Stator and method for manufacturing a stator

Abstract

The problem this invention aims to solve is to provide a stator with high efficiency in coil insertion operations, which effectively utilizes the curl marks of insulating paper, thereby preventing inward warping of the insulating paper in the slots and enabling smooth insertion of the coil into the slots. To solve the above problem, the stator comprises: a stator core having multiple slots; and a coil, inserted into the slots through insulating paper, wherein the insulating paper is composed of a bent form, which is formed by bending a base paper with arc-shaped curl marks along a bending line extending in a direction of curvature with the concave side facing the back, and the insulating paper has unfolded marks with the open side facing outwards.

Description

Technical Field

[0001] This invention relates to a stator and a method for manufacturing the stator. Background Technology

[0002] To insulate the coil from the stator core, insulating paper is inserted into the slots of the stator core. The insulating paper is formed by bending raw paper into shape. Typically, the raw paper is wound into a roll and then unwound and cut into specified lengths for use.

[0003] Generally, the base paper wound into a roll has curl marks. When insulating paper is bent into shape from base paper with curl marks, the insulating paper develops an inward warping in the groove due to the curl marks, which may hinder the insertion of the coil into the groove. Therefore, when bending the base paper into insulating paper, bending is required to eliminate the curl marks.

[0004] Previously, the following technique was known: while unwinding the base paper of insulating paper wound into a roll, the two ends of the roll in the width direction were cut to a specified length while being folded towards the outer surface of the roller. Then, the cut base paper was bent along the fold in the width direction of the roll in the opposite direction to the folding direction to form insulating paper. After inserting the insulating paper into the groove, the coil was inserted into the inside of the insulating paper to manufacture the stator (for example, see Patent Document 1).

[0005] [Previous Technical Documents]

[0006] (Patent Documents)

[0007] Patent Document 1: Japanese Patent No. 5754349 Summary of the Invention

[0008] [The problem the invention aims to solve]

[0009] However, in the past, in order to eliminate the curl marks, it was necessary to fold the base paper of the insulating paper, which complicated the forming process of the insulating paper.

[0010] The purpose of this invention is to provide a stator and a method for manufacturing the stator, wherein the stator can effectively utilize the curl marks of the insulating paper to prevent the insulating paper in the slot from warping inward, thereby enabling the coil to be smoothly inserted into the slot, and the coil insertion operation is highly efficient.

[0011] [Technical means to solve the problem]

[0012] (1) The stator of the present invention (e.g., stator 1 described later) has: a stator core (e.g., stator core 2 described later) having a plurality of slots (e.g., slot 23 described later); and a coil (e.g., coil 3 described later) inserted into the aforementioned slots through an insulating paper (e.g., insulating paper 4 described later), wherein the aforementioned insulating paper is made of a bent article formed by bending a base paper (e.g., base paper 101 described later) having arc-shaped creases along a curved line (e.g., curved line L described later) extending in a direction having curvature (e.g., direction D described later) with the concave side (e.g., concave surface 101a described later) becoming the back side, and the aforementioned insulating paper has an unfolded crease with the open side opening outward (e.g., outer E described later).

[0013] (2) Optionally, in the stator described in (1) above, the aforementioned slot has a tapered portion (e.g., tapered portion 23d described later) that widens the opening width at the opening portion (e.g., opening portion 23a described later) along the radial opening of the aforementioned stator core, and the aforementioned insulating paper has an outer curved portion (e.g., outer curved portion 43 described later) at the front end portion (e.g., front end portion 4b described later) on the aforementioned opening side that bends outward along the aforementioned tapered portion.

[0014] (3) Optionally, in the stator described in (1) or (2) above, the two ends of the aforementioned insulating paper along the axial direction of the aforementioned stator core protrude from the end face (e.g., end face 2a described later) of the aforementioned stator core.

[0015] (4) The stator manufacturing method of the present invention is a method for manufacturing a stator (e.g., stator 1 described later), the stator having: a stator core (e.g., stator core 2 described later) having a plurality of slots (e.g., slot 23 described later); and a coil (e.g., coil 3 described later) inserted into the aforementioned slots through insulating paper (e.g., insulating paper 4 described later), the stator manufacturing method comprising: an insulating paper bending step, wherein a base paper (e.g., base paper 101 described later) having arc-shaped creases is bent along a bending line (e.g., bending line L described later) extending in a direction having curvature (e.g., direction D described later) such that the concave side (e.g., concave surface 101a described later) becomes the back side, thereby forming the aforementioned insulating paper; an insulating paper insertion step, wherein the aforementioned insulating paper is inserted into the aforementioned slot before the aforementioned coil is inserted into the aforementioned slot; and a coil insertion step, wherein the aforementioned coil is inserted from the opening side of the aforementioned insulating paper into the interior of the aforementioned insulating paper in the aforementioned slot.

[0016] (The effect of the invention)

[0017] According to (1) above, since the insulating paper is made of a bent article, which is formed by bending a base paper with arc-shaped creases along a bending line extending in a direction with curvature, with the concave side facing the back, the insulating paper has unfolding marks with the open side facing outwards, thus the creases can be effectively utilized, and the insulating paper achieves self-holding along the inner surface of the slot. Therefore, a stator with high operating efficiency for coil insertion can be provided, which can prevent the insulating paper in the slot from warping inwards and can smoothly insert the coil into the slot.

[0018] According to (2) above, when inserting the coil using the outer curved portion of the insulating paper along the tapered part of the slot, it is possible to prevent the coil from hooking onto the insulating paper due to shape deviation. Therefore, the coil can be inserted into the slot more smoothly, and the work efficiency of coil insertion can be further improved.

[0019] According to (3) above, insulation between the coil and the axial end edge of the slot can be easily achieved without folding the insulating paper.

[0020] According to (4) above, the arc-shaped curl marks of the base paper of the insulating paper can be effectively utilized, and the insulating paper can be self-retained along the inner surface of the slot. Therefore, a stator with high operating efficiency for coil insertion can be easily manufactured, which can prevent the insulating paper in the slot from warping inward and can smoothly insert the coil into the slot. Attached Figure Description

[0021] Figure 1 This is a perspective view illustrating a stator according to one embodiment of the present invention.

[0022] Figure 2 It is a drawing Figure 1 The stator core of the stator shown is a top view.

[0023] Figure 3 It is a drawing Figure 2 A perspective view of the insulating paper in the slots of a portion of the stator core.

[0024] Figure 4 This is a front view of the coil installed before the stator.

[0025] Figure 5 It is a diagram illustrating the manufacturing process of insulating paper.

[0026] Figure 6 It is a diagram illustrating the manufacturing process of insulating paper.

[0027] Figure 7 This is a plan view of the insulating paper.

[0028] Figure 8 It is a diagram showing the insertion of a coil into a slot into which insulating paper has been inserted.

[0029] Figure 9 This is a plan view illustrating a portion of the stator core of a stator according to another embodiment of the present invention.

[0030] Figure 10 It is a drawing inserted in Figure 9 The diagram shows a plan view of the insulating paper in the slots of the stator core.

[0031] Figure 11 It is a drawing inserted. Figure 10 The diagram shows the situation where a coil is inserted into a groove in the insulating paper. Detailed Implementation

[0032] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Figure 1 As shown, the stator 1 of this embodiment has: a stator core 2; and a coil 3, which is mounted in a ring on the stator core 2.

[0033] like Figure 2 As shown, the stator core 2 has a centrally located circular shaft hole 21 and an annular portion 22, which is, for example, constructed from a laminate of multiple thin-walled core plates. The annular portion 22 has multiple slots 23 extending axially through the stator core 2. The slots 23 are arranged radially at certain intervals along the circumference of the stator core 2 and have openings 23a that open towards the shaft hole 21 radially inward of the annular portion 22. The stator core 2 of this embodiment has 72 slots 23. Furthermore, as... Figure 2 As shown, in the stator 1 and stator core 2, the A direction of the slots 23 is circumferential, and the B direction, which runs radially from the center of the shaft hole 21, is radial. Figure 1 The C direction shown (and) Figure 2 The direction perpendicular to the paper surface is the axis.

[0034] like Figure 2 and Figure 3 As shown, insulating paper 4 is inserted into the slots 23 of the stator core 2. The insulating paper 4 is a bent product formed by bending into a U-shape, mimicking the approximate U-shaped inner surface shape of the slots 23 when viewed from the axial direction. That is, as... Figure 3 As shown, the insulating paper 4 has: a pair of radial portions 41, 44, on the inner surface of a groove 23 extending radially in the stator core 2; and a circumferential portion 42, which connects the radially outer ends of the radial portions 41, 41 to each other circumferentially in the stator core 2.

[0035] The insulating paper 4 inserted into the slot 23 has a flanged portion 4a. The flanged portion 4a is a portion in which the radial portion 41, 41 and the circumferential portion 42 of the insulating paper 4 extend in the axial direction of the stator core 2 and protrude from the slot 23, and protrude outward from the end face 2a in the axial direction of the stator core 2. Figure 3 Only one flange 4a of the insulating paper 4 extending from one end face 2a of the stator core 2 is shown, but the flange 4a may also extend from the two end faces 2a, 2a of the stator core 2 in the axial direction.

[0036] like Figure 4 As shown, the coil 3, which is mounted in a ring on the stator core 2, is a strip-shaped coil formed by a flat wire 31 with a roughly rectangular cross-sectional shape. The flat wire 31 is formed, for example, by a metal with high conductivity such as copper or aluminum.

[0037] The coil 3 has multiple straight portions 32 and multiple coil ends 33. The straight portions 32 are inserted into the slots 23 of the stator core 2, extending in a generally straight line and arranged in parallel at certain intervals. The coil ends 33 are respectively located closer to the side ends of the coil 3 than the straight portions 32, and adjacent straight portions 32 are connected to each other in an alternating V-shape. The coil ends 33 are portions that protrude axially from the slots 23 towards the stator core 2 when the coil 3 is installed in the slots 23 of the stator core 2. In this embodiment, the coil 3 is formed by bundling six flat wires 31 with the straight portions 32 arranged in parallel at certain intervals, thereby forming a long strip. Each of the six flat wires 31 is formed by bending multiple straight portions 32 and multiple coil ends 33.

[0038] Next, refer to Figures 5-8 The manufacturing method of stator 1 will be explained. First, refer to... Figures 5-7 A more detailed explanation of insulating paper 4 will follow. Figure 5 and Figure 6 As shown, the insulating paper 4 is formed by bending the rectangular base paper 101 into a U-shape. The base paper 101 is unwound from the base paper roll 100 that is wound into a cylinder and cut into a specified length.

[0039] Because the base paper 101 was previously wound into a roll, therefore... Figure 5 As shown, it has a curl line that is bent into an arc shape. The curl line is generated in the direction along the winding direction of the roll. The concave surface 101a of the arc-shaped base paper 101 is the surface disposed on the inner surface side when the base paper 101 is wound on the base paper roll 100 (the surface disposed on the radial inner side of the base paper roll 100). Figure 5 and Figure 6 The direction D in the figure represents the direction in which the arc-shaped roll has curvature. This direction D is along the direction in which the base paper 101 is unwound from the base paper roll 100. In addition, the direction D is also along the axial direction of the groove 23 when the insulating paper 4 is inserted into the groove 23. The length along the direction D of the cut base paper 101 is longer than the length along the axial direction of the groove 23.

[0040] The base paper 101 is bent into a U-shape along a pair of bending lines L, L, with the concave side of the roll 101a as the back side, and along the inner surface shape of the groove 23 (insulating paper bending process).

[0041] In detail, such as Figure 6 As shown, the outer ends 101b and 101b of a pair of curved lines L, L on the base paper 101 are curved toward opposite sides of the concave surface 101a. The pair of curved lines L, L extend parallel to the direction of curvature on the base paper 101 with arc-shaped curls. The spacing W1 of the pair of curved lines L, L is equal to the circumferential width W11 of the groove 23 (refer to...). Figure 8 The distances from the outer ends 101b and 101b to the bending line L, the lengths W2 and W2 of L, and the radial depth W12 of the groove 23 are approximately equal. Figure 8 They are roughly equal.

[0042] Additionally, the bending lines L and L can be lines that are imaginarily set on the paper 101 when it is bent. Furthermore, the bending lines L and L serve as a reference for the position of bending the paper 101, but the paper 101 does not necessarily have to be bent in a way that forms a clear crease along the bending lines L and L.

[0043] Bend the base paper 101 as described above, thus... Figure 7 As shown, an insulating paper 4 is formed in the shape of a U-shape. A pair of outer ends 101b, 101b, bent by curves L, L, constitute the radial portions 41, 41 of the insulating paper 4. The space between the curves L, L, constitutes the circumferential portion 42 of the insulating paper 4. The U-shaped insulating paper 4 has an opening at the front end side (the side opposite to the circumferential portion 42) of the pair of radial portions 41, 41.

[0044] Because the insulating paper 4 is bent such that the concave side 101a of the arc-shaped curl becomes the back side, the arc-shaped curl exerts a force along the D direction on the back side, i.e., the circumferential portion 42, which warps toward the side opposite to the curved side of the radial portions 41, 41. As a result, the insulating paper 4 has unfolded marks on a pair of radial portions 41, 41 that open toward each other toward the outer surfaces E, E. These outer surfaces E are along the circumferential direction of the stator core 2.

[0045] Next, as Figure 8As shown, before inserting the coil 3 into the slot 23, insulating paper 4 is inserted into the slot 23 (insulating paper insertion process). The insulating paper 4 is positioned with its open side facing the opening 23a side of the slot 23, and the circumferential portion 42 side of the insulating paper 4 is first inserted into the slot 23 from the radially inward side towards the outer side. The positions of the radially inward front ends 4b, 4b of the insulating paper 4 inserted into the slot 23 are approximately aligned with the positions of the opening 23a of the slot 23. Since the insulating paper 4 in the slot 23 has unfolded lines with a pair of radial portions 41, 41 opening towards the opposite outer surfaces E, E, the radial portions 41, 41 of the insulating paper 4 are in close contact with the radially extending inner surfaces 23b, 23b of the slot 23. Thus, the insulating paper 4 is self-held in the slot 23, and inward warping of the insulating paper 4 in the slot 23 is prevented.

[0046] The length of the base paper 101 along the D direction is longer than the axial length of the groove 23, therefore, as Figure 3 As shown, the insulating paper 4 inserted into the slot 23 has a flanged portion 4a protruding from the axial end face 2a of the stator core 2. This flanged portion 4a is not a bent portion as in the past, but simply a direct extension of the ends of the radial portions 41, 41 and the circumferential portion 42 of the insulating paper 4. Therefore, the insulating paper 4 can easily achieve an axial end edge 23c (see reference) with the slot 23. Figure 3 Insulation between coils 3 in )

[0047] After the insulating paper 4 is inserted into the slot 23, the straight portion 32 of the coil 3 is inserted into the interior of the insulating paper 4 in the slot 23 from the opening side (coil insertion process). Although not shown, the coil 3 is pre-wound into an annular shape with a diameter smaller than the shaft hole 21 of the stator core 2 and inserted into the shaft hole 21. The annular coil 3 in the shaft hole 21 expands radially outward, thereby allowing the straight portion 32 to be inserted into the interior of the insulating paper 4 through the opening 23a of the slot 23. At this time, the radial portions 41, 41 of the insulating paper 4 in the slot 23 are arranged to make close contact with the inner surfaces 23b, 23b of the slot 23 by utilizing the unfolding marks of the outer surfaces E, E caused by the arc-shaped curling marks of the original paper 101, so that the insertion of the straight portion 32 is not hindered by the insulating paper 4 hooking onto it. Therefore, the straight portion 32 of the coil 3 can be smoothly inserted into the slot 23, and the work efficiency of the coil insertion operation can be improved. Then, all the straight portions 32 of coil 3 are inserted into slots 23, thus completing the process. Figure 1 Stator 1 is shown.

[0048] As described above, the stator 1 of this embodiment includes: a stator core 2 having a plurality of slots 23; and a coil 3 inserted into the slots 23 through insulating paper 4. The insulating paper 4 is made of a bent article, which is formed by bending a base paper 101 with arc-shaped creases along bending lines L, L extending in the direction of curvature D, with the concave side 101a as the back side, into a U-shape along the inner surface shape of the slot 23. The insulating paper 4 has unfolding marks with the open side facing outward E, E. Accordingly, the insulating paper 4 can effectively utilize the arc-shaped creases of the base paper 101 and achieve self-holding along the inner surfaces 23b, 23b of the slot 23. Therefore, a stator 1 with high operating efficiency for coil insertion can be provided, which can prevent the insulating paper 4 in the slot 23 from warping inward and can smoothly insert the straight portion 32 of the coil 3 into the slot 23.

[0049] In this embodiment, the insulating paper 4 along the axial direction of the stator core 2 protrudes from the end face 2a of the stator core 2 at both ends. Accordingly, insulation between the insulating paper 4 and the coil 3 on the axial end edge 23c of the slot 23 can be easily achieved without folding or turning the insulating paper 4.

[0050] Furthermore, the stator 1 manufacturing method of this embodiment is a method for manufacturing stator 1, wherein the stator 1 has: a stator core 2 having a plurality of slots 23; and a coil 3 inserted into the slots 23 through insulating paper 4. The method includes: an insulating paper bending process, in which a base paper 101 having arc-shaped creases is bent along bending lines L, L extending in the direction having curvature D, with the concave side 101a as the back side, and is bent into a U-shape along the inner surface shape of the slot 23, thereby forming insulating paper 4; an insulating paper insertion process, in which the insulating paper 4 is inserted into the slot 23 before the straight portion 32 of the coil 3 is inserted into the slot 23; and a coil insertion process, in which the straight portion 32 of the coil 3 is inserted into the interior of the insulating paper 4 in the slot 23 from the opening side of the insulating paper 4. Accordingly, the arc-shaped creases of the base paper 101 of the insulating paper 4 can be effectively utilized, and the insulating paper 4 can achieve self-holding along the inner surface 23b of the slot 23. Therefore, a stator 1 with high efficiency in coil insertion operation can be easily manufactured, which can prevent the insulating paper 4 in the slot 23 from warping inward and can smoothly insert the straight part 32 of the coil 3 into the slot 23.

[0051] Figures 9-11 Other embodiments of the stator core 2 and insulating paper 4 are shown. For example... Figure 9 As shown, the slot 23 of the stator core 2 has tapered portions 23d and 23d at the opening 23a to widen the opening. That is, the width of the slot 23 along the circumference is formed to be the widest at the opening 23a on the radially inner side.

[0052] The insulating paper 4 inserted into the slot 23 of the stator core 2 utilizes Figure 5 and Figure 6 The method shown is formed by bending the base paper 101. However, as... Figure 10 As shown, the front ends 4b and 4b on the opening side each have outer curved portions 43 and 43 that bend outwards E and E along the tapered portions 23d and 23d of the groove 23. The outer curved portions 43 and 43... Figure 6 Before or after the outer ends 101b, 101b of a pair of curved lines L, L on the base paper 101 are bent, the outer sides of the pair of curved lines L, L are bent towards the concave surface 101a along a curved line (not shown) parallel to the curved lines L, L.

[0053] like Figure 11 As shown, when the insulating paper 4 with outer curved portions 43, 43 is inserted into the slot 23, the radial portions 41, 41 of the insulating paper 4 have unfolding marks that open outwards to the outside, allowing the outer curved portions 43, 43 to make close contact with the tapered portions 23d, 23d of the slot 23. Therefore, the insulating paper 4 opens significantly towards the shaft hole 21 of the stator core 2, thus preventing the straight portion 32 of the coil 3 from hooking onto the insulating paper 4 due to shape deviations. Furthermore, even in this case, the position of the radially inner front ends 4b, 4b of the insulating paper 4 inserted into the slot 23 is approximately aligned with the position of the opening 23a of the slot 23.

[0054] Thus, in this embodiment, the slot 23 has a tapered portion 23d that widens the opening width at the opening 23a of the stator core 2 along the radial direction of the stator 1. The insulating paper 4 has outer curved portions 43 and 43 at its front ends 4b and 4b on the opening side, respectively, that bend outwards along the tapered portions 23d and 23d. Accordingly, by utilizing the outer curved portions 43 and 43 of the insulating paper 4 along the tapered portions 23d and 23d of the slot 23, hooking of the coil 3 with the insulating paper 4 due to shape deviation can be prevented when inserting the straight portion 32 of the coil 3. Therefore, the straight portion 32 of the coil 3 can be inserted into the slot more smoothly, and the work efficiency of the coil insertion operation can be further improved.

[0055] In the above embodiments, when viewed from the axial direction of the stator core 2, the insulating paper 4 is bent into a U-shape along the inner surface of the slot 23. However, the shape of the insulating paper 4 is not limited to this and can be appropriately changed according to the inner surface shape of the slot 23. For example, when viewed from the axial direction of the stator core 2, the insulating paper 4 can also be bent into a U-shape, a V-shape, etc.

[0056] In the above embodiments, the slot 23 of the stator core 2 is provided to open inward to the inner circumference, but the slot 23 may also be provided to open inward to the outer circumference of the stator core 2.

[0057] Figure Labels

[0058] 1 stator

[0059] 2 stator core

[0060] 2a end face

[0061] 23 slots

[0062] 23a opening

[0063] 23d conical part

[0064] 3 coils

[0065] 4. Insulating paper

[0066] 4d front end

[0067] 43 Outer curved part

[0068] 101 base paper

[0069] 101a concave surface

[0070] D has the direction of curvature

[0071] E external

[0072] L-curve

Claims

1. A method of manufacturing a stator having a stator core with a plurality of slots and a coil inserted into the slots via an insulation paper, characterized by comprising: an insulation paper bending step of bending a raw paper having a bending mark bent in a circular arc shape in a winding direction of a raw paper roll into a concave side as a back surface along a bending line extending in a direction having a curvature, thereby forming the insulation paper; an insulation paper insertion step of inserting the insulation paper into the slots before the coil is inserted into the slots; and a coil insertion step of inserting the coil from an opening side of the insulation paper into an inside of the insulation paper in the slots.

2. The method of manufacturing a stator according to claim 1, characterized in that: the stator core has a shaft hole in a center thereof; each slot has an opening portion opening in the shaft hole; in the insulation paper bending step, the raw paper is bent so that the insulation paper includes a pair of radial portions, a circumferential portion linking end portions of outer sides of the radial portions to each other, and a front end portion formed in each of the radial portions at a free end thereof on an opposite side to the circumferential portion at an intersection of the radial portion and the circumferential portion; and in the insulation paper insertion step, the insulation paper is completely inserted into the plurality of slots with the circumferential portion in close contact with an inner periphery of the slots before the coil is inserted into the slots, a position of the front end portion of the coil on a radial inner side is adjusted, and the insulation paper inserted into the slots is substantially aligned with the position of the opening portion of the slots. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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