding sections; Forming leads; Connecting leads to terminals
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
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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
- Y10T29/49009—Dynamoelectric machine
Definitions
- the present invention relates to a method and an apparatus for manufacturing a stator in which concentrated winding coils are respectively attached to a plurality of teeth in a stator core.
- coils are respectively arranged in a plurality of slots in the stator core, or coils are respectively attached to a plurality of teeth in the stator core, and all the coils are arranged or attached. After that, the ends of the coils are welded together.
- the rotating electrical machine of Patent Document 1 and the motor stator of Patent Document 2 after arranging coils made of rectangular wires with respect to the stator core, the ends of the rectangular wires of each coil are joined together by welding or the like. Yes.
- the present invention has been made in view of such a background, and can reduce the apparatus used for manufacturing the stator, and can reduce the space occupied by the apparatus in the manufacturing process of the stator. And an attempt to provide a manufacturing apparatus.
- a concentrated winding coil in which a rectangular conductor is wound is attached to each of a plurality of teeth in a stator core, and an end of the concentrated winding coil is welded to an end of the other concentrated winding coil.
- a method of manufacturing a stator After the first concentrated winding coil and the second concentrated winding coil are mounted on the tooth, when the third concentrated winding coil is mounted on the tooth, the end of the first concentrated winding coil and the second concentrated coil are mounted. It is in the manufacturing method of the stator characterized by starting welding with the edge part of a wound coil.
- Another aspect of the present invention is a coil mounting means for sequentially mounting concentrated winding coils each having a rectangular conductor wound around a plurality of teeth in a stator core; Welding means for welding the end portion of the concentrated winding coil to the other end portion of the concentrated winding coil, When the third concentrated winding coil is mounted on the tooth by the coil mounting means, the end of the first concentrated winding coil already mounted on the tooth by the welding unit and the first mounted on the tooth by the welding means.
- the stator manufacturing apparatus is configured to start welding with an end portion of the two concentrated winding coils.
- a concentrated winding coil wound with a rectangular conductor is attached to the teeth of the stator core, the attachment of the coil to the stator core and the welding of the ends of the coil are performed in the same space. I am doing. Specifically, a first concentrated winding coil that is one of the concentrated winding coils and a second concentrated winding coil that is another concentrated winding coil are attached to the teeth of the stator core. And when the 3rd concentrated winding coil which is another concentrated winding coil is mounted
- the mounting and welding of the concentrated winding coil can be performed in the same process for manufacturing the stator, and the apparatus used for manufacturing the stator can be reduced. Further, the space used in the stator manufacturing process by the apparatus used for manufacturing the stator can be reduced.
- stator manufacturing apparatus the same effects as those of the stator manufacturing method can be obtained by using coil mounting means and welding means. Moreover, by using the coil mounting means and the welding means in the same process of manufacturing the stator, devices such as jigs attached to these means can be combined.
- FIG. 1 is an explanatory perspective view showing a stator manufacturing apparatus according to a first embodiment.
- FIG. 3 is an explanatory plan view showing the stator according to the first embodiment.
- BRIEF DESCRIPTION OF THE DRAWINGS FIG. BRIEF DESCRIPTION OF THE DRAWINGS
- FIG. BRIEF DESCRIPTION OF THE DRAWINGS FIG. BRIEF DESCRIPTION OF THE DRAWINGS
- FIG. Explanatory drawing which shows the concentrated winding coil with which it mounts on the slot of a stator core concerning Example 1 from the inner peripheral side of the stator core.
- Plane explanatory drawing which shows the state which manufactures the stator concerning Example 2.
- FIG. Plane explanatory drawing which shows the state which manufactures the stator concerning Example 2.
- FIG. 1 is an explanatory perspective view showing a stator manufacturing apparatus according to a first embodiment.
- FIG. 3 is an explanatory plan view showing the stator according to the first embodiment.
- the rectangular conductor refers to a conductor having a cross section such as a substantially rectangular shape or a flat shape.
- the concentrated coil may be formed by winding a single rectangular conductor. Further, the welding of the end portion of the first concentrated winding coil and the end portion of the second concentrated winding coil may be completed within the time when the third concentrated winding coil is attached to the teeth. It does not have to be completed in time. That is, the time during which the third concentrated winding coil is attached to the tooth overlaps with the time during which the end of the first concentrated winding coil and the end of the second concentrated winding coil are welded. It only has to be.
- the end portions of the concentrated winding coils may be welded each time the concentrated winding coils are attached to the teeth.
- welding of the ends of the concentrated winding coil and mounting of the concentrated winding coil on each tooth can be repeated in the same time zone. Therefore, the time for manufacturing the stator can be easily reduced.
- the concentrated winding coil is divided into three phases of U phase, V phase, and W phase, and the three phase concentrated winding coils are repeatedly arranged adjacent to each other in the circumferential direction of the stator core in the same arrangement order.
- a stator for a three-phase rotating electrical machine attached to the stator, by rotating the stator core sequentially in the circumferential direction by a predetermined rotation angle, and attaching the three-phase concentrated winding coils to the teeth in the same arrangement order;
- the attached concentrated winding coil may be sequentially welded in the circumferential direction.
- the apparatus for manufacturing the stator can be simplified.
- the first concentrated winding coil and the second concentrated winding coil are the concentrated winding coils of the same phase, and the third concentrated winding coil is different from the first concentrated winding coil and the second concentrated winding coil.
- the concentrated winding coil of the phase may be used.
- the concentrated winding coil of the other phase is attached to the teeth, the concentrated winding coil of the same phase can be welded.
- the device used for mounting the concentrated winding coil of each phase or the concentrated winding coil mounted on this device and the device used for welding of the concentrated winding coil of each phase do not interfere with each other, It is possible to efficiently mount and weld the concentrated winding coil of the phase.
- the second concentrated winding coil may be attached to the tooth just before the third concentrated winding coil is attached to the tooth.
- the time for manufacturing the stator can be made as short as possible.
- At least two or more of the plurality of concentrated winding coils of each phase are such that one of the winding ends of the rectangular conductor is at one of an inner peripheral side position and an outer peripheral side position, and the stator core shaft The other end of the winding end portion of the rectangular wire conductor is pulled out outward in the axial direction of the stator core at the other of the inner peripheral side position and the outer peripheral side position. After that, a crossing portion extended to the drawing portion of the other coil in the same phase may be formed. In this case, the lead-out portion of the concentrated winding coil and the transition portion of another concentrated winding coil in the same phase can be welded together.
- the end of the concentrated winding coil of each phase located at one end is connected to the end of each concentrated winding coil of each phase.
- the lead conductors are welded to form a three-phase lead portion, and the end portions of the concentrated winding coils of the respective phases are welded to the end portions of the concentrated winding coils of the respective phases located at the other end.
- a neutral point may be formed.
- the stator in the same process of manufacturing the stator, not only the mounting of the coil to the stator core and the welding of the ends of the coil but also the welding of the three-phase lead conductor and the welding of the neutral point are performed. It can also be done. Therefore, the stator can be manufactured in a shorter time and with fewer devices.
- the stator manufacturing apparatus includes a rotating unit that rotates the stator core around a central axis thereof, and the coil mounting unit and the welding unit are respectively separated by a predetermined interval in the circumferential direction of the stator core. You may be comprised so that mounting
- the welding of the ends of the concentrated winding coils by the welding means is repeated each time the concentrated winding coils are mounted on the teeth by the coil mounting means. May be. In this case, welding of the ends of the concentrated winding coil and mounting of the concentrated winding coil on each tooth can be repeated in the same time zone. Therefore, the time for manufacturing the stator can be easily reduced.
- stator manufacturing method As shown in FIG. 1, three-phase concentrated winding coils 71U, 71V, 71W each having a rectangular conductor 711 wound are mounted on a plurality of teeth 61 in the stator core 6, respectively.
- the stator 5 is manufactured by welding the end portions 72a of the concentrated winding coils 71U, 71V, 71W of the respective phases to the end portions 72b of the other concentrated winding coils 71U, 71V, 71W of the same phase.
- the first concentrated winding coil and the second concentrated winding coil are attached to the teeth 61.
- the stator 5 of this example includes concentrated winding coils 71U, 71V, 71W divided into U-phase, V-phase, and W-phase three-phase continuous coils 7U, 7V, 7W.
- This is a stator 5 for a three-phase rotating electrical machine attached to the teeth 61.
- the stator core 6 has slots 62 and teeth 61 radially on the inner peripheral side thereof, and is disposed on the outer peripheral side of the inner rotor.
- the concentrated winding coils 71U, 71V, 71W are formed by winding a rectangular conductor (flat rectangular wire) 711 having a cross section such as a substantially rectangular shape or a flat shape into a shape along the outer periphery of the tooth 61.
- the rectangular conductor 711 is formed of a conductor layer made of a copper material and an insulating layer made of an insulating resin that covers the outer periphery of the conductor layer.
- Each concentrated winding coil 71U, 71V, 71W is formed by winding a single rectangular conductor 711.
- the same number of three-phase concentrated winding coils 71U, 71V, 71W are repeatedly mounted on the teeth 61 adjacent to each other in the circumferential direction C of the stator core 6 in the same arrangement order. And in the edge part of the axial direction one end side of the stator core 6, end part 72a, 72b of the concentrated winding coil 71U (or 71V, 71W) of the same phase is joined by welding.
- the stator core 6 is provided with three-phase continuous coils 7U, 7V, and 7W in which concentrated winding coils 71U, 71V, and 71W of the respective phases are connected for each phase.
- the three-phase continuous coils 7U, 7V, 7W are star-connected.
- a three-phase lead 73 is formed at one end of the three-phase continuous coils 7U, 7V, and 7W, and a neutral point 74 is formed at the other end of the three-phase continuous coils 7U, 7V, and 7W.
- the end portions 72a of the concentrated winding coils 71U, 71V, 71W of the respective phases located at one end of the three-phase continuous coils 7U, 7V, 7W are respectively connected to the end portions 72a of the concentrated winding coils 71U, 71V, 71W of the respective phases.
- a lead conductor 731 is welded to a three-phase lead portion 73.
- the end portions 72c of the concentrated winding coils 71U, 71V, 71W of the respective phases located at the other ends of the three-phase continuous coils 7U, 7V, 7W are connected to the ends of the concentrated winding coils 71U, 71V, 71W of the respective phases.
- the neutral points 74 are formed by welding the portions 72c to each other.
- the three-phase lead portion 73 is disposed with respect to the terminal block 8 attached to the axial end surface of the stator core 6.
- the three-phase lead conductor 731 is attached to the terminal block 8 in advance. Then, the lead conductor 731 on the terminal block 8 and the end portions 72a of the concentrated winding coils 71U, 71V, 71W of the respective phases are welded to form a three-phase lead portion 73.
- One end 72 a drawn to the position on the outer peripheral side is composed of one winding end of the rectangular conductor 711.
- One end portion 72 a forms a lead-out portion that is drawn outward in the axial direction of the stator core 6.
- the other end 72 b drawn from the position on the inner peripheral side of the stator core 6 to the position on the outer peripheral side is composed of the other winding end of the rectangular conductor 711.
- the other end portion 72b forms a crossing portion that is pulled out outward in the axial direction of the stator core 6 and then extended to one end portion 72a of the other coils 71U, 71V, 71W in phase.
- One end portion 72 a as a lead-out portion and the other end portion 72 b as a transition portion are formed other than the end portion 72 c that forms the neutral point 74.
- the stator manufacturing apparatus 1 provided with the coil mounting means 2, the welding means 3, and the rotation means 4 is used.
- the coil mounting means 2 is configured to sequentially mount concentrated winding coils 71U, 71V, 71W around which a rectangular conductor 711 is wound around a plurality of teeth 61 in the stator core 6.
- the coil mounting means 2 has a holding portion 21 that holds the concentrated winding coils 71U, 71V, 71W.
- the holding portion 21 of the coil mounting means 2 is sequentially opposed to each tooth 61 in the stator core 6, advances toward the tooth 61, and the concentrated winding coils 71 ⁇ / b> U, 71 ⁇ / b> V, 71 ⁇ / b> W held by the holding portion 21 are attached to the tooth 61. It is configured as follows.
- the welding means 3 has a welding torch 31 for performing TIG welding (tungsten-inert gas welding).
- the welding torch 31 can be attached to a robot (moving device) and moved to each welding site where the end portions 72a, 72b of the concentrated winding coils 71U, 71V, 71W are located.
- the coil mounting means 2 and the welding means 3 are connected to the concentrated winding coils 71U, 71V, 71W and the concentrated winding coils 71U, 71V, 71W, respectively, in a state where they are separated from each other in the circumferential direction C of the stator core 6. It is comprised so that the edge parts 72a and 72b may be welded.
- the stator core 6 is held by the rotating means 4.
- the rotating means 4 is configured to hold the stator core 6 and rotate the stator core 6 about its central axis by an angle corresponding to the formation interval of the teeth 61 in the circumferential direction C.
- the rotating means 4 can be configured to rotate the coil mounting means 2 in addition to the structure that rotates the stator core 6. Further, the welding torch 31 can be fixed at an appropriate place.
- the stator manufacturing apparatus 1 may include a monitoring camera that monitors whether or not the part welded by the welding means 3 is normally welded.
- the surveillance camera can check the quality of the welded state by performing image processing.
- the surveillance camera attaches the concentrated winding coils 71U, 71V, 71W to the teeth 61 or ends 72a, 72b of the concentrated winding coils 71U, 71V, 71W for each part where the welding means 3 performs welding. When welding each other, the quality of each welded part can be determined.
- the welding of the end portions 72a, 72b of the three-phase concentrated winding coils 71U, 71V, 71W is repeated each time the concentrated winding coils 71U, 71V, 71W are attached to the teeth 61.
- the stator core 6 is sequentially rotated in the circumferential direction C by a predetermined rotation angle, and the three-phase concentrated winding coils 71U, 71V, 71W are mounted on the teeth 61 in the same arrangement order, and the mounted concentrated winding coil 71U is mounted.
- 71V, 71W are sequentially welded in the circumferential direction C.
- a terminal block 8 provided with a three-phase lead conductor 731 is attached to the axial end surface of the stator core 6.
- the coil mounting means 2 mounts the three-phase concentrated winding coils 71U, 71V, 71W of the U phase, the V phase, and the W phase to the teeth 61 of the stator core 6.
- the concentrated winding coils 71U, 71V, 71W are positioned at one end of the continuous coils 7U, 7V, 7W of the respective phases in order to form the lead portion 73.
- the V-phase concentrated winding coil positioned at one end of the V-phase continuous coil 7V is mounted on the teeth 61 by the coil mounting means 2, the V-phase concentrated winding coil positioned at one end of the V-phase continuous coil 7V.
- the welding means 3 welds the lead conductor 731 on the terminal block 8 and one end 72a of the U-phase concentrated winding coil 71Ua to provide a U-phase lead.
- a portion 73 can be formed (see FIG. 2).
- the W-phase concentrated winding coil 71Wa is attached to the tooth 61
- the V-phase lead portion 73 can be formed (see FIG. 2).
- one end means one end of each continuous coil 7U, 7V, 7W.
- the coil mounting means 2 mounts the U-phase concentrated winding coil 71 ⁇ / b> Ub located second from one end in the slot 62.
- one end 72a of the U-phase concentrated winding coil 71Ub located second from the one end faces the other end 72b of the U-phase concentrated winding coil 71Ua located at one end.
- the welding means 3 causes the lead conductor 731 on the terminal block 8 and one end 72a of the W-phase concentrated winding coil 71Wa located at one end. Can be welded to form a W-phase lead 73 (see FIG. 2).
- the coil mounting means 2 mounts the V-phase concentrated winding coil 71 Vb (third concentrated winding coil) located second from the one end in the slot 62.
- the V-phase concentrated winding coil 71Vb (third concentrated winding coil) is mounted, one of the U-phase concentrated winding coils 71Ub (second concentrated winding coil) located second from one end is installed.
- the end 72 a and the other end 72 b of the U-phase concentrated winding coil 71 Ua (first concentrated winding coil) located at one end can be welded by the welding means 3.
- the coil mounting means 2 mounts the W-phase concentrated winding coil 71 ⁇ / b> Wb (third concentrated winding coil) located second from one end in the slot 62.
- Wb third concentrated winding coil
- the W-phase concentrated winding coil 71Wb (third concentrated winding coil) is attached, one of the V-phase concentrated winding coils 71Vb (second concentrated winding coil) located second from one end is installed.
- the end 72 a and the other end 72 b of the V-phase concentrated winding coil 71 Va (first concentrated winding coil) located at one end can be welded by the welding means 3.
- 72 b can be welded together by the welding means 3.
- the concentrated winding of each phase positioned at the other end of the three-phase continuous coils 7U, 7V, 7W by the welding means 3.
- the end portions 72c of the coils 71U, 71V, 71W can be welded together to form a neutral point 74 (see FIG. 2).
- the formation of the lead portions 73 of each phase by the welding means 3 can also be performed when the neutral points 74 are formed.
- the concentrated winding coils 71U of the respective phases are sequentially applied in the direction C1 that rotates from the side where the one end 72a is located to the side where the other end 72b is located.
- 71V, 71W are mounted in the slots 62 of the stator core 6 in the same arrangement order. As shown in FIG.
- the concentrated winding coils 71U, 71V, 71W can be mounted and welded in the same process for manufacturing the stator 5. Then, by using the coil mounting means 2 and the welding means 3 in the same process of manufacturing the stator 5, devices such as jigs attached to these means 2 and 3 can be combined. Therefore, the apparatus used in order to manufacture the stator 5 can be reduced. Further, the space used by the apparatus used for manufacturing the stator 5 in the manufacturing process of the stator 5 can be reduced.
- Example 2 the concentrated winding coils 71U, 71V, 71W of the respective phases are sequentially arranged in the other direction C2 opposite to the one direction C1 of the stator core 6 shown in the first embodiment.
- Each concentrated winding coil 71U, 71V, 71W of the present example is sequentially rotated in the circumferential direction C of the stator core 6 so as to turn from the side where the other end 72b is located to the side where the one end 72a is located.
- the slot 62 is mounted.
- the concentrated winding coils 71U, 71V, 71W of this example have one end as a lead-out portion of the concentrated winding coils 71U, 71V, 71W having already mounted the other end 72b as a transition portion thereof in the slot 62 of the stator core 6. It is mounted in the slot 62 while passing between the portion 72a and the other end 72b as a transition portion of the concentrated winding coils 71U, 71V, 71W. Then, one end portion 72a of the concentrated winding coil 71U (or 71V, 71W) is connected to the other two-phase concentrated winding coils 71V, 71W (or 71U, 71W, or 71U, 71V) previously attached to the slot 62.
- the mounting position by the coil mounting means 2 is used. And the welding position by the welding means 3 are separated as much as possible.
- the welding means 3 is attached. Start welding using.
- FIG. 8 when a W-phase concentrated winding coil 71W located third from one end of the W-phase continuous coil 7W is mounted in the slot 62, V positioned at one end of the V-phase continuous coil 7V.
- a state is shown in which welding is performed between one end 72a of the concentrated winding coil 71V of the phase and the other end 72b of the concentrated winding coil 71V of the V phase located second from one end of the continuous coil 7V of the V phase. .
- FIG. 9 when the V-phase concentrated winding coil 71 ⁇ / b> V located third from one end of the V-phase continuous coil 7 ⁇ / b> V is mounted in the slot 62, it is positioned at one end of the U-phase continuous coil 7 ⁇ / b> U. Welding one end 72a of the concentrated U-phase coil 71U and the other end 72b of the U-phase concentrated coil 71U located second from one end of the U-phase continuous coil 7U Indicates.
- the other concentrated winding coils 71U, 71V, 71W are sequentially mounted and welded so as to rotate in the other direction C2 of the stator core 6.
- the other configurations and the reference numerals in the drawing are the same as those in the first embodiment, and the same effects as those in the first embodiment can be obtained.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
- Windings For Motors And Generators (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
Abstract
Description
例えば、特許文献1の回転電機、特許文献2のモータ固定子においては、ステータコアに対して、平角線からなるコイルを配置した後に、各コイルの平角線の端部同士を溶接等によって接合している。
第1集中巻コイルと第2集中巻コイルとを上記ティースに装着した後、第3集中巻コイルを上記ティースに装着しているときに、上記第1集中巻コイルの端部と上記第2集中巻コイルの端部との溶接を開始することを特徴とするステータの製造方法にある。
上記集中巻コイルの端部を他の上記集中巻コイルの端部と溶接する溶接手段と、を備え、
上記コイル装着手段によって、上記ティースに第3集中巻コイルを装着しているときに、上記溶接手段によって、上記ティースに既に装着した第1集中巻コイルの端部と、上記ティースに既に装着した第2集中巻コイルの端部との溶接を開始するよう構成されていることを特徴とするステータの製造装置にある。
具体的には、ステータコアのティースには、いずれかの集中巻コイルである第1集中巻コイルと他の集中巻コイルである第2集中巻コイルとを装着する。そして、さらに他の集中巻コイルである第3集中巻コイルをティースに装着しているときに、第1集中巻コイルの端部と第2集中巻コイルの端部とを溶接する。
上記ステータの製造方法及び製造装置において、上記角線導体とは、略矩形状、扁平形状等の断面を有する導体のことをいう。また、上記集中巻コイルは、一本の角線導体を巻回して形成されていてもよい。
また、上記第1集中巻コイルの端部と上記第2集中巻コイルの端部との溶接は、上記第3集中巻コイルを上記ティースに装着している時間内に完了してもよく、この時間内に完了しなくてもよい。すなわち、上記第3集中巻コイルを上記ティースに装着している時間と、上記第1集中巻コイルの端部と上記第2集中巻コイルの端部とを溶接している時間とがオーバラップしていればよい。
この場合には、集中巻コイルの端部同士の溶接と、各ティースに対する集中巻コイルの装着とを、同じ時間帯に繰り返し行うことができる。そのため、ステータを製造する時間を容易に短縮することができる。
この場合には、ステータの製造を行う装置を簡略化することができる。
この場合には、他相の集中巻コイルをティースに装着しているときに、同相の集中巻コイルの溶接をすることができる。これにより、各相の集中巻コイルの装着に使用する装置又はこの装置に装着された集中巻コイルと、各相の集中巻コイルの溶接に使用する装置とが、互いに干渉しないようにして、各相の集中巻コイルの装着及び溶接を効率的に行うことができる。
この場合には、ステータを製造する時間をできるだけ短くすることができる。
この場合には、集中巻コイルの引出部と、同相の他の集中巻コイルの渡り部とを互いに溶接して連結することができる。
この場合には、ステータを製造する同じ工程において、ステータコアへのコイルの装着とコイルの端部同士の溶接とを行うだけでなく、3相のリード導体の溶接と、中性点の溶接とを行うこともできる。そのため、ステータをより短時間で、かつ少ない装置によって製造することができる。
この場合には、コイル装着手段と溶接手段との干渉を避けて、ステータコアを回転させながらステータの製造を行うことができる。
この場合には、集中巻コイルの端部同士の溶接と、各ティースに対する集中巻コイルの装着とを、同じ時間帯に繰り返し行うことができる。そのため、ステータを製造する時間を容易に短縮することができる。
本例のステータ5の製造方法においては、図1に示すごとく、ステータコア6における複数のティース61に、角線導体711を巻回した3相の集中巻コイル71U,71V,71Wをそれぞれ装着し、各相の集中巻コイル71U,71V,71Wの端部72aを他の同相の集中巻コイル71U,71V,71Wの端部72bと溶接して、ステータ5を製造する。このステータ5の製造に当たっては、第1集中巻コイルと第2集中巻コイルとをティース61に装着する。次いで、第1集中巻コイル及び第2集中巻コイルとは異なる相の第3集中巻コイルをティース61に装着しているときに、第1集中巻コイルの端部72aと第2集中巻コイルの端部72bとの溶接を開始する。また、第2集中巻コイルは、第3集中巻コイルをティース61に装着する一つ前に、ティース61に装着されたものである。
(実施例1)
図2に示すごとく、本例のステータ5は、集中巻コイル71U,71V,71WをU相、V相、W相の3相の連コイル7U,7V,7Wごとに分けて、ステータコア6の各ティース61に装着する3相回転電機用のステータ5である。ステータコア6は、その内周側に、スロット62及びティース61を放射状に有するものであり、インナーロータの外周側に配置されるものである。集中巻コイル71U,71V,71Wは、略矩形状、扁平形状等の断面を有する角線導体(平角線)711を、ティース61の外周に沿った形状に巻回して形成されている。角線導体711は、銅材料からなる導体層と、導体層の外周を被覆する絶縁樹脂からなる絶縁層とによって形成されている。各集中巻コイル71U,71V,71Wは、一本の角線導体711を巻回して形成されている。
引出部としての一方の端部72a及び渡り部としての他方の端部72bは、中性点74を形成する端部72c以外に形成されている。
コイル装着手段2は、ステータコア6における複数のティース61に、角線導体711を巻回した集中巻コイル71U,71V,71Wを順次装着するよう構成されている。コイル装着手段2は、集中巻コイル71U,71V,71Wを保持する保持部21を有している。コイル装着手段2の保持部21は、ステータコア6における各ティース61に順次対向され、ティース61に向かって前進して、保持部21に保持する集中巻コイル71U,71V,71Wをティース61に装着するよう構成されている。
また、コイル装着手段2と溶接手段3とは、ステータコア6の周方向Cに所定の間隔離れた状態で、それぞれ集中巻コイル71U,71V,71Wの装着と、集中巻コイル71U,71V,71Wの端部72a,72b同士の溶接とを行うよう構成されている。
本例においては、3相の集中巻コイル71U,71V,71Wの端部72a,72b同士の溶接は、各ティース61に対して集中巻コイル71U,71V,71Wを装着するごとに繰り返し行う。また、ステータコア6を所定の回転角度ずつ周方向Cに順次回転させて、3相の集中巻コイル71U,71V,71Wを同じ配列順序でティース61に装着するとともに、該装着された集中巻コイル71U,71V,71Wを周方向Cに順次溶接する。
また、各相の全ての集中巻コイル71U,71V,71Wの装着が行われた後には、溶接手段3によって、3相の連コイル7U,7V,7Wの他端に位置する各相の集中巻コイル71U,71V,71Wの端部72cを互いに溶接して、中性点74を形成することができる(図2参照)。また、溶接手段3による各相のリード部73の形成は、中性点74を形成するときに行うこともできる。
図7に示すごとく、各相の集中巻コイル71U(又は71V,71W)をスロット62に装着するときには、この集中巻コイル71U(又は71V,71W)の引出部としての一方の端部72aを、スロット62に先に装着された他の2相の集中巻コイル71V,71W(又は71U,71W、あるいは71U,71V)の渡り部としての他方の端部72bに対する軸方向内方を通過させる。そのため、他方の端部72bがステータコア6の軸方向外方に引き出された位置は、一方の端部72aがステータコア6の軸方向外方に引き出された位置よりも、軸方向外方に位置する。
本例は、図8に示すように、上記実施例1で示したステータコア6の一方向C1と反対側の他方向C2に向けて、順次、各相の集中巻コイル71U,71V,71Wを、同じ配列順序で装着する例である。本例の各集中巻コイル71U,71V,71Wは、ステータコア6の周方向Cにおいて、他方の端部72bが位置する側から一方の端部72aが位置する側へ回るように、順次、ステータコア6のスロット62に装着される。
本例においても、その他の構成及び図中の符号は上記実施例1と同様であり、上記実施例1と同様の作用効果を得ることができる。
Claims (8)
- ステータコアにおける複数のティースに、角線導体を巻回した集中巻コイルをそれぞれ装着し、該集中巻コイルの端部を他の該集中巻コイルの端部と溶接して、ステータを製造する方法において、
第1集中巻コイルと第2集中巻コイルとを上記ティースに装着した後、第3集中巻コイルを上記ティースに装着しているときに、上記第1集中巻コイルの端部と上記第2集中巻コイルの端部との溶接を開始することを特徴とするステータの製造方法。 - 上記集中巻コイルの端部同士の溶接は、上記各ティースに対して上記集中巻コイルを装着するごとに繰り返し行うことを特徴とする請求項1に記載のステータの製造方法。
- 上記ステータは、上記集中巻コイルがU相、V相、W相の3相に分けられて、該3相の集中巻コイルが同じ配列順序で上記ステータコアの周方向に隣り合って繰り返し上記各ティースに装着された3相回転電機用のステータであり、
上記ステータコアを所定の回転角度ずつ周方向に順次回転させて、上記3相の集中巻コイルを同じ配列順序で上記ティースに装着するとともに、該装着された集中巻コイルを周方向に順次溶接することを特徴とする請求項1又は2に記載のステータの製造方法。 - 上記第2集中巻コイルは、上記第3集中巻コイルを上記ティースに装着する一つ前に、上記ティースに装着されたものであることを特徴とする請求項1~3のいずれか一項に記載のステータの製造方法。
- 各相の上記集中巻コイルごとにそれぞれ連結される3相の連コイルにおいて、一端に位置する各相の上記集中巻コイルの端部には、該各相の集中巻コイルの端部ごとにリード導体を溶接して3相のリード部を形成するとともに、他端に位置する各相の上記集中巻コイルの端部には、該各相の集中巻コイルの端部を互いに溶接して中性点を形成することを特徴とする請求項3又は4に記載のステータの製造方法。
- ステータコアにおける複数のティースに、角線導体を巻回した集中巻コイルを順次装着するコイル装着手段と、
上記集中巻コイルの端部を他の上記集中巻コイルの端部と溶接する溶接手段と、を備え、
上記コイル装着手段によって、上記ティースに第3集中巻コイルを装着しているときに、上記溶接手段によって、上記ティースに既に装着した第1集中巻コイルの端部と、上記ティースに既に装着した第2集中巻コイルの端部との溶接を開始するよう構成されていることを特徴とするステータの製造装置。 - 上記ステータコアを、その中心軸線の回りに回転させる回転手段を備え、
上記コイル装着手段と上記溶接手段とは、上記ステータコアの周方向に所定の間隔離れた状態で、それぞれ上記集中巻コイルの装着と上記集中巻コイルの端部同士の溶接とを行うよう構成されていることを特徴とする請求項6に記載のステータの製造装置。 - 上記溶接手段による上記集中巻コイルの端部同士の溶接は、上記コイル装着手段によって上記各ティースに対して上記集中巻コイルを装着するごとに繰り返し行うよう構成されていることを特徴とする請求項6又は7に記載のステータの製造装置。
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