WO2020067353A1 - Procédé de fabrication de stator - Google Patents

Procédé de fabrication de stator Download PDF

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Publication number
WO2020067353A1
WO2020067353A1 PCT/JP2019/037988 JP2019037988W WO2020067353A1 WO 2020067353 A1 WO2020067353 A1 WO 2020067353A1 JP 2019037988 W JP2019037988 W JP 2019037988W WO 2020067353 A1 WO2020067353 A1 WO 2020067353A1
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WO
WIPO (PCT)
Prior art keywords
conductor
stator core
segment
stator
axial
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Application number
PCT/JP2019/037988
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English (en)
Japanese (ja)
Inventor
神谷友貴
斉藤正樹
Original Assignee
アイシン・エィ・ダブリュ株式会社
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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 WO2020067353A1 publication Critical patent/WO2020067353A1/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 Literature 1 Japanese Patent Application Laid-Open No. 2014-027851 discloses a technique in which a coil is disposed around a tooth (12) of a stator core (10) and fixed thereto (in the description of the background art).
  • the code shown in parentheses is that of Patent Document 1.
  • spacers (20, 30) are fixed to both end surfaces of the tooth (12) on the coil end side.
  • the characteristic configuration of the method for manufacturing a stator is a cylinder having a plurality of slots that are opened on both the first axial side which is one side in the axial direction and the second axial side which is the other side in the axial direction.
  • a stator coil comprising: a stator core having a cylindrical shape; and a stator coil formed by joining a plurality of segment conductors inserted into a plurality of the slots, wherein a conductor arrangement for arranging the segment conductors in the slots is provided. And a conductor supporting step of supporting the segment conductor by a supporting member such that a target end that is the axial end of the segment conductor is at an appropriate position with respect to the stator core after the conductor arrangement step.
  • the conductor fixing step is performed in a state where the target end of the segment conductor is supported at an appropriate position by the support member, the state where the target end of the segment conductor is disposed at the appropriate position can be maintained. In this state, the conductor bonding step can be performed with high accuracy.
  • the target end of the segment conductor can be maintained in a state where it is disposed at an appropriate position. Therefore, even if the support of the segment conductor by the support member is released, the target The state of the end can be maintained. Therefore, even when the support of the segment conductor is released, the conductor bonding step can be performed with high accuracy.
  • Partial perspective view of a stator for a rotating electric machine Partial radial sectional view of a stator for a rotating electric machine
  • Radial and axial views of segment conductors 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 conductor arrangement step Illustration of conductor placement process Illustration of core support process
  • Explanatory drawing of the axial support process Illustration of radial support process Illustration of conductor molding process 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. As for the “axial direction L”, one side is defined as “first axial direction L1” and the other side is defined as “second axial direction L2”. Regarding the “radial direction R”, the inside is “radially inside R1” and the outside is “radially outside R2”. In this specification, 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 with most of the coil end portions 2 ⁇ / b> E protruding from the stator core 1 in the axial direction L being omitted.
  • the stator 100 joins a cylindrical stator core 1 having a plurality of slots 11 opened on both the first axial side L1 and the second axial side L2, and a plurality of segment conductors 20 inserted into the plurality of slots 11. And a stator coil 2 configured as described above.
  • 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 end of the stator core 1 on the first side L1 in the axial direction is a first core end E1
  • the end on the second side L2 in the axial direction is a second core end E2 (FIG. 9 and the like). reference).
  • each of the first core end E1 and the second core end E2 has a surface orthogonal to the axial direction L.
  • the stator core 1 can be appropriately supported by the core supporting step S3 (see FIG. 6) described later.
  • the first core end E1 corresponds to a “reference end”.
  • a plurality of slots 11 extending in the axial direction L and the radial direction R are dispersedly arranged in the circumferential direction C in the stator core 1.
  • the slot 11 is open on both the first axial side L1 and the second axial side L2. That is, the slot 11 has an axial opening that opens at each end face of the stator core 1 in the axial direction L.
  • the slot 11 is also opened on 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 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.
  • each of the slots 11 is a semi-open slot.
  • the width in the circumferential direction C of the opening 11A that opens to the radially inner side R1 of the slot 11 is smaller than the interval between a pair of circumferential inner surfaces 11Fc that face each other in the circumferential direction C.
  • protruding portions that protrude on both sides in the circumferential direction C are formed at ends of the teeth 12 on the radial inner side R1.
  • the stator coil 2 is configured by joining a plurality of segment conductors 20.
  • the segment conductor 20 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 segment conductor 20 includes those in which corners are chamfered (R chamfering, C chamfering, etc.). In the illustrated example, R chamfering is applied to the four corners.
  • the surface of the segment conductor 20 is covered with an insulating coating made of a resin (for example, enamel or the like) except for a part of the connection with the other segment conductor 20 and the like.
  • the segment conductor 20 is configured such that a pair of conductor sides 20 ⁇ / b> A extending in the axial direction L and ends of the pair of conductor sides 20 ⁇ / b> A on the first axial side L1 are mutually connected. And a connecting portion 20B for connection.
  • Each of the pair of conductor side portions 20A in one segment conductor 20 is inserted into a different slot 11 (a pair of slots 11 spaced apart in the circumferential direction C) while being offset in the radial direction R. .
  • the crossover portion 20B connects a pair of conductor side portions 20A offset in the radial direction R and spaced apart in the circumferential direction C outside the stator core 1 (outside the axial direction L).
  • FIG. 3 schematically shows only a part of the segment conductor 20 and the stator core 1, and omits other components (for example, a foamed resin 3 described later).
  • the transition portion 20B is disposed at a position protruding from the stator core 1 to the first axial side L1. Then, both ends of the pair of conductor sides 20A on the second axial side L2 are disposed at positions protruding from the stator core 1 on the second axial side L2.
  • the portion of the segment conductor 20 that protrudes from the stator core 1 in the first axial direction L1 is referred to as a first protrusion 21
  • the portion of the segment conductor 20 that protrudes in the second axial direction L2 from the stator core 1 is the second protrusion. 22.
  • An assembly of the first protrusions 21 and an assembly of the plurality of second protrusions 22 in the plurality of segment conductors 20 are each referred to as a coil end 2E (see FIG. 9 and the like).
  • an aggregate of portions (portions not protruding from the stator core 1) of the plurality of segment conductors 20 other than the first projecting portion 21 and the second projecting portion 22 and disposed inside the slot 11 is referred to as a slot.
  • the slot accommodating portion 2 ⁇ / b> A includes a plurality of segment conductors 20 arranged in the radial direction R inside the slot 11, and in the present example, includes six segment conductors 20. ing.
  • the second protrusion 22 corresponds to a “projection”.
  • the end of the segment conductor 20 on the second axial side L2, that is, the end of the conductor side 20A on the second axial side L2 is the target end 22a.
  • the target end 22a has a portion (exposed portion) where the insulating film is removed from the conductor side portion 20A (segment conductor 20) to expose the linear conductor.
  • the target end 22a is joined to the target end 22a of the other segment conductor 20 in the same phase in the conductor joining step S10 (see FIG. 6).
  • the outer surface 2AF of the slot accommodating portion 2A has a pair of circumferential outer surface portions 2AFc facing in opposite directions in the circumferential direction C and extending in the radial direction R, and a pair of circumferential direction outer circumferential portions R2 in the radial outer side R2.
  • a radially outer surface 2AFro that connects the outer surface 2AFc and extends in the circumferential direction C
  • a radially inner outer surface 2AFri that connects the pair of circumferentially outer surfaces 2AFc and extends in the circumferential direction C at the radially inner side R1. included.
  • the radially inner outer surface portion 2AFri is an end surface of the radially inner side R1 in the slot accommodating portion 2A and faces the rotor (not shown) after the rotor (not shown) is assembled.
  • the slot accommodating portion 2A is disposed inside the slot 11 such that the distance in the radial direction R between the radially inner outer surface portion 2AFri 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 2A 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 2A 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.
  • a foamed resin 3 is provided between the slot 11 and the slot accommodating portion 2A. More specifically, the foamed resin 3 is provided between the inner surface 11F of the slot 11 and the outer surface 2AF of the slot housing.
  • the slot resin 2A is fixed to the slot 11 by the foam resin 3, and the slot core 2A 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 2AFc of the slot housing portion 2A, and the radial inner surface portion 11Fr of the slot 11 and the radial direction of the slot housing portion 2A. It is provided between the outer outer surface 2AFRo. Further, in this example, the foamed resin 3 is provided so as to also cover the radially inner surface 2AFri in the slot housing 2A.
  • 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 formed of a resin that has a material that expands by heating and has adhesiveness.
  • FIG. 4 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. 5 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 is foamed and expanded as shown on the right side of FIG. 5 by being heated from the state before heating shown on the left side of FIG. 5.
  • the entire foamed resin material 31 is expanded by heating. Note that, even after the foamed resin material 31 is cured after heating, the capsule body 31B remains in an expanded state inside the foamed resin material 31. 2 shows a state after foaming of the sheet-like foamed resin 30, and FIGS. 7 and 11 show a state before foaming of the sheet-like foamed resin 30.
  • the segment conductor 20 is inserted into the slot 11 from the first axial side L ⁇ b> 1, and is the end of the second axial side L ⁇ b> 2 of the segment conductor 20.
  • An axial supporting step S4 (corresponding to a conductor supporting step) for supporting the segment conductor 20 by an axial supporting jig 5 (corresponding to a supporting member: see FIG. 10) so as to be positioned, and a segment by the axial supporting jig 5
  • a conductor fixing step S6 for fixing the segment conductor 20 to the slot 11 while the conductor 20 is supported, and after the conductor fixing step S6, the segment is fixed by the axial support jig 5.
  • a conductor bonding step S10 described bonding a plurality of target ends 22a together, a.
  • the conductor fixing step S6 is performed using the foamed resin 3. Therefore, the manufacturing method of the stator 100 includes a resin disposing step S1 of disposing the foamed resin 3 before foaming inside the slot 11 before the conductor fixing step S6.
  • a core supporting step S3 for supporting the stator core 1 is provided.
  • a radial support step S5 of supporting the segment conductor 20 from the radial inner side R1 by the inner diameter support jig 6 is provided.
  • a radial support release step S8 for releasing the support of the segment conductor 20 by the inner diameter support jig 6 is also provided.
  • the second protruding portion 22 is bent and formed after the axial support release step S7 and before the conductor bonding step S10, so that the target end 22a is formed.
  • a conductor forming step S9 for arranging the conductor at a joint position with another target end 22a.
  • a joint insulating step S11 for insulating the joints joined in the conductor joining step S10.
  • the left diagram of FIG. 7 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 placement step S1 is performed before the conductor placement 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.
  • FIG. 8 shows a conductor arrangement step S2.
  • the conductor arranging step S2 is a step of arranging the segment conductors 20 on the stator core 1.
  • the segment conductor 20 is inserted into the slot 11 from the first axial side L1 to the second axial side L2.
  • the transition portion 20B of the segment conductor 20 is made to protrude from the first core end E1 of the stator core 1 to the first axial side L1, and the conductor of the segment conductor 20
  • the target end 22a of the side 20A is projected from the second core end E2 of the stator core 1 to the second axial side L2.
  • the portion of the segment conductor 20 that protrudes from the stator core 1 in the first axial direction L1 is the first protruding portion 21, and the portion that protrudes from the stator core 1 in the second axial direction L2 is the second protruding portion.
  • all the segment conductors 20 constituting the stator coil 2 are inserted into the slots 11 in one conductor arrangement step S2.
  • a plurality of (six in the illustrated example) segment conductors 20 are inserted into one slot 11, and the plurality of segment conductors 20 insert the inside of the slot 11.
  • the slot accommodating portion 2A is formed.
  • the target end 22a formed at the end of the conductor side portion 20A constituting the slot accommodating portion 2A on the second axial side L2 is closer to the second axial side L2 than the stator core 1 in shape and shape of the slot 11. It is arranged at a position corresponding to the arrangement position (a position overlapping the slot 11 when viewed in the axial direction L).
  • the plurality of target end portions 22a arranged on the second axial side L2 with respect to the stator core 1 are arranged along the radial direction R of the stator core 1 according to the shape of each slot 11. Further, since a plurality of slots 11 are arranged in the circumferential direction C, a plurality of rows of such target end portions 22a are also arranged in the circumferential direction C.
  • the sheet-like foamed resin 30 before foaming is arranged between the inner surface 11F of the slot 11 and the outer surface 2AF of the slot accommodating portion 2A.
  • FIG. 9 shows the core supporting step S3.
  • the core supporting step S3 is a step of supporting the stator core 1, and is performed before the axial supporting step S4.
  • the stator core 1 is supported in the axial direction L using the core support 4.
  • the core support 4 supports the first core end E1 of the stator core 1 from the first axial side L1 and the second core end E2 of the stator core 1 from the second axial side L2.
  • the core support 4 supports the first core end E1 and has a fixed support portion 41 in which the position in the axial direction L is fixed, and the second core end E2 supports the core support 4 in the axial direction L.
  • a movable support portion 42 that is movable.
  • the operation mechanism of the movable support portion 42 may have any configuration, but in the illustrated example, the operation mechanism is configured to move in the axial direction L by a screw mechanism.
  • the stator core 1 is supported at a plurality of locations (for example, three locations) in the circumferential direction C of the stator core 1 so as to sandwich the stator core 1 from both sides in the axial direction L. That is, in this example, the fixed support portion 41 and the movable support portion 42 are arranged at a plurality of positions along the circumferential direction C of the stator core 1 in a state where the stator core 1 is supported.
  • the fixed support portion 41 and the movable support portion 42 may be formed in, for example, an annular shape (or an arc shape) around the axis of the stator core 1.
  • a state in which the axis (axial direction L) of the stator core 1 is vertically aligned, more specifically, the first protrusion 21 is disposed above the stator core 1 and the second protrusion 22 is The stator core 1 is supported in a state where the stator core 1 is disposed below the stator core 1.
  • the self-weight of the stator core 1 can be made to act in a direction (axial direction L) that supports the stator core 1. Therefore, the stator support 1 can accurately support the stator core 1 in the axial direction L.
  • the transition portion 20B constituting the first projecting portion 21 is disposed above the stator core 1, it is possible to prevent the segment conductor 20 from dropping out of the slot 11.
  • FIG. 10 shows the axial support step S4.
  • the axial supporting step S4 is a step of supporting the segment conductor 20 in the axial direction L, and is performed after the conductor arranging step S2 and before the conductor fixing step S6. In this step, the segment conductor 20 is supported in the axial direction L using the axial support jig 5.
  • the axial supporting step S4 corresponds to a “conductor supporting step”
  • the axial supporting jig 5 corresponds to a “supporting member”.
  • the axial supporting step S4 is performed in a state where the stator core 1 is supported by the core supporting step S3.
  • the distal end (lower end) of the second projection 22 projecting below the stator core 1 is supported from below by the axial support jig 5 in the axial support step S4.
  • the tip (lower end) of the second protrusion 22 is the target end 22a.
  • the axial support jig 5 has an abutment surface 51F that abuts the target end 22a and is movable in the up-down direction (axial direction L).
  • a vertical drive unit 52 (drive unit) that is driven in the vertical direction (axial direction L).
  • the contact surface 51F is brought into contact with the target end portion 22a by moving the axial direction support portion 51 upward, and the target end portion 22a is supported from below (the second axial side L2). I do.
  • the segment conductor 20 is supported such that the distance from the first core end E1 of the stator core 1 to the target end 22a of the segment conductor 20 is the specified distance PD.
  • specified distance PD is a distance determined based on a design value of the position of stator coil 2 with respect to stator core 1.
  • the segment conductor 20 is supported such that the target end portion 22a is at a proper position in the axial direction L with respect to the stator core 1.
  • the amount of protrusion of the second protrusion 22 from the stator core 1 to the second axial side L2 in the radial direction R2 of the target end 22a toward the radially outer side R2 is determined as the appropriate position. It is set to be large. That is, among the plurality of target end portions 22a arranged at appropriate positions, the one arranged on the radially inner side R1 is the second one of the stator core 1 in the axial direction L, compared with the one arranged on the radially outer side R2.
  • the contact surface 51F of the above-described axial support portion 51 has such a shape that each of the plurality of target end portions 22a can be arranged at an appropriate position. That is, the contact surface 51F is shaped such that the radially inner portion R1 is disposed above the radially outer portion R2 (first axial side L1). In the illustrated example, the contact surface 51F is formed in a curved surface shape in which a central portion corresponding to the axis of the stator core 1 is convex upward (first axial direction side L1). Thus, by simultaneously pushing up the plurality of target ends 22a upward (first axial direction L1) by the contact surface 51F, each of the plurality of target ends 22a can be arranged at an appropriate position.
  • FIG. 11 shows the radial support step S5.
  • the radial support step S5 is a step of supporting the segment conductor 20, more specifically, the slot accommodating portion 2A, which is an aggregate of the plurality of segment conductors 20, from the radial inside R1, and is performed before the conductor fixing step S6.
  • the slot accommodating portion 2A is disposed at the radial position shown in FIG. 2 by the radial supporting step S5, and the radial direction between the radially inner outer surface portion 2AFri of the slot accommodating portion 2A and the core inner peripheral surface 1F.
  • the distance R is set to be equal to or longer than a predetermined set distance SD.
  • the slot receiving portion 2A is pressed against the radial outer R2 by using the inner diameter support jig 6 arranged on the radial inner R1 of the stator 100.
  • the inner diameter support jig 6 sandwiches the inner diameter support portion 61 in the circumferential direction C, and the inner diameter support portion 61 arranged in the circumferential direction C corresponding to the number of all slots 11 of the stator core 1.
  • a guide portion 62 for guiding the inner diameter support portion 61 in the radial direction R.
  • the inner diameter support portion 61 is configured to move in the radial direction R, and a driving unit (not shown) that drives the inner diameter support portion 61 in the radial direction R is provided on the radial inner side R1 of the inner diameter support portion 61. ing. Then, the inner diameter support jig 6 is arranged on the radially inner side R1 of the stator 100 in a state where the plurality of inner diameter support parts 61 are on the radially inner side R1, and the drive unit drives the inner diameter support jig 6 from the radially inner side R1. By moving it to R2, the slot accommodating portion 2A in each slot 11 is pressed toward the radially outer side R2.
  • the pressing of the slot accommodating portion 2A in each slot 11 is released by moving the plurality of inner diameter support portions 61 to the radial inner side R1 by the driving portion. (Step S8 of radial support release described later).
  • the inner diameter support portion 61 is moved in this manner, the inner diameter support portion 61 is appropriately guided by the pair of guide portions 62 arranged on both sides of the inner diameter support portion 61 in the circumferential direction C.
  • the slot accommodating portion 2A is pressed toward the radially outer side R2 together with the overlapping portion 3A formed by overlapping both ends of the sheet-like foamed resin 30 in the radial supporting step S5. Thereby, the sheet-like foamed resin 30 is easily bonded at the overlapping portion 3A, and the displacement of the sheet-like foamed resin 30 with respect to the slot accommodating portion 2A can be suppressed.
  • a conductor fixing step S6 is performed.
  • the conductor fixing step S6 is performed while the support state of the axial supporting step S4 and the radial supporting step S5 is continued.
  • the stator coil 2 can be fixed to the stator core 1 in a state where the target end portion 22a is maintained at an appropriate position and a state where the slot accommodating portion 2A is maintained at the radial position shown in FIG. it can.
  • the slot 11 and the segment conductor 20 are fixed by 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 space between the inner surface 11F of the slot 11 and the outer surface 2AF of the slot housing portion 2A can be filled with the foamed sheet-like resin 30. Therefore, the fixing force of stator coil 2 to stator core 1 can be ensured in the area where sheet-like foamed resin 30 exists. Further, electrical insulation between the inner surface 11F of the slot 11 and the outer surface 2AF of the slot housing 2A can be ensured.
  • the axial support release step S7 is a step of releasing the axial support of the segment conductor 20.
  • the contact surface 51F is separated from the target end portion 22a by moving the axial support portion 51 downward (the second axial side L2) with respect to the stator 100, and the axial support jig 5 is used.
  • the support of the segment conductor 20 is released.
  • the segment conductor 20 is fixed to the slot 11 (stator core 1) by the conductor fixing step S6. Therefore, even after execution of the axial support release step S7, the target end portion 22a is maintained at an appropriate position.
  • the axial support release step S7 corresponds to a “support release step”.
  • a radial support release step S8 is performed.
  • the radial support release step S8 is a step of releasing the radial support of the segment conductor 20.
  • the radial support release step S8 is performed by releasing the pressing of the slot accommodating portion 2A by the inner diameter support jig 6 and removing the inner diameter support jig 6 from the stator 100.
  • the release of the pressing of the slot accommodating portion 2A by the inner diameter support jig 6 is performed by moving the plurality of inner diameter support portions 61 to the radially inner side R1 as described above.
  • the inner diameter support jig 6 and the stator 100 are relatively moved in the axial direction L, so that the inner diameter support jig 6 is removed from the stator 100.
  • the radial support release step S8 may be performed simultaneously and in parallel with the axial support release step S7, or may be performed before the axial support release step S7.
  • each of the steps performed after the axial support release step S7 and the radial support release step S8 includes support by the core supporting step S3. It may be performed during the continuation of the state, or may be performed in a state where the support of the stator core 1 in the core supporting step S3 is released.
  • FIG. 12 shows a conductor forming step S9.
  • the second projecting portion 22 of the segment conductor 20 is bent and formed, and the target end 22a formed at the tip of the second projecting portion 22 is connected to the target end 22a of the other segment conductor 20.
  • This is a step of arranging at the joining position.
  • the conductor forming step S9 is performed after the axial support release step S7 and before the conductor bonding step S10.
  • the second protruding portions 22 before being bent are indicated by phantom lines, and the second protruding portions 22 after being bent are indicated by solid lines.
  • the “joining position” is a position where the pair of target ends 22a joined in the conductor joining step S10 are in contact with each other, and in this example, is a position where the pair of target ends 22a are in contact with each other in the radial direction R. is there.
  • the “joining position” may be, for example, a position where the pair of target end portions 22a contact each other in the axial direction L or the circumferential direction C.
  • the conductor forming step S9 is performed so that the first bent portion 22b, the second bent portion 22c, and the circumferentially extending portion 22d are formed on the second projecting portion 22 extending along the axial direction L. .
  • the first bent portion 22b is a bent portion formed by bending a portion extending along the axial direction L from a central portion in the axial direction L of the second projecting portion 22 in the circumferential direction C.
  • the circumferentially extending portion 22d is an extending portion that is continuous with the first bent portion 22b and extends along the circumferential direction C on the second axial side L2 of the first bent portion 22b.
  • the circumferentially extending portion 22d extends along the circumferential direction C while having a component in the axial direction L (that is, inclined in the radial direction R).
  • the second bent portion 22c is a bent portion that is continuous with the circumferentially extending portion 22d and bent in the axial direction L on the second axial side L2 of the circumferentially extending portion 22d.
  • a portion of the second protruding portion 22 on the second side L2 in the axial direction from the second bent portion 22c extends along the axial direction L, and a target end 22a is formed at a distal end thereof.
  • the pair of second projecting portions 22 each having a pair of target end portions 22a joined to each other has a pair of target end portions 22a as viewed in the radial direction R (in FIG. Only the target end 22a on the side is shown.), And is formed to be line symmetric (or substantially line symmetric) with respect to an imaginary line in the axial direction L passing through.
  • conductor molding is performed using a molding device (not shown) that can hold the second protrusion 22 and has a holding portion that can move relative to the stator core 1 in the circumferential direction C and the axial direction L.
  • Step S9 is performed.
  • the forming device holds the holding portion with respect to the stator core 1 on one side in the circumferential direction C and the first axial direction L1 with the holding portion holding the target end portion 22a and the vicinity thereof in the second projecting portion 22.
  • a first bent portion 22b, a second bent portion 22c, and a circumferentially extending portion 22d are formed.
  • the pair of second protrusions 22 each having a pair of target ends 22a to be joined are bent and formed so as to approach each other in the circumferential direction C. 22a is arranged at the joining position.
  • FIG. 13 shows the conductor bonding step S10.
  • the conductor joining step S10 is a step of joining the plurality of segment conductors 20.
  • the conductor joining step S10 is performed at least after the conductor fixing step S6 and the axial support releasing step S7. In this example, the conductor joining step S10 is performed after the conductor forming step S9.
  • a pair of target end portions 22a that come into contact at the joining position (in this example, come into contact in the radial direction R) are joined.
  • the pair of target ends 22a are joined by welding using the welding device 99.
  • 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.
  • FIG. 14 shows a joint insulating step S11.
  • the joint insulating step S11 is a step of insulating the joint joined in the conductor joining step S10.
  • the insulating surrounding portion 7 that integrally covers the pair of target end portions 22a joined in the conductor joining step S10 together with the peripheral portions thereof is formed in the joint insulating step S11.
  • the insulating surrounding portion 7 is formed using a resin material having electrical insulation. Further, the insulating surrounding portion 7 is formed using a resin material having a certain or more mechanical strength.
  • any of a thermoplastic resin and a thermosetting resin may be used.
  • the formation of the insulating surrounding portion 7 in the joint insulating step S11 is performed by powder coating.
  • the coil end 2E on the second core end E2 side is opposed to the liquid resin 98 placed in the container from above (see the left diagram in FIG. 14).
  • all the target end portions 22a joined in the conductor joining step S10 are immersed in the liquid resin 98 (see the center view in FIG. 14).
  • the liquid resin 98 is applied to the peripheral portion including the target end 22a.
  • the liquid resin 98 is dried and hardened to form the insulating surrounding portion 7 (see the right diagram in FIG. 14).
  • the insulating surrounding portion 7 may be formed by molding using a mold to insulate the joint.
  • the joint may be insulated by various known methods.
  • the conductor forming step S9 may not be included in the method for manufacturing the stator 100 according to the present disclosure.
  • the core supporting step S3 for supporting the stator core 1 is executed after the conductor arranging step S2 and before the axial supporting step S4.
  • the timing for executing the core supporting step S3 is not limited to this.
  • it may be executed before the resin arrangement step S1, or after the resin arrangement step S1 and before the conductor arrangement step S2.
  • the configuration in which the core supporting step S3 is performed by supporting the stator core 1 with reference to the first core end E1 has been described as an example.
  • the method of supporting the stator core 1 in the core supporting step S3 is not limited to this.
  • the stator core 1 may be supported based on the second core end E2, or may be supported based on the outer peripheral surface of the stator core 1.
  • the example in which the conductor arranging step S2 is executed after the resin arranging step S1 is executed has been described.
  • the resin placement step S1 may be performed after the conductor placement step S2.
  • the resin placement step S1 and the conductor placement step S2 may be performed simultaneously.
  • the foamed resin 3 before foaming is arranged around the slot accommodating portion 2A before being arranged inside the slot 11, and these slot accommodating portions 2A and the foamed resin 3 before foaming are put together. It may be arranged inside the slot 11.
  • the slot 11 and the segment conductor 20 are fixed using the foamed resin 3 in the conductor fixing step S6 as an example, but the present invention is not limited to this.
  • the slot 11 and the segment conductor 20 may be fixed by impregnating the gap between the slot 11 and the segment conductor 20 with varnish without using the foamed resin 3.
  • the slot 11 and the segment conductor 20 may be fixed using both the foamed resin 3 and the varnish.
  • the appropriate position of the target end 22a in the axial support step S4 is set such that the proper position of the target end 22a in the radial direction R moves toward the radially outer side R2.
  • the appropriate position of the target end 22a may be such that the amount of protrusion from the stator core 1 to the second axial side L2 is constant regardless of the position of the target end 22a in the radial direction R.
  • the contact surface 51F of the axial support portion 51 be formed on a plane orthogonal to the axial direction L.
  • the segment conductor 20 constituting the stator coil 2 is a U-shaped conductor having a pair of conductor side portions 20A and a crossover portion 20B connecting these to each other
  • the segment conductor 20 may be an I-shaped conductor formed in a linear bar shape having one conductor side, or one conductor side and a connecting portion connected to the conductor side.
  • a J-shaped conductor having the following.
  • stator 100 is for an inner rotor type rotating electric machine
  • the present invention is not limited to this.
  • the stator 100 may be configured to be applied to an outer rotor type rotating electric machine in which a rotor is disposed radially outside R2 with respect to the stator 100.
  • 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.
  • a plurality of slots (11) are formed on both an axial first side (L1), which is one side in the axial direction (L), and an axial second side (L2), which is the other side in the axial direction (L).
  • a stator (100) including a cylindrical stator core (1) having a stator coil (2) formed by joining a plurality of segment conductors (20) inserted into the plurality of slots (11).
  • the axial direction A conductor supporting step (S4) of supporting the segment conductor (20) by a supporting member (5) such that a target end (22a) which is an end of L) is at an appropriate position with respect to the stator core (1).
  • the support member 5) With the segment conductor (20) being supported by the segment conductor (20), the conductor fixing step (S6) for fixing the segment conductor (20) to the slot (11); And a conductor bonding step (S10) of bonding the target ends (22a) to each other.
  • the conductor fixing step (S6) is performed in a state where the target end (22a) of the segment conductor (20) is supported at an appropriate position by the support member (5).
  • the state where the part (22a) is arranged at an appropriate position can be maintained.
  • the conductor bonding step (S10) can be accurately performed.
  • the state in which the target end portion (22a) of the segment conductor (20) is arranged at an appropriate position can be maintained. Even when the support of 20) is released, the state of the target end portion (22a) can be maintained. Therefore, even when the support of the segment conductor (20) is released, the conductor bonding step (S10) can be performed with high accuracy.
  • the foamed resin (3) is arranged inside the slot (11), and the segment is formed by a relatively simple process of only foaming the foamed resin (3) in the conductor fixing step (S6).
  • the conductor (20) can be appropriately fixed to the slot (11).
  • the method further includes a support release step (S7) for releasing the support of the segment conductor (20) by the support member (5), and after the support release step (S7). It is preferable to perform the conductor joining step (S10).
  • the support member (5) can be removed after the conductor fixing step (S6). Then, even after the support release step (S7), since the position of the target end portion (22a) is maintained at an appropriate position by the conductor fixing step (S6), the conductor bonding step (S10) can be appropriately performed. it can.
  • the segment conductor (20) is inserted into the slot (11) from the first axial direction side (L1), and the segment conductor (20) is inserted in the axial direction.
  • the end on the second side (L2) is the target end (22a), and the target end (22a) is arranged to protrude from the stator core (1) toward the second axial side (L2). It is.
  • the method further includes a support release step (S7) for releasing the support of the segment conductor (20) by the support member (5).
  • the portion protruding from the stator core (1) to the second axial side (L2) is defined as a protruding portion (22).
  • the projecting portion (22) Prior to the joining step (S10), the projecting portion (22) is bent and formed, and the conductor forming step (S9) of arranging the target end (22a) at a position where the target end (22a) is joined to the other target end (22a). ) Is preferable.
  • the conductor joining step (S10) after the conductor molding step (S9) the plurality of target ends (22a) can be appropriately joined to each other. Since the conductor forming step (S9) is a step performed after the conductor fixing step (S6), the support of the segment conductor (20) by the support member (5) is released after the support releasing step (S7). In this state, the state where the segment conductor (20) is arranged at an appropriate position in the axial direction (L) is maintained. Therefore, the support member (5) for supporting the segment conductor (20) at an appropriate position in the axial direction (L) is unnecessary. Therefore, the cost of preparing the support member in the conductor molding step (S9) and the trouble of attaching and detaching the support member can be eliminated.
  • the appropriate position is determined by the radial direction (R) of the target end (22a).
  • the projecting portion (22) of the segment conductor (20) projecting from the stator core (1) to the second axial side (L2) is bent toward one side in the circumferential direction (C).
  • the amount of protrusion of the protrusion (22) can be adapted to the interval of the slot (11) in the circumferential direction (C) that increases toward the outside in the radial direction (R2). Therefore, it is easy to appropriately perform such bending of the protruding portion (22).
  • the conductor supporting step (S4) is preferably performed in a state where the stator core (1) is supported in the core supporting step (S3).
  • the distance from the reference end (E1) of the stator core (1) to the target end (22a) of the segment conductor (20) is set to a specified distance (PD).
  • the segment conductor (20) is supported.
  • the segment conductor (20) has a pair of conductor sides (20A) extending in the axial direction (L) and a pair of conductor sides (20A) on the first side (L1) in the axial direction.
  • both ends of the segment conductor (20) project from the stator core (1) to the second axial side (L2) as target ends (22a). Be placed. Therefore, it is easy to appropriately perform the conductor bonding step (S10).
  • 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 E1: First core end (reference end) 11: slot 2: stator coil 20: segment conductor 20A: conductor side portion 20B: crossover portion 22: second projecting portion (projecting portion) 22a: target end 3: foam resin 5: axial support (support member)
  • S7 Axial support release step (support release step)

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

Abstract

La présente invention concerne un procédé de fabrication de stator comprenant les étapes suivantes : une étape d'agencement de conducteur (S2) consistant à agencer un conducteur de segment par rapport à une fente ; une étape de support de conducteur (S4) consistant à supporter, après l'étape d'agencement de conducteur (S2), le conducteur de segment au moyen d'un élément de support de telle sorte qu'une partie d'extrémité cible se trouve dans une position appropriée par rapport au noyau de stator ; une étape de fixation de conducteur (S6) consistant à fixer, dans un état dans lequel le conducteur de segment est supporté par l'élément de support, le conducteur de segment par rapport à la fente ; et une étape de jonction de conducteur (S10) consistant à joindre, après l'étape de fixation de conducteur (S6), une pluralité de parties d'extrémité cible l'une à l'autre.
PCT/JP2019/037988 2018-09-26 2019-09-26 Procédé de fabrication de stator WO2020067353A1 (fr)

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JP2018-180040 2018-09-26
JP2018180040 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
WO2023176956A1 (fr) * 2022-03-18 2023-09-21 株式会社アイシン Procédé de fabrication de stator pour machine tournante électrique

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
WO2023176956A1 (fr) * 2022-03-18 2023-09-21 株式会社アイシン Procédé de fabrication de stator pour machine tournante électrique

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