Method for manufacturing stator of rotary electric machine, stator of rotary electric machine, and rotary electric machine

Abstract

The present invention prevents varnish from adhering to a non-adhesion area while satisfying required performance of the varnish. A method for manufacturing a stator of a rotary electric machine, the stator of the rotary electric machine having a coil wound on a stator core, includes: a first varnish application step of applying varnish to a coil end portion of the coil protruding from the stator core, the coil end portion being located at a position closest to the stator core, to form a first varnish portion; and a second varnish application step of applying varnish to a position farther from the stator core than the first varnish application step to form a second varnish portion in such a manner that a non-varnish-applied non-existing area is provided between the first varnish portion and the second varnish portion.

Description

Technical Field

[0001] This invention relates to a method for manufacturing the stator of a rotating electric machine. Background Technology

[0002] There is a stator in which coils are housed in armature slots formed along the circumference. The coils housed in the armature slots are fixed with varnish.

[0003] As background technology in this field, there is Japanese Patent Application Publication No. 2008-109732 (Patent Document 1). Japanese Patent Application Publication No. 2008-109732 discloses a varnish treatment method in which varnish is impregnated into a coil mounted on a stator core. This varnish treatment method is characterized by comprising: a first supply step in which the stator core is held in a vertical orientation with the coil end of the coil mounted on the stator core in the vertical direction; varnish is injected into the upper surface of the upper coil end protruding from the upper end face of the stator core from the coil; and varnish is impregnated and flows downwards from the upper coil end into the coil. The varnish is supplied in a controlled manner, with the amount of varnish supplied being gelled before the outer surface of the lower end face of the stator core protruding from the lower coil end; a flipping process is performed, in which the stator core on which the coil is mounted is flipped over, allowing an interval of more than the time required for the gelling of the last supplied varnish in the first supply process; and a second supply process is performed, in which the amount of varnish supplied is controlled after the flipping process, such that the varnish is impregnated to the vicinity of the position where gelling began in the first supply process, and then gelling begins (for example, refer to claim 1).

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2008-109732 Summary of the Invention

[0007] The problem the invention aims to solve

[0008] In such rotating electric motors, there is a problem that the varnish applied to the coils during the stator manufacturing process can adhere to the prohibited areas of the stator, rendering it unusable. On the other hand, if the amount of varnish is reduced to prevent it from adhering to the prohibited areas, the varnish's fixation force on the coils and insulation paper, as well as its fixing force on the insulation paper and the iron core, will decrease. This can lead to damage to the coils and insulation paper due to vibration during motor rotation, reducing insulation performance and posing a risk of motor breakage and fire.

[0009] Therefore, a stator manufacturing method is required that meets the following product quality requirements: while injecting a sufficient amount of varnish into the armature slot to meet the required performance of the varnish, the varnish will not adhere to the restricted adhesion area.

[0010] Technical means to solve the problem

[0011] A representative example of the invention disclosed in this application is shown below. Specifically, a method for manufacturing a stator of a rotary electric machine, wherein the stator of the rotary electric machine has coils wound on a stator core, the method comprising: a first varnishing step, wherein varnish is applied to the coil at a position on the outermost or innermost periphery and close to the stator core from the coil end portion protruding from the stator core to form a first varnished portion; and a second varnishing step, wherein varnish is applied at a position further away from the stator core than in the first varnishing step to form a second varnished portion, i.e., such that an unvarnished non-existent area is provided between the first varnished portion and the second varnished portion.

[0012] The effects of the invention

[0013] According to the present invention, it is possible to prevent the adhesion of varnish to areas where adhesion is prohibited. Issues, configurations, and effects other than those described above will be clarified through the following description of embodiments. Attached Figure Description

[0014] Figure 1 This is a cross-sectional view of the rotary motor used in an embodiment.

[0015] Figure 2 for Figure 1 The diagram shows a cross-sectional view of the rotating electric motor along line AA.

[0016] Figure 3 This is a three-dimensional diagram of the stator.

[0017] Figure 4 for Figure 3 A schematic diagram of a section of the stator coil is shown.

[0018] Figure 5 A diagram illustrating the varnishing process.

[0019] Figure 6 A three-dimensional view of the stator that has been coated with varnish.

[0020] Figure 7 A three-dimensional view of the stator that has been coated with varnish.

[0021] Figure 8 A side view of the end of the coil of the stator, which has been coated with varnish. Detailed Implementation

[0022] [Rotary motor]

[0023] First, a general overview of the rotary motor in this embodiment will be given. The rotary motor in this embodiment uses a flat wire that enables miniaturization and high power, making it suitable for use in automobiles. Automobiles using rotary motors include hybrid electric vehicles (HEVs) equipped with both an engine and a rotary motor, and electric vehicles (EVs) that rely solely on the rotary motor for propulsion without an engine. The rotary motor described below can be applied to any type. The following description will use a rotary motor for a hybrid electric vehicle as an example.

[0024] Figure 1 This is a cross-sectional view of a rotary motor 100 according to an embodiment of the present invention. The rotary motor 100 is a three-phase motor with a built-in permanent magnet. In the rotary motor 100, the stator coil 110 is wound on the stator core 111. When a three-phase alternating current is supplied to the stator coil 110, it operates as a motor that rotates the rotor 120. Furthermore, when the rotary motor 100 is driven by an engine, it operates as a generator that generates three-phase alternating current. In other words, the above functions can be selectively utilized depending on the vehicle's driving status.

[0025] like Figure 1 As shown, the rotary electric motor 100 has a housing 130 and a stator 112 fixed in the housing 130. As described above, the stator 112 has stator coils 110 and a stator core 111. A rotor 120 is rotatably disposed inside the stator core 111 with a gap 140. The rotor 120 includes a rotor core 121, a permanent magnet 150, and a non-magnetic pad 160. The rotor core 121 is fixed on a cylindrical shaft 170. Furthermore, in the following description, the axial direction of the shaft 170 is referred to as the "axial direction", the direction of rotation around the axis is referred to as the "circumferential direction", and the radial direction around the axis is referred to as the "radial direction".

[0026] The housing 130 has an end bracket 180 with bearings 10A and 10B, and the rotating shaft 170 is rotatably held by these bearings 10A and 10B. A rotary transformer 190 for detecting the position and speed of the poles of the rotor 120 is provided on the rotating shaft 170.

[0027] Figure 2 for Figure 1 The diagram shows a cross-sectional view of the rotary motor 100 along line AA. Furthermore, Figure 2 Descriptions of the housing 130 and stator coil 110 are omitted. A plurality of armature slots 200 extending axially are arranged at equal intervals in the circumferential direction on the stator core 111. The number of armature slots 200 is, for example, 48 in this embodiment. The stator coil 110 is housed within each armature slot 200.

[0028] Furthermore, although not illustrated, each armature slot 200 is fitted with insulating paper (so-called slot liner). This insulating paper is disposed between the stator coils 110 inserted into the armature slots 200 and between the stator coils 110 and the inner surface of the armature slots 200, improving the insulation withstand voltage between the stator coils 110 and between the stator coils 110 and the inner surface of the armature slots 200. Moreover, the insulating paper is, for example, an insulating sheet of heat-resistant polyamide paper, with a thickness of approximately 0.1 to 0.5 mm.

[0029] On the rotor core 121, cuboid magnet insertion holes are arranged at equal intervals along the circumference near the outer periphery. Permanent magnets 150 are embedded in each magnet insertion hole and fixed with adhesive or the like. The circumferential width of the magnet insertion hole is larger than the circumferential width of the permanent magnet 150, and magnetic gaps 151 are formed on both sides of the permanent magnet 150. These magnetic gaps 151 can be filled with adhesive or solidified with resin to form a single unit with the permanent magnet 150.

[0030] The magnetization direction of the permanent magnet 150 is radial, and the orientation of the magnetization direction is reversed for each magnetic pole. That is, if the stator side of the permanent magnet 150 used to form a certain magnetic pole is the N pole and the shaft side is the S pole, then the stator side of the permanent magnet 150 forming the adjacent magnetic pole is the S pole and the shaft side is the N pole. In this embodiment, eight permanent magnets 150 are magnetized at equal intervals along the circumference in such a way that the magnetization direction is alternately changed for each magnetic pole, and the rotor 120 forms eight poles.

[0031] Furthermore, the permanent magnet 150 can be embedded in the magnet insertion hole of the rotor core 121 after magnetization, or it can be inserted into the magnet insertion hole of the rotor core 121 before magnetization and then magnetized by applying a stronger magnetic field.

[0032] However, the magnetized permanent magnet 150 has a strong magnetic force. If the magnet is magnetized before being fixed to the stator 112, a strong attractive force will be generated between the magnet and the rotor core 121 during the fixing process, which will hinder operation. Furthermore, there is a risk that iron powder and other dust will adhere to the permanent magnet 150 due to the strong attractive force. Therefore, to improve the productivity of the rotary electric machine 100, it is ideal to magnetize it after inserting the permanent magnet 150 into the magnet insertion hole of the rotor core 121.

[0033] [Stator of a rotary electric machine]

[0034] Figure 3This is a perspective view of the stator 112. The stator 112 is fixed to the inner circumference of the housing 130 and has a cylindrical stator core 111 and stator coils 110 mounted on the stator core 111. A plurality of U-shaped coil ends 110a of the stator coils 110 are formed at one axial end of the stator core 111. On the other hand, welded coil ends 110b are formed at the opposite end of the stator core 111, where the welded portions of the stator coils 110 are arranged in a circular pattern. The welded coil ends 110b are welded, for example, using TIG (Tungsten Inert Gas). Furthermore, Figure 3 The diagram of the power output line is omitted.

[0035] The stator core 111 is composed of stacked electromagnetic steel plates (e.g., silicon steel plates) 500, each with a thickness of approximately 0.05–1 mm. These plates are shaped by stamping or etching and then fixed by welding after stacking. This welding allows the stacked electromagnetic steel plates 500 to be joined together, thereby suppressing deformation of the electromagnetic steel plates 500 caused by the fastening force when pressed into the housing 130.

[0036] The stator core 111 is fitted and fixed inside the cylindrical housing 130 by thermoforming. As a specific assembly method, for example, the stator core 111 is first positioned, and the housing 130, which has been preheated and expanded by thermal expansion, is then fitted onto the stator core 111. Next, the housing 130 is cooled, causing the inner diameter to shrink, thereby securing the outer periphery of the stator core 111 through this thermal shrinkage.

[0037] To prevent the stator core 111 from spinning freely relative to the housing 130 due to the reaction force of the stator 112 torque during operation, the inner diameter of the housing 130 is set to be a predetermined value smaller than the outer diameter of the stator core 111. As a result, the stator core 111 is securely fixed to the housing 130 by thermoforming. The difference between the outer diameter of the stator core 111 at room temperature and the inner diameter of the housing 130 is called the interference fit. This interference fit is set by assuming the maximum torque of the rotating motor 100, and the housing 130 can hold the stator core 111 with a predetermined clamping force. Furthermore, the stator core 111 is not limited to being fixed by thermoforming; it can also be fixed to the housing 130 by pressing.

[0038] [Stator coil]

[0039] Next, the stator coil 110 will be described. Figure 4 for Figure 3The diagram shows a section of the stator coil 110. In this embodiment, the stator coil 110 uses flat wire and is wound in a distributed winding manner. The flat wire is coated with a surface film of polyimide, polyester, polyesterimide, polyamideimide, etc., and in this embodiment, the material and shape of the coil surface are not limited. Distributed winding refers to a winding method in which the stator coil 110 is housed in spaced armature slots 200, spanning multiple armature slots 200. Furthermore, the present invention can also be applied to a stator 112 having a stator coil 110 with a concentrated winding method rather than a distributed winding method.

[0040] A flat wire with a rectangular cross-section is pre-formed into a U-shape by bending the vertex portion 110d towards the rotation axis using a template forming method. This U-shape is then inserted into the stator coil 110 along the armature slot 200 where insulating paper 300 is provided. The straight portion of the U-shape is inserted into two spaced armature slots 200 that span multiple armature slots 200. For example... Figure 7 , Figure 8 As shown, a first bend 110e and a second bend 110f are formed on the stator coil 110 on the side of the coil end 110a. The first bend 110e is close to the vertex 110d of the stator coil 110, which is shaped like a U, and is located directly above the portion of the stator coil 110 that extends obliquely between the vertex 110d and the stator core 111 (parallel overlapping portion 110g). The second bend 110f is close to the stator core 111 and is located directly below the portion of the stator coil 110 that extends obliquely between the vertex 110d and the stator core 111 (parallel overlapping portion 110g).

[0041] Subsequently, the straight conductor portion 110c protruding to the opposite side of the axial direction of the stator core 111 is twisted and shaped, and its end is welded to the end of other stator coils 110 that have also been twisted and shaped. By inserting multiple stator coils 110 into the armature slots 200 of the stator core 111 and connecting them in this way, a phase winding is formed.

[0042] The above-described method for forming the stator coil 110 is just one example. The stator coil 110 can also be formed into a U-shape using a mold, or it can be formed into a U-shape after the stator coil 110 is inserted into the armature slot 200.

[0043] The stator coil 110 is fixed to the insulating paper 300 within the armature slot 200 using varnish, and the insulating paper 300 protects the surface of the coil. Furthermore, the insulating paper 300 is fixed to the stator core 111 using varnish. This prevents reduction in thickness and damage to the insulating paper 300 and the surface coating of the flat wire caused by vibrations during the rotation of the rotating electric machine 100, thereby preventing a decrease in the insulation performance of the rotating electric machine 100. The varnish not only fixes the stator coil 110 and the stator core 111 via the insulating paper 300, but also functions as a heat sink for conducting heat generated by the stator coil 110 to the heat sink of the stator core 111.

[0044] The portion of the stator coil 110 protruding from the stator core 111 is fixed to the adjacent stator coil 110 with the help of varnish, thereby suppressing the vibration of the stator coil 110 when the rotary motor 100 rotates.

[0045] Varnishes are liquids and come in polyester and epoxy forms, and can be single-component or two-component mixtures. Ideally, varnishes are heat-cured, hardening upon heating, but room-temperature curing is also possible.

[0046] The varnish should be applied to both the coil end 110a and the solder side coil end 110b, but it may also be applied to only one coil end 110a and 110b.

[0047] [Clear Varnish Process]

[0048] Figure 5 A perspective view of the stator 112 is shown to illustrate the varnishing process of this embodiment.

[0049] The stator 112, in which the stator coil 110 is inserted into the armature slot 200, is heated before applying varnish. Alternatively, either the stator 112 or the varnish can be heated, but ideally, the varnish is applied after the stator 112 is heated. In the varnishing process of this embodiment, a metered amount of varnish is dripped onto the target location using a dispenser, liquid pump, nozzle, etc., and the dripped varnish is applied to the stator coil 110. The term "drip application" in this specification and claims refers to the varnish discharged by the coating apparatus dripping onto the stator coil 110; the varnish droplets may drip discontinuously or continuously. Furthermore, the size of the varnish droplets is not limited. Moreover, the "drip application position" is the location where the varnish discharged by the coating apparatus first contacts the stator coil 110. Generally, "drip application" occurs multiple times within a single stator 112, changing the relative position of the coating apparatus and the stator coil; therefore, there are multiple "drip application positions."

[0050] Specifically, the varnishing process includes a first varnishing process and a second varnishing process. The first varnishing process involves applying varnish to a position near the stator core 111 of the stator coil 110 connected to the coil within the armature slot 200 to form a first varnished portion. The second varnishing process involves applying varnish to a position further away from the stator core 111 than the first varnishing process (e.g., near the vertex portion 110d) to form a second varnished portion. As a result, an unvarnished non-existent area is formed between the first varnished portion and the second varnished portion.

[0051] During the varnishing process, the varnish dripping onto the stator coil 110 moves on the surface of the stator coil 110. At this time, there is a situation where the varnish detaches from the stator coil 110 and drips, and the dripped varnish falls onto the stator core 111 and adheres to the no-attachment area of ​​the stator core 111.

[0052] For example, if varnish adheres to the outer surface of the stator core 111 (which is a no-attachment zone) on the outer periphery of the stator 112, the outer diameter of the stator 112 will locally increase, preventing the stator 112 from being installed in the housing 130. Furthermore, if varnish adheres to the inner surface of the stator core 111 (which is a no-attachment zone) on the inner periphery of the stator 112, it will interfere with the rotor 120 installed inside the stator 112, preventing the rotor 120 from being positioned correctly and causing rotational malfunctions or defects. To prevent these phenomena, the position where varnish is applied to the stator coils 110 is set close to the stator core 111, thereby reducing the amount of varnish movement on the coil surface and lowering the risk of varnish detaching from the stator coils 110. Specifically, a first varnish section is formed by placing the varnish dropper on the outermost stator coil 110 close to the stator core 111, and a second varnish section is formed by placing the varnish dropper on the stator coil 110 outside the outermost periphery close to the apex 110d (for example, the portion formed by the inclined surface of the stator coil 110 slightly below the apex 110d). By placing the varnish dropper in the first varnish process closer to the stator core 111 than the varnish dropper in the second varnish process, and by placing the first varnish section closer to the stator core 111 than the second varnish section, the amount of varnish movement can be reduced, the risk of varnish detaching from the stator coil 110 can be lowered, and sufficient varnish can penetrate into the armature slot 200 to reliably secure the stator coil 110.

[0053] Each varnishing process is performed in the order of first varnishing process, second varnishing process. The varnish applied to the stator coil 110 penetrates into the iron core along the stator coil 110. If the varnish drips from the outermost coil onto the stator core 111, the varnish will adhere to the restricted area. Therefore, the first varnishing process is performed on the outermost periphery before the varnish penetrates into the armature slot 200. By performing the varnishing on the outermost periphery before the varnish penetrates into the stator core 111, compared to applying varnish after applying it to the other stator coils 110, the varnish has better penetration and can prevent the varnish from overflowing from the armature slot 200, thereby suppressing the generation of defective products.

[0054] In this embodiment, the stator 112 can be arranged vertically between varnishing processes. However, for the sake of the accessibility of the dripping device, the stator 112 should be arranged at an angle and rotated around the axis. In particular, the inclination angle θ1 of the stator 112 in the first varnishing process should be greater than the inclination angle θ2 of the stator 112 in the second varnishing process. Furthermore, the inclination angle θ of the stator 112 in each varnishing process is defined as the angle between the axial direction of the stator 112 and the dripping direction (vertical direction) of the varnish. When the inclination angle θ = 0, the axial direction is vertical, and the end face of the stator core 111 is horizontal.

[0055] In the second varnishing process, the varnish flows down the mesh portion of the stator coil 110. Therefore, if the inclination of the stator 112 is the same as in the first varnishing process, the varnish will have difficulty penetrating into the armature slot 200, and thus will not reach the interior of the stator core 111. Therefore, the inclination of the stator 112 in each varnishing process is ideally set as θ1 > θ2.

[0056] In addition, as shown in the figure, besides the first and second varnishing processes, a third varnishing process can also be provided, that is, varnish is applied to the inner circumference of the stator coil 110 at a position closer to the stator core 111 than the second varnishing part to form the third varnishing part.

[0057] If the applied varnish drips on the inner circumference of the stator coil 110, there is a high risk that it will adhere to the stator core 111. Therefore, to prevent the varnish from detaching from the stator coil 110 and dripping onto the stator core 111 as it moves along the stator coil 110, varnish is applied on the inner circumference of the stator coil 110 near the stator core 111. This reduces the amount of varnish moving on the coil surface, lowers the risk of varnish detaching from the stator coil 110, and allows sufficient varnish to penetrate into the armature slot 200 to reliably secure the stator coil 110.

[0058] In the above description, the first varnish step involves applying varnish to the outer peripheral side, but it can also be applied to the inner peripheral side. That is, without the third varnish step, the first varnish step involves applying varnish to the inner peripheral side, and the second varnish step involves applying varnish near the apex 110d. Furthermore, with the third varnish step, the first varnish step involves applying varnish to the inner peripheral side, the second varnish step involves applying varnish near the apex 110d, and the third varnish step involves applying varnish to the outer peripheral side.

[0059] In cases involving a third varnish step, the varnishing process should preferably be performed in the order of the first varnish step, the second varnish step, and the third varnish step, but it may also be performed in the order of the first varnish step, the third varnish step, and the second varnish step.

[0060] [Varnish already applied to the stator]

[0061] Figure 6 , Figure 7 This is a perspective view of the stator 112 with varnish applied according to this embodiment. Figure 8 A diagram showing the coil end 110a of the varnished stator 112 in this embodiment, viewed from the side.

[0062] like Figure 6 As shown, the stator coil 110 mounted on the stator 112 is fixed to the stator core 111 by varnish. The portion of the stator coil 110 protruding from the end face of the stator core 111 is provided with a first varnish portion, a second varnish portion, and a non-existent area. The first varnish portion is coated with varnish on the part of the stator coil 110 near the stator core 111. The second varnish portion is coated with varnish on the upper part compared to the first varnish portion. The non-existent area is not coated with varnish between the first varnish portion and the second varnish portion.

[0063] As mentioned above, if the varnish adheres to the no-attachment zone set on the stator core 111, it will become a waste product. In the stator 112 shown in the figure, the movement distance of the varnish on the surface of the outermost coil is shortened, which can prevent the varnish from dripping and suppress the generation of waste products.

[0064] In addition, such as Figure 6 , Figure 7 , Figure 8As shown, a non-existent area without varnish is formed between the first bend 110e and the second bend 110f. There is a situation where varnish dripped onto the apex 110d remains at the first bend 110e of the stator coil 110, and the remaining varnish drips from the first bend 110e and adheres to the stator core 111. Furthermore, the second bend 110f is close to the stator core 111, and its extension direction changes at the second bend 110f, where the stator coil 110 is housed in the armature slot 200. Therefore, on the side closer to the stator core 111 than the second bend 110f, the circumferential gap between adjacent stator coils 110 increases, creating space. Therefore, if varnish is dripped onto the side closer to the stator core 111 than the second bend 110f, the dripped varnish will fall into the space between the stator coils 110 and adhere to the forbidden area of ​​the stator core 111, becoming waste. Therefore, it is not appropriate to place the varnish dropper at a lower position than the second bend 110f. Therefore, by providing the lower end of the first varnish portion and the upper end of the second varnish portion between the first bend 110e and the second bend 110f of the stator coil 110, it is possible to suppress the varnish from remaining on the stator coil 110, thereby reducing the risk of varnish dripping from the stator coil 110 adhering to the stator core 111.

[0065] Furthermore, since the upper end of the first varnish portion is located between the first bend 110e and the second bend 110f, it can suppress the varnish dripping along the stator coil 110 from adhering to the end of the stator core 111. In the first varnishing process, varnish is applied at a position closer to the stator core 111 (lower side in the figure) than the first bend 110e and closer to the apex 110d (upper side in the figure) than the second bend 110f, that is, between the first bend 110e and the second bend 110f. Therefore, by providing the upper end of the first varnish portion between the first bend 110e and the second bend 110f, it is possible to suppress the adhesion of dripping varnish to the end of the stator core 111.

[0066] In addition, such as Figure 8As shown, regarding the upper end of the first varnish section, viewed from a direction perpendicular to the axis, the stator 112 is formed in a parallel overlapping portion 110g, where the upper end is arranged in parallel overlapping arrangement with adjacent stator coils 110. In this parallel overlapping portion 110g, the stator coils 110 are preferably arranged in parallel overlapping arrangement with gaps. In the first varnishing process, varnish is dripped onto the coils of the rotating stator core 111. At this time, the varnish remaining at the first bend 110e will drip, so the varnish dripping position is set closer to the stator core 111 than the first bend 110e. Furthermore, if adjacent stator coils 110 are separated from each other, there is a possibility that the dripped varnish may fall into the gap and adhere to the restricted adhesion area. Therefore, in the first varnishing process, varnish is dripped onto the parallel overlapping portion 110g, which forms a parallel gap between the first bend 110e and the second bend 110f, to prevent the varnish drips flowing along the stator coil 110 from adhering to the stator core 111.

[0067] Furthermore, this invention includes various modifications and equivalents within the spirit of the appended claims and is not limited to the embodiments described above. For example, the embodiments described above are detailed descriptions provided to illustrate the invention in an easily understandable manner, and the invention is not necessarily limited to having all the described configurations. Additionally, a portion of the configuration of one embodiment may be replaced with the configuration of another embodiment. Furthermore, the configuration of one embodiment may be incorporated into the configuration of another embodiment. Furthermore, other configurations may be added to, deleted from, or replaced in parts of the configurations of each embodiment.

[0068] Symbol Explanation

[0069] 10A, 10B... Bearings

[0070] 100… Rotary motor

[0071] 110…Stator coil

[0072] 110a, 110b... coil ends

[0073] 110c… Linear Conductor Section

[0074] 110d…Vertex

[0075] 110e…First Bend

[0076] 110f…Second Bend

[0077] 110g…parallel overlap

[0078] 111…Stator core

[0079] 112…Stator

[0080] 120… rotor

[0081] 121… Rotor core

[0082] 130…shell

[0083] 140…gap

[0084] 150… permanent magnet

[0085] 151… magnetic gap

[0086] 160…pad

[0087] 170…spindle

[0088] 180…end frame

[0089] 190… Rotary Transformer

[0090] 200…armature slots

[0091] 300…insulating paper

[0092] 500… Electromagnetic steel sheet.

Claims

1. A method for manufacturing a stator of a rotary electric machine, wherein the stator of the rotary electric machine has coils wound on a stator core, the method for manufacturing the stator of the rotary electric machine being characterized by comprising: The first varnishing process involves applying varnish to the portion of the coil protruding from the stator core, positioned at the outermost or innermost circumference and close to the stator core, to form the first varnished section; and In the second varnishing process, varnish is applied dropwise at a position farther from the stator core than in the first varnishing process, forming a second varnished section in such a way that an unvarnished non-existent area is created between the first varnished section and the second varnished section. The coil has a vertex portion, a first bend portion, and a second bend portion. The vertex portion bends towards the rotation axis. The first bend portion is located near the vertex portion and directly above the portion of the coil that extends obliquely. The second bend portion is located directly below the portion of the coil that extends obliquely after protruding from the stator core. In the first varnishing process, varnish is applied by dripping onto the upper end of the first varnishing portion between the first curved portion and the second curved portion.

2. The method for manufacturing the stator of a rotary electric motor according to claim 1, characterized in that, The second varnishing process is performed after the first varnishing process.

3. The method for manufacturing the stator of a rotary electric machine according to claim 1, characterized in that, The angle between the varnish dripping direction and the stator axis in the first varnishing process is larger than the angle between the varnish dripping direction and the stator axis in the second varnishing process.

4. The method for manufacturing the stator of a rotary electric motor according to claim 1, characterized in that, The third varnishing process involves applying varnish to the coil located on the outermost or innermost periphery of the coil where the first varnishing portion is not located, at a position closer to the stator core than the second varnishing portion, to form the third varnishing portion.

5. The method for manufacturing the stator of a rotary electric machine according to claim 1, characterized in that, In the first varnishing process, varnish is applied in such a way that, when viewed from a direction perpendicular to the axial direction, the upper end of the first varnishing portion is located at a position where the adjacent coils are arranged in parallel overlapping configuration.

6. A stator for a rotary electric motor, characterized in that, have: The stator core has multiple armature slots; and The coils, arranged radially, are housed within the armature slots. The coil has a first varnish portion, a second varnish portion, and a non-existent region. The first varnish section is formed by applying varnish to the coil end portion protruding from the armature slot, at a position near the stator core of the coil located on the outermost or innermost periphery. The second varnish section is formed by applying varnish dropwise at a position away from the stator core. The non-existent area is the area between the first varnish portion and the second varnish portion where no varnish has been applied. The coil has a vertex portion, a first bend portion, and a second bend portion. The vertex portion bends towards the rotation axis. The first bend portion is located near the vertex portion and directly above the portion of the coil that extends obliquely. The second bend portion is located directly below the portion of the coil that extends obliquely after protruding from the stator core. The first curved portion is located in the non-existent area.

7. The stator of the rotary electric motor according to claim 6, characterized in that, The coil has a third varnish portion, which is formed by applying varnish to a position on the outermost or innermost periphery of the coil where the first varnish portion is not located, closer to the stator core than the second varnish portion.

8. The stator of the rotary electric motor according to claim 6, characterized in that, When viewed from a direction perpendicular to the axis, the upper end of the first varnish section is arranged in parallel overlapping configuration.

9. A rotary electric motor, characterized in that, It has a stator according to any one of claims 6 to 8.

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