WO2020067352A1 - Procédé de fabrication de stator - Google Patents

Procédé de fabrication de stator Download PDF

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Publication number
WO2020067352A1
WO2020067352A1 PCT/JP2019/037987 JP2019037987W WO2020067352A1 WO 2020067352 A1 WO2020067352 A1 WO 2020067352A1 JP 2019037987 W JP2019037987 W JP 2019037987W WO 2020067352 A1 WO2020067352 A1 WO 2020067352A1
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WO
WIPO (PCT)
Prior art keywords
slot
stator
resin
jig
conductor
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Application number
PCT/JP2019/037987
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English (en)
Japanese (ja)
Inventor
加藤貴俊
木村英明
Original Assignee
アイシン・エィ・ダブリュ株式会社
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Filing date
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Application filed by アイシン・エィ・ダブリュ株式会社 filed Critical アイシン・エィ・ダブリュ株式会社
Publication of WO2020067352A1 publication Critical patent/WO2020067352A1/fr

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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
    • 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
    • H02K15/08—Forming windings by laying conductors into or around core parts
    • H02K15/085—Forming windings by laying conductors into or around core parts by laying conductors into slotted stators

Definitions

  • the present invention relates to a method for manufacturing a stator used for a rotating electric machine.
  • Patent Document 1 Japanese Patent No. 6350666 discloses a method of manufacturing a stator for a rotating electric machine.
  • a post-process such as bending or joining the lead wires [50, 52] of the stator coil [26] is performed.
  • the reference numerals in parentheses in the description of the background art are those of Patent Document 1).
  • stator coil In a post-process after the stator coil is mounted on the stator core, it is necessary to deform the stator coil to a prescribed shape or to arrange each part of the stator coil at a prescribed position. is there.
  • stator coil since the stator coil is made of metal such as copper or aluminum, it is accompanied by elastic deformation (spring back). Therefore, in a post-process after the stator coil is mounted on the stator core, a jig for stabilizing the shape of the stator coil and the position of each part has been required.
  • the characteristic configuration of the method for manufacturing a stator includes a stator core having a plurality of slots, a stator coil configured by joining a plurality of conductor wires and having a slot accommodating portion arranged inside the slot,
  • the stator core has a cylindrical shape
  • the slot has an opening in an inner peripheral surface of the stator core, and a resin arrangement for arranging a foamed resin before foaming inside the slot.
  • the slot accommodating portion can be fixed at a correct position with respect to the slot by the resin foamed in the resin foaming step. Therefore, even after the support jig is removed from the stator after the resin foaming step, the conductor joining step can be accurately performed on the stator coil fixed at the correct position.
  • post-processes other than the conductor bonding process those processes can be similarly performed.
  • the support jig since the support jig is not required in the process after the resin foaming process, it is possible to reduce the cost for preparing a large number of jigs and the trouble of attaching and detaching the jig in each process. .
  • the slot storage portion after being inserted into the slot tends to move radially inward due to springback, so that the slot storage portion is held at an appropriate position when performing a post-process.
  • such holding can be appropriately performed by the resin foamed in the resin foaming step.
  • Partial perspective view of a stator for a rotating electric machine Partial radial sectional view of a stator for a rotating electric machine Explanatory drawing showing an example of the structure of a foamed resin Explanatory drawing showing before and after foaming of foamed resin
  • Flow chart showing manufacturing process of stator for rotating electric machine Explanatory drawing of the resin arrangement step and the slot accommodation section arrangement step Illustration of the jig mounting process Explanatory drawing of the projection processing step Illustration of the conductor bonding process Illustration of the joint insulation process
  • the stator 100 manufactured by the manufacturing method of the present embodiment is used as an armature of a rotating electric machine, and in particular, an inner rotor in which a rotor (not shown) as a field is arranged radially inside the stator 100.
  • a rotor not shown
  • the term “rotating electric machine” is used as a concept including any of a motor (electric motor), a generator (generator), and a motor / generator that performs both functions of a motor and a generator as necessary. I have.
  • the “axial direction L”, the “radial direction R”, and the “circumferential direction C” are the cylindrical core inner peripheral surface 1F (see FIG. 2 and the like), unless otherwise specified. Is defined with reference to the axis of.
  • the inner side is “radial inner side R1” and the outer side is “radial outer side R2”.
  • terms relating to dimensions, arrangement directions, arrangement positions, and the like of each member are used as a concept including a state having a difference due to an error (an error that is allowable in manufacturing).
  • stator 100 manufactured by the manufacturing method of the present embodiment will be described with reference to FIGS.
  • stator coil 2 is not shown in a state where most of the coil end portions 22 protruding from the stator core 1 in the axial direction L are cut off.
  • the stator 100 includes a stator core 1 having a plurality of slots 11 and a stator coil 2 formed by joining a plurality of conductor wires W and having a slot accommodating portion 21 disposed inside the slot 11. .
  • the stator 100 functions as an armature of a rotating electric machine, and in this example, functions as an armature of a radial gap type (inner rotor type) rotating electric machine.
  • the stator core 1 is configured by laminating a plurality of magnetic steel sheets of magnetic material in the axial direction L, or is mainly configured by a compact formed by pressing a powder of a magnetic material.
  • the stator core 1 is formed in a cylindrical shape.
  • a plurality of slots 11 extending in the axial direction L and the radial direction R are dispersedly arranged in the circumferential direction C.
  • the slots 11 are open in the core inner peripheral surface 1F (inner peripheral surface) of the stator core 1. That is, the slot 11 has the opening 11A that opens to the radial inside R1.
  • the slots 11 are also opened at both end surfaces of the stator core 1 in the axial direction L.
  • the plurality of slots 11 are arranged at regular intervals in the circumferential direction C.
  • a tooth 12 is formed between two slots 11 adjacent in the circumferential direction C.
  • the teeth 12 are formed so as to protrude inward in the radial direction R1 from the annular yoke portion 13, and a plurality of the teeth 12 are dispersedly arranged along the circumferential direction C.
  • the above-mentioned opening 11A is formed between the tips of the pair of teeth 12 adjacent in the circumferential direction C.
  • the core inner peripheral surface 1F is a cylindrical virtual surface that connects the ends of the plurality of teeth 12 on the radially inner side R1.
  • the inner surface 11F of the slot 11 is connected to a pair of circumferential inner surface portions 11Fc facing in the circumferential direction C and extending in the radial direction R, and a pair of circumferential inner surface portions 11Fc at the radial outer side R2. And a radial inner surface 11Fr extending in the circumferential direction C.
  • the radial inner surface 11Fr is disposed in an end region of the radial outer R2 of the slot 11, and connects the ends of the radial outer R2 of the pair of circumferential inner surfaces 11Fc to each other.
  • the circumferential inner surface portion 11Fc is constituted by the side surface of the teeth 12 in the circumferential direction C.
  • the radial inner surface portion 11Fr is formed to be a flat surface facing the radial inner side R1, and is configured by a surface of the yoke portion 13 in the radial inner side R1.
  • the slot 11 is configured as a so-called full open slot in which a pair of circumferential inner surface portions 11Fc are formed so as to be a continuous plane up to the core inner circumferential surface 1F of the stator core 1. Therefore, at the end of the tooth 12 in the radially inner side R1, for example, a protruding portion that protrudes in the circumferential direction C provided in the case of a semi-open slot is not formed.
  • Stator coil 2 includes a plurality of conductor wires W.
  • the conductor wire W is formed using a conductive material (for example, a metal such as copper or aluminum).
  • a conductive material for example, a metal such as copper or aluminum.
  • the shape of the cross section orthogonal to the extending direction is configured as a rectangular so-called rectangular wire. ing.
  • the “rectangular shape” of the cross-sectional shape of the conductor wire W includes one in which a corner is chamfered (R chamfering, C chamfering, or the like). In the illustrated example, R chamfering is applied to the four corners.
  • the surface of the conductor wire W is covered with an insulating film made of a resin (for example, enamel or the like) except for a part of a connection portion with another conductor wire W and the like.
  • the stator coil 2 is partially inserted into the slot 11 and wound around the stator core 1, and is disposed outside the stator core 1 in the axial direction L with respect to the slot accommodating portion 21 arranged inside the slot 11 in the stator core 1. And a coil end portion 22.
  • the slot accommodating portion 21 is composed of a plurality of conductor wires W arranged side by side in the radial direction R inside the slot 11, and is composed of six conductor wires W in this example.
  • the outer surface 21F of the slot accommodating portion 21 has a pair of circumferential outer surface portions 21Fc facing in opposite directions in the circumferential direction C and extending in the radial direction R, and a pair of circumferential outer surfaces R2 in the radial outer side R2.
  • the radially inner outer surface portion 21Fri is an end surface of the radially inner side R1 in the slot accommodating portion 21, and faces the rotor (not shown) after the rotor (not shown) is assembled.
  • the slot accommodating portion 21 is disposed inside the slot 11 so that the distance in the radial direction R between the radially inner outer surface portion 21Fri and the core inner peripheral surface 1F is equal to or longer than a predetermined set distance SD. Is done.
  • the “set distance SD” is set based on an eddy current generated in the slot accommodating portion 21 due to a change in magnetic flux from a rotor (not shown). More specifically, assuming that the limit distance that can suppress the loss due to the eddy current generated in the slot accommodating portion 21 to the allowable limit or less is the allowable distance AD, the set distance SD is set to a value larger than the allowable distance AD. And good.
  • the “allowable distance AD” is a distance that depends on the size of the rotating electric machine, required performance, and the like, and is determined based on experiments and the like. In the present embodiment, the set distance SD and the allowable distance AD are defined based on the core inner peripheral surface 1F.
  • the present invention is not limited to this, and the base points of the set distance SD and the allowable distance AD can be set arbitrarily.
  • the set distance SD and the allowable distance AD may be defined based on the axial center position of the cylindrical stator core 1.
  • the coil end portion 22 is configured by a plurality of projecting portions 23 which are portions of the conductor wire W arranged outside the stator core 1.
  • the protrusion 23 is a portion of the conductor wire W that protrudes outside the stator core 1.
  • a part of the plurality of projecting portions 23 has the joining target portion 23A.
  • the projecting portion 23 arranged on the radially inner side R1 of one slot 11 and the projecting portion 23 arranged on the radially outer side R2 of the other slot 11 have a joining target portion 23A.
  • These joining target portions 23A are joined to each other by welding or the like as shown in FIG.
  • a plurality of conductors constituting stator coil 2 are electrically connected.
  • the pair of protrusions 23 joined here corresponds to the conductor wires W in the same phase.
  • the stator coil 2 has the joining target portion 23 ⁇ / b> A provided on the projecting portion 23.
  • the joining target portion 23A is configured by a portion (exposed portion) where the insulating film is removed from the conductor wire W to expose the linear conductor. Although details will be described later, the joining target portion 23A is joined to the joining target portion 23A formed on the other projecting portion 23 in the conductor joining step S7 (see FIG. 5).
  • the foamed resin 3 is provided between the slot 11 and the slot accommodating portion 21. More specifically, the foamed resin 3 is provided between the inner surface 11F of the slot 11 and the outer surface 21F of the slot housing.
  • the slot housing 21 is fixed to the slot 11 by the foamed resin 3, and the slot housing 21 and the stator core 1 are electrically insulated.
  • the foamed resin 3 is formed between the circumferential inner surface portion 11Fc of the slot 11 and the circumferential outer surface portion 21Fc of the slot housing portion 21, and the radial inner surface portion 11Fr of the slot 11 and the radial direction of the slot housing portion 21. It is provided between the outer surface 21Fro. Further, in this example, the foamed resin 3 is provided so as to cover the radially inner outer surface portion 21Fri of the slot accommodating portion 21.
  • the foamed resin 3 expands by heating.
  • a sheet-shaped foamed resin 30 in which a foamed resin material 31 is provided integrally with the sheet member 32 along both surfaces of the sheet member 32 is used.
  • the foamed resin material 31 may be provided along only one of the two surfaces of the sheet member 32.
  • the foam resin material 31 is used as a material that expands and expands under predetermined conditions.
  • the foamed resin material 31 is made of a resin which has a material that expands by heating and has adhesiveness.
  • FIG. 3 is an explanatory view of the structure of the foamed resin material 31 and is a perspective view conceptually showing the foamed resin material 31 before heating.
  • FIG. 4 is a diagram conceptually showing a state before and after expansion by heating in a capsule body 31B as an example of a material that expands by heating.
  • the foamed resin material 31 is an epoxy resin 31A in which a number of capsule bodies 31B that expand by heating are mixed.
  • the capsule body 31B foams and expands as shown on the right side of FIG. 4 by being heated from the state before heating shown on the left side of FIG. 4.
  • the entire foamed resin material 31 is expanded by heating.
  • FIG. 2 shows a state of the sheet-shaped foamed resin 30 after foaming
  • FIGS. 6 and 7 show a state of the sheet-shaped foamed resin 30 before foaming.
  • a method for manufacturing the stator 100 according to the present embodiment will be described.
  • a resin disposing step S ⁇ b> 1 in which the foamed resin 3 before foaming is disposed in the slot 11, and a slot receiving section in which the slot receiving section 21 is disposed in the slot 11.
  • the jig mounting step S3 for mounting the support jig 4 for supporting the slot accommodating portion 21 at an appropriate position inside the slot 11, and the jig mounting step S3, the foamed resin 3 is removed.
  • a jig removing step S5 for removing the support jig 4 from the stator 100 and a jig removing step S5 a plurality of conductor wires W are formed.
  • a conductor joining step S7 for joining a conductor joining step S7 for joining.
  • the projecting portion 23 of the coil end portion 22 is deformed and provided on the projecting portion 23.
  • a projecting portion processing step S6 of arranging the joined target portion 23A at the joining position is performed after the jig removing step S5 and before the conductor bonding step S7.
  • the conductor joining step S7 there is provided a joint insulating step S8 for insulating a portion joined in the conductor joining step S7.
  • the left diagram of FIG. 6 shows the resin disposing step S1.
  • the resin disposing step S ⁇ b> 1 is a step of disposing the foamed resin 3 before foaming inside the slot 11.
  • the resin arranging step S1 is performed before the slot housing section arranging step S2.
  • the sheet-like foamed resin 30 before foaming is arranged along the inner surface 11F of the slot 11.
  • the sheet-like foamed resin 30 is disposed at least over the entire area of the slot 11 in the axial direction L.
  • both ends of the sheet-like foaming resin 30 on the radially inner side R1 are located on the opening 11A side of the slot 11 (in the radial direction). It is in a state of extending toward the inside R1).
  • the slot accommodation section arranging step S2 is a step of arranging the slot accommodation section 21 inside the slot 11.
  • the slot accommodation section 21 is inserted into the slot 11 from the radial inside R1.
  • the slot accommodating portions 21 corresponding to the respective slots 11 are inserted into all the slots 11 included in the stator core 1 from the radially inner side R1.
  • all of the slots 11 are radially inward from the radially inner side R1.
  • the slot accommodation section 21 is arranged.
  • the sheet-like foamed resin 30 before foaming is arranged between the inner surface 11F of the slot 11 and the outer surface 21F of the slot housing portion.
  • the sheet-like foamed resin 30 is arranged so as to surround the entire circumference of the outer surface 21 ⁇ / b> F of the slot housing 21.
  • an overlapping portion 3A is formed at a portion where both end portions of the sheet-like foamed resin 30 are overlapped with each other, and the overlapping portion 3A is arranged in a region of the slot 11 on the radially inner side R1.
  • FIG. 7 shows the jig mounting step S3.
  • the jig mounting step S3 is a step of mounting the support jig 4 for supporting the slot accommodating portion 21 at an appropriate position inside the slot 11 to the stator 100.
  • the “proper position” here is the position of the slot accommodating portion 21 shown in FIG. 2, and the distance in the radial direction R between the radially inner outer surface portion 21Fri of the slot accommodating portion 21 and the core inner peripheral surface 1F is predetermined. It is a position that is longer than the set distance SD.
  • the jig mounting step S3 includes a pressing step S31 of pressing the slot accommodating portion 21 disposed inside the slot 11 from the radial inside R1 to the radial outside R2 (see FIG. 5). Reference).
  • the pressing step S31 is performed using the support jig 4.
  • the support jig 4 includes a support portion 41 arranged in the circumferential direction C corresponding to the number of all slots 11 of the stator core 1, and the support portion 41 sandwiching the support portion 41 in the circumferential direction C. And a guide portion 42 for guiding the portion 41 in the radial direction R.
  • the support portion 41 is configured to move in the radial direction R, and a drive unit (not shown) that drives the support portion 41 in the radial direction R is provided on the radial inner side R1 of the support portion 41. Then, the support jig 4 is arranged on the radially inner side R1 of the stator 100 in a state where the plurality of supporting parts 41 are on the radially inner side R1, and the driving unit moves the plural supporting parts 41 to the radially outer side R2 from there. By doing so, the slot accommodating portion 21 in each slot 11 is pressed to the radial outside R2.
  • the pressing of the slot accommodating portions 21 in the respective slots 11 is released by moving the plurality of support portions 41 to the radial inside R1 by the driving portion.
  • the support portion 41 is moved in this way, the support portion 41 is appropriately guided by the pair of guide portions 42 arranged on both sides of the support portion 41 in the circumferential direction C.
  • the slot accommodating portion 21 and the overlapping portion 3A of the sheet-like foamed resin 30 are pressed radially outward R2. Thereby, the sheet-shaped foamed resin 30 is easily bonded at the overlapping portion 3A, and the displacement of the sheet-shaped foamed resin 30 with respect to the slot accommodating portion 21 can be suppressed.
  • the resin foaming step S4 is a step of heating and foaming the foamed resin 3.
  • the sheet-shaped foamed resin 30 is expanded by heating at a foaming temperature at which the foamed resin material 31 of the sheet-shaped foamed resin 30 foams.
  • the resin foaming step S4 is performed during the continuation of the pressing step S31. Thereby, the resin foaming step S4 can be performed in a state where the slot back 21 is restrained from so-called springback in which the slot accommodating portion 21 is elastically deformed radially inward R1.
  • the jig removing step S5 is a step of removing the support jig 4 from the stator 100.
  • the pressing is performed after the pressing of the slot accommodating portion 21 by the support jig 4 is released. As described above, the release of the pressing is performed by moving the plurality of support portions 41 to the radial inside R1.
  • the support jig 4 is removed from the stator 100 by relatively moving the support jig 4 and the stator 100 in the axial direction L. In this example, the stator 100 is moved relative to the support jig 4 in the axial direction L. Conversely, the support jig 4 may be moved in the axial direction L with respect to the stator 100.
  • FIG. 8 shows the protrusion processing step S6.
  • the projecting portion processing step S6 is a step of deforming the projecting portion 23 of the coil end portion 22 to arrange the joining target portion 23A formed on the projecting portion 23 at the joining position, and after the resin foaming step S4. This is performed before the conductor bonding step S7.
  • the protrusion processing step S6 is performed after the jig removing step S5 and before the conductor bonding step S7.
  • the joining target portion 23 ⁇ / b> A in which the insulating coating of the conductor wire W is removed and the linear conductor is exposed is formed at the distal end portion of the protruding portion 23.
  • the distal end portion of the projecting portion 23 disposed on the radially outer side R2 is bent so as to face the radially outer side R2. .
  • the distal end portion of the projecting portion 23 is arranged along the radial direction R, and the joining target portion 23A at the distal end of the projecting portion 23 is arranged radially outside R2 of the slot 11.
  • the position of the joining target portion 23A in this state is the above-mentioned “joining position”.
  • the protruding portion processing step S6 as shown in the right diagram of FIG. 8, the protruding portion 23 disposed on the radially inner side R1 is bent so as to face the radially outer side R2. As a result, the distal end portion of the projecting portion 23 is arranged along the radial direction R, and the joining target portion 23A at the distal end of the projecting portion 23 is arranged radially outside R2 of the slot 11. Thereby, the joining target portion 23A is arranged at the joining position.
  • the pair of joining target portions 23A are arranged so as to be in contact with each other in the circumferential direction C at the radially outer side R2 than the slot 11 (FIG. 9). reference).
  • the present invention is not limited to this, and the pair of joining target portions 23A may be arranged so as to contact in the axial direction L at the joining position. Further, the pair of joining target portions 23A may not be disposed along the radial direction R, but may be disposed along the axial direction L.
  • the example in which the protruding portion 23 arranged on the radially outer side R2 is bent before the protruding portion 23 arranged on the radially inner side R1 has been described, but this order is reversed. Or at the same time.
  • the bending of the protruding portion 23 is performed using a bending device (not shown).
  • FIG. 9 shows the conductor bonding step S7.
  • the conductor joining step S7 is a step of joining a plurality of conductor wires W.
  • the conductor joining step S7 is performed at least after the resin foaming step S4 and the jig removing step S5.
  • the conductor joining step S7 is performed after the protrusion processing step S6.
  • a pair of joining target portions 23A that are in contact at the joining position are joined.
  • a pair of joining target portions 23A is joined by welding using a welding device 99.
  • the joint 2A is formed between the pair of joining target portions 23A.
  • This joining can be performed by, for example, arc welding such as TIG welding, electron beam welding, laser beam welding, resistance welding, ultrasonic welding, brazing, soldering, or the like.
  • the joint insulating step S8 is a step of insulating the portions joined in the conductor joining step S7.
  • FIG. 10 shows the stator 100 after performing the joint insulating step S8.
  • the insulating surrounding portion 5 that integrally covers the pair of joining target portions 23A joined in the conductor joining process S7 together with the peripheral portions thereof is formed in the joining portion insulating process S8.
  • the insulating surrounding portion 5 is formed using a resin material having electrical insulation. Further, the insulating surrounding portion 5 is formed using a resin material having a certain or more mechanical strength. As the resin material forming the insulating surrounding portion 5, any of a thermoplastic resin and a thermosetting resin may be used.
  • the formation of the insulating surrounding portion 5 in the bonding portion insulating step S8 is performed by using a molding technique (for example, injection molding technology) after forming the bonding portion 2A (ie, after bonding the pair of bonding target portions 23A).
  • a molding technique for example, injection molding technology
  • the mold is arranged so as to wrap the plurality of joining portions 2A (the peripheral portion including the pair of joining target portions 23A) that protrude in the radial direction R and are annularly arranged.
  • the insulating surrounding portion 5 is formed by performing molding in the mold.
  • the present invention is not limited to such a configuration.
  • the insulating surrounding portion 5 is immersed in a liquid resin material to immerse the joint 2A (a peripheral portion including the pair of joining target portions 23A). May be formed.
  • the joint 2A may be insulated by various known methods.
  • the protrusion processing step S6 may not be included in the method for manufacturing the stator 100 according to the present disclosure.
  • the joint insulating step S8 may not be included in the method for manufacturing the stator 100 according to the present disclosure.
  • the slot housing section arranging step S2 is executed after the resin arranging step S1 is executed.
  • the resin placement step S1 may be performed after the execution of the slot accommodation section placement step S2.
  • the resin placement step S1 and the slot accommodation section placement step S2 may be performed simultaneously.
  • the foamed resin 3 before foaming is arranged around the slot accommodating portion 21 before being arranged inside the slot 11, and these slot accommodating portions 21 and the foamed resin 3 before foaming are put together. It may be arranged inside the slot 11.
  • the configuration in which the slot accommodating portion 21 is inserted into the slot 11 from the radial inner side R1 in the slot accommodating portion arranging step S2 has been described as an example.
  • the method is not limited to this.
  • a configuration may be adopted in which a plurality of segment conductors are used as the stator coil 2 and the segment conductors are inserted into the slots 11 in the axial direction L to be disposed in the slot accommodating portions 21.
  • stator core 1 is cylindrical and the stator 100 is for an inner rotor type rotating electric machine is described as an example, but the present invention is not limited to this.
  • the stator 100 is configured so as to be applied to an outer rotor type rotating electric machine in which a rotor is arranged radially outside R2 with respect to the stator 100. Is also good.
  • the slots 11 of the stator core 1 are preferably formed so as to open on the outer peripheral surface of the stator core 1.
  • the stator 100 may be configured for an axial gap type rotating electric machine.
  • the method for manufacturing the stator 100 according to the present disclosure is applicable regardless of the type of the rotating electric machine or the shape of the stator 100.
  • a stator coil (1) having a plurality of slots (11) and a stator coil configured by joining a plurality of conductor wires (W) and having a slot accommodating portion (21) disposed inside the slot (11).
  • the stator core (1) has a cylindrical shape, and the slot (11) is formed on an inner peripheral surface (1F) of the stator core (1).
  • a resin disposing step (S1) in which the foamed resin (3) before foaming is disposed inside the slot (11), and the slot accommodating portion (21) has a diameter relative to the slot (11).
  • the foamed resin (3) is heated and foamed.
  • the jig removing step (S5) for removing the support jig (4) from the stator (100), and the jig removing step ( After S5) a conductor joining step (S7) of joining the plurality of conductor wires (W) is included.
  • the slot accommodating portion (21) can be fixed at a correct position with respect to the slot (11) by the resin (3) foamed in the resin foaming step (S4). Therefore, even after the support jig (4) is removed from the stator (100) after the resin foaming step (S4), the conductor joining step (S7) is accurately performed on the stator coil (2) fixed at a correct position. It can be carried out. When there are post-processes other than the conductor bonding process (S7), those processes can be similarly performed.
  • the support jig (4) is not necessary in the step after the resin foaming step (S4), the cost for preparing a large number of jigs and the time for attaching and detaching the jig in each step are reduced. Can be reduced. Further, according to this configuration, since the slot accommodating portion (21) after being inserted into the slot (11) tends to move radially inward (R1) by springback, the slot accommodating portion (21) is not used when performing the post-process. Although it is necessary to hold the storage section (21) at an appropriate position, such holding can be appropriately performed by the resin (3) foamed in the resin foaming step (S4). Further, according to this configuration, there is an advantage that the heat generated during the resin foaming step (S4) can reduce, for example, residual stress caused by deforming the stator coil (2).
  • the stator coil (2) is provided on the protruding portion (23) protruding outside of the stator core (1) and is connected to the protruding portion (23) in the conductor bonding step (S7).
  • the projecting portion (23) is deformed after the resin foaming step (S4) and before the conductor joining step (S7). It is preferable to include a projection processing step (S6) of arranging the projection 23A) at the joining position.
  • the plurality of conductor wires (W) constituting the stator coil (2) can be appropriately joined.
  • the protruding portion processing step (S6) is performed after the resin foaming step (S4), when the protruding portion processing step (S6) is performed, the resin foamed in the resin foaming step (S4) ( According to 3), the stator coil (2) is fixed at a correct position with respect to the stator core (1). Therefore, the projection processing step (S6) can be performed with high accuracy.
  • the projecting portion processing step (S6) is preferably performed after the jig removing step (S5) and before the conductor bonding step.
  • the protruding part processing step (S6) is a step performed after the jig removing step (S5), and when the protruding part processing step (S6) is performed, the resin foaming step (S4) is performed. Since the stator coil (2) is fixed at the correct position with respect to the stator core (1) by the foamed resin (3), the support jig (4) is unnecessary. Therefore, it is possible to reduce the cost of preparing the jig in the protruding portion processing step (S6) and the trouble of attaching and detaching the jig.
  • a joint insulating step (S8) for insulating a portion bonded in the conductor bonding step (S7) is provided.
  • the joint insulating step (S8) is a step performed after the conductor joining step (S7).
  • the resin foamed in the resin foaming step (S4) is used.
  • the joining target portion (23A) of the conductor wire (W) is appropriately adjusted in the conductor joining step (S7). Since they are joined, the portions joined by the conductor joining step (S7) can be correctly positioned without the support jig (4). Therefore, it is possible to reduce the cost of preparing the jig and the time for attaching and detaching the jig in the joint insulating step (S8).
  • the jig mounting step (S3) includes a pressing step (R3) of pressing the slot accommodating portion (21) disposed inside the slot (11) from the radial inside (R1) to the radial outside (R2). It is preferable to include S31).
  • the slot receiving portion (21) which is to be moved radially inward (R1) by the springback inside the slot (11) can be held at a correct position by the pressing step (S31). it can. Then, in order to foam the resin (3) in the resin foaming step (S4) while holding the slot accommodating portion (21) in this manner, the stator coil (2) is formed by the foamed resin (3). It can be fixed at a correct position with respect to the stator core (1).
  • the resin arranging step (S1), before the slot accommodating section arranging step (S2) the sheet-like foamed resin (30) before foaming is removed from the inner surface (11F) of the slot (11). It is preferable to arrange along.
  • the foamed resin material (31) is provided both between the sheet member (32) and the slot accommodating portion (21) and between the sheet member (32) and the inner surface (11F) of the slot (11).
  • the technology according to the present disclosure can be used for a method of manufacturing a stator used for a rotating electric machine.
  • Stator 1 Stator core 1F: Core inner peripheral surface 11: Slot 11F: Slot inner surface 2: Stator coil W: Conductor wire 2A: Joint portion 21: Slot accommodating portion 23: Projecting portion 23A: Joint target portion 3: Foam resin 30: sheet-like foamed resin 31: foamed resin material 32: sheet member 4: support jig C: circumferential direction L: axial direction R: radial direction R1: radial inner side R2: radial outer side S1: resin disposing step S2: slot Housing part arrangement step S3: jig mounting step S31: pressing step S4: resin foaming step S5: jig removing step S6: projecting part processing step S7: conductor joining step S8: joint part insulating step

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

Ce procédé de fabrication de stator comprend : une étape de placement de résine (S1) pour placer une résine expansive dans un état non expansé à l'intérieur d'une encoche ; une étape de placement de partie de réception d'encoche (S2) pour placer une partie de réception d'encoche à l'intérieur de l'encoche par insertion de la partie de réception d'encoche dans l'encoche par un côté intérieur dans la direction radiale ; une étape de montage de gabarit (S3) pour monter, sur le stator, un gabarit de support destiné à supporter la partie de réception d'encoche à une position appropriée à l'intérieur de l'encoche ; une étape de moussage de résine (S4) pour chauffer et faire mousser la résine expansive après l'étape de montage de gabarit (S3) ; une étape de retrait de gabarit (S5) pour retirer le gabarit de support du stator après l'étape de moussage de résine (S4) ; et une étape de liaison de conducteurs (S7) pour lier une pluralité de fils conducteurs après l'étape de retrait de gabarit (S5).
PCT/JP2019/037987 2018-09-26 2019-09-26 Procédé de fabrication de stator WO2020067352A1 (fr)

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JP2018180039 2018-09-26
JP2018-180039 2018-09-26

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023062977A1 (fr) * 2021-10-14 2023-04-20 株式会社アイシン Procédé de fabrication de stator

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018033238A (ja) * 2016-08-24 2018-03-01 株式会社デンソー 回転電機の固定子
JP2018148765A (ja) * 2017-03-09 2018-09-20 本田技研工業株式会社 回転電機のステータ

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018033238A (ja) * 2016-08-24 2018-03-01 株式会社デンソー 回転電機の固定子
JP2018148765A (ja) * 2017-03-09 2018-09-20 本田技研工業株式会社 回転電機のステータ

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023062977A1 (fr) * 2021-10-14 2023-04-20 株式会社アイシン Procédé de fabrication de stator

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