Stator and method of manufacturing the same

Abstract

The present application provides a stator and a manufacturing method thereof, in which segmented conductors can be easily connected to each other in each slot. The stator has a stator core and a coil. The aforementioned stator core has a first portion, a second portion, and a first intermediate portion sandwiched between the aforementioned first portion and the aforementioned second portion. A slot is provided on an inner peripheral surface of the aforementioned stator core. The aforementioned coil has a first segmented conductor and a second segmented conductor. In the aforementioned slot within the range of the aforementioned first intermediate portion, the aforementioned first segmented conductor and the aforementioned second segmented conductor overlap in the circumferential direction of the aforementioned stator core. A first protrusion protruding from the aforementioned first intermediate portion with respect to the aforementioned first portion and the aforementioned second portion is provided on the aforementioned first side surface. The aforementioned first segmented conductor and the aforementioned second segmented conductor are connected to each other by being sandwiched by the aforementioned first protrusion and the aforementioned second side surface.

Description

TECHNICAL FIELD

[0001] The technology disclosed in this specification relates to a stator and a manufacturing method thereof. BACKGROUND

[0002] In Japanese Patent Application Publication No. 2019-129658, a stator of an electric motor is disclosed. The stator has a stator core of a cylindrical shape. On an inner peripheral surface of the stator core, a plurality of slots are provided at intervals in the circumferential direction. On the stator core, a coil is fixed. The coil is constituted by a plurality of segment conductors having a U shape. A part of the segment conductors is inserted into the corresponding slots from one end portion (hereinafter, referred to as a first end portion) of the stator. The remaining segment conductors are inserted into the corresponding slots from the other end portion (hereinafter, referred to as a second end portion) of the stator. In each slot, the leading end portions of the segment conductors inserted into the slot from the first end portion and the leading end portions of the segment conductors inserted into the slot from the second end portion overlap in the radial direction of the stator core in a state of being electrically connected. In this way, the coil is constituted by the segment conductors electrically connected to each other. SUMMARY

[0003] PROBLEMS TO BE SOLVED BY THE INVENTION

[0004] As described above, in the stator of Japanese Patent Application Publication No. 2019-129658, in each slot, the leading end portions of the segment conductors are connected to each other in a state of overlapping in the radial direction of the stator core. Therefore, in the manufacturing process of the stator, it is necessary to stack the leading end portions of the segment conductors in the radial direction of the stator core in each slot and press the stacked portion in the radial direction of the stator core, thereby connecting the leading end portions of the segment conductors to each other. Therefore, a jig or a member for pressing the stacked portion of the leading end portions of the segment conductors is required. In this specification, a stator in which the segment conductors can be easily connected to each other in each slot is proposed.

[0005] METHOD FOR SOLVING THE PROBLEM

[0006] The stator disclosed in the present specification has a stator core having a cylindrical shape, and a coil fixed to the stator core. The stator core has a first end surface and a second end surface arranged on both sides in an axial direction of the stator core. The stator core has a first portion, a second portion arranged at a position closer to the second end surface than the first portion, and a first intermediate portion sandwiched between the first portion and the second portion in the axial direction. On an inner peripheral surface of the stator core, a slot extending across the first portion, the first intermediate portion, and the second portion in the axial direction is provided. The slot has a first side surface, and a second side surface facing the first side surface in a circumferential direction of the stator core. The coil has a first segment conductor and a second segment conductor. The first segment conductor is inserted into the slot from the first end surface. The first segment conductor extends in the slot from a range of the first portion to a range of the first intermediate portion. A leading end of the first segment conductor is located in the slot. The second segment conductor is inserted into the slot from the second end surface. The second segment conductor extends in the slot from a range of the second portion to a range of the first intermediate portion. A leading end of the second segment conductor is located in the slot. In the slot in the range of the first intermediate portion, the first segment conductor and the second segment conductor overlap each other in the circumferential direction of the stator core. A first protrusion protruding from the first portion and the second portion with respect to the first intermediate portion is provided on the first side surface. The first segment conductor and the second segment conductor are connected to each other by being sandwiched by the first protrusion and the second side surface.

[0007] In the manufacturing process of the stator, after the first segment conductor is inserted into the slot from the first end surface and the second segment conductor is inserted into the slot from the second end surface, the first intermediate portion can be rotated with respect to the first portion and the second portion. When the first intermediate portion is rotated with respect to the first portion and the second portion, the first intermediate portion protrudes from the first portion and the second portion on the first side surface. By the protruding first intermediate portion, the first protrusion is formed. When the first protrusion is formed on the first side surface, the first segment conductor and the second segment conductor are sandwiched by the first protrusion and the second side surface. In the slot in the range of the first intermediate portion, the first segment conductor and the second segment conductor overlap each other in the circumferential direction of the stator core. Therefore, when the first protrusion is formed, the first segment conductor and the second segment conductor are pressed in their stacking direction (i.e., the circumferential direction of the stator core). Thus, the first segment conductor and the second segment conductor are connected. In this way, in the stator, by rotating the first intermediate portion that is a part of the stator core, the first segment conductor and the second segment conductor can be easily connected.

[0008] Further, the present specification discloses a manufacturing method of a stator. The manufacturing method of the stator disclosed in the present specification has a process of fixing a coil on a stator core having a cylindrical shape. The stator core has a first end surface and a second end surface arranged on both sides in an axial direction of the stator core. The stator core has a first portion, a second portion arranged at a position closer to the second end surface than the first portion, and a first intermediate portion sandwiched between the first portion and the second portion in the axial direction. On an inner peripheral surface of the stator core, a slot extending across the first portion, the first intermediate portion, and the second portion in the axial direction is provided. The slot has a first side surface and a second side surface facing the first side surface in a circumferential direction of the stator core. The coil has a first segment conductor and a second segment conductor. The process of fixing the coil on the stator core has a process of inserting the first segment conductor into the slot from the first end surface, a process of inserting the second segment conductor into the slot from the second end surface, and a process of rotating the first intermediate portion with respect to the first portion and the second portion. The process of inserting the first segment conductor into the slot is performed in such a manner that the first segment conductor extends in the slot from a range of the first portion to a range of the first intermediate portion, and a leading end of the first segment conductor is positioned in the slot. The process of inserting the second segment conductor into the slot is performed in such a manner that the second segment conductor extends in the slot from a range of the second portion to a range of the first intermediate portion, and a leading end of the second segment conductor is positioned in the slot. The process of inserting the first segment conductor into the slot and the process of inserting the second segment conductor into the slot are performed in the slot in the range of the first intermediate portion. The first segment conductor and the second segment conductor overlap in the circumferential direction of the stator core. In the process of rotating the first intermediate portion, a first protrusion is formed by the first intermediate portion protruding with respect to the first portion and the second portion on the first side surface, and the first segment conductor and the second segment conductor are connected to each other by being sandwiched by the first protrusion and the second side surface.

[0009] According to the manufacturing method, the first segment conductor and the second segment conductor can be easily connected by rotating the first intermediate portion that is a part of the stator core. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 is a perspective view of a stator.

[0011] Figure 2 is a perspective view of a stator core.

[0012] Figure 3 is a cross-sectional view of a stator core on a plane orthogonal to an axis Z1.

[0013] Figure 4 is a perspective view of the coil wire.

[0014] Figure 5 is a side view of the segmented conductor.

[0015] Figure 6 is a view showing the coil wire 42a installed on the stator core.

[0016] Figure 7 is an enlarged view of the connection portion in the range A of Figure 6

[0017] Figure 8 Figure 6 is an enlarged view of the connection portion in the range B of

[0018] Figure 9 is a cross-sectional view of the slot and the coil wire on a plane orthogonal to the axis Z1.

[0019] Figure 10 is a view showing the coil wire 42b installed on the stator core.

[0020] Figure 11 is an enlarged view of the connection portion in the range C of Figure 10

[0021] Figure 12 is a view showing the arrangement of the plurality of coil wires in the slot in a plane along the radial direction and the axial direction.

[0022] Figure 13 is a cross-sectional view showing the position of the intermediate portion in a state where the protrusions 38a, 39a are not formed.

[0023] Figure 14 is a plan view showing the position of the intermediate portion in a state where the protrusions 38a, 39a are not formed.

[0024] Figure 15 is a cross-sectional view showing the position of the intermediate portion in a state where the protrusions 38a, 39a are formed.

[0025] Figure 16 is a plan view showing the position of the intermediate portion in a state where the protrusions 38a, 39a are formed. DETAILED DESCRIPTION

[0026] In the example of the stator disclosed in the present specification, a recess in which the aforementioned first intermediate portion is recessed with respect to the aforementioned first portion and the aforementioned second portion can also be provided on the aforementioned second side surface.

[0027] ​​​In the stator disclosed in one example of the present specification, the first segment conductor can also have a first thick plate portion and a first thin plate portion that is thinner than the first thick plate portion. The first thin plate portion can be formed by a recessed portion provided in a range of the side surface of the first segment conductor that includes the front end of the first segment conductor. The second segment conductor can also have a second thick plate portion and a second thin plate portion that is thinner than the second thick plate portion. The second thin plate portion can be formed by a recessed portion provided in a range of the side surface of the second segment conductor that includes the front end of the second segment conductor. In the slot in the range of the first intermediate portion, the first thin plate portion and the second thin plate portion can overlap in the circumferential direction of the stator core in a state in which the recessed portion of the first segment conductor faces the recessed portion of the second segment conductor.

[0028] According to this structure, the first segment conductor and the second segment conductor can be connected more strongly.

[0029] In the stator disclosed in one example of the present specification, the first protrusion can not contact the first thick plate portion and the second thick plate portion.

[0030] According to this structure, the thin plate portion of the first segment conductor and the thin plate portion of the second segment conductor can be pressed more strongly.

[0031] In the stator disclosed in one example of the present specification, the first protrusion can contact one of the first thin plate portion and the second thin plate portion. Both the second side surface in the range of the first portion and the second side surface in the range of the second portion can contact the other of the first thin plate portion and the second thin plate portion.

[0032] According to this structure, the thin plate portion of the first segment conductor and the thin plate portion of the second segment conductor can be pressed more strongly.

[0033] In one example of the stator disclosed in this specification, the stator core may also have a third portion disposed closer to the second end face than the second portion, and a second intermediate portion sandwiched between the second and third portions in the aforementioned axial direction. The slot may also extend along the aforementioned axial direction across the first portion, the first intermediate portion, the second portion, the second intermediate portion, and the third portion. The coil may also have a third segment conductor and a fourth segment conductor. The third segment conductor may also be inserted into the slot from the first end face at a position radially offset from the first segment conductor relative to the stator core. The third segment conductor may also extend within the slot from the range of the second portion to the range of the second intermediate portion. The front end of the third segment conductor may also be located within the slot. The fourth segment conductor may also be inserted into the slot from the second end face at a position radially offset from the second segment conductor relative to the second segment conductor relative to the stator core. The fourth segment conductor may also extend within the slot from the range of the third portion to the range of the second intermediate portion. The leading edge of the aforementioned fourth segment conductor may also be located within the aforementioned groove. Alternatively, within the aforementioned groove within the range of the aforementioned second intermediate portion, the aforementioned third segment conductor and the aforementioned fourth segment conductor may overlap circumferentially in the aforementioned stator core. Alternatively, a second protrusion may be provided on the aforementioned first side surface, protruding from the aforementioned second and third portions relative to the aforementioned second and third portions. The aforementioned third and fourth segment conductors may also be interconnected by being clamped by the aforementioned second protrusion and the aforementioned second side surface.

[0034] According to this structure, the connection points of the third and fourth segment conductors within the slot are positioned offset from the connection points of the first and third segment conductors along the length of the slot. Therefore, leakage current between the connection points can be suppressed.

[0035] [Example 1]

[0036] Figure 1 The stator 10 of the illustrated embodiment forms part of the motor. The stator 10 has a stator core 20 and a coil 40. The coil 40 is fixed to the stator core 20.

[0037] like Figure 2 As shown, the stator core 20 has a cylindrical shape with the shaft Z1 as the central axis. The stator core 20 has end faces 20a and 20b on both sides along the direction of the shaft Z1 (hereinafter referred to as the axial direction).

[0038] The stator core 20 is divided into multiple parts in the axial direction. The stator core 20 has a first part 21, a first intermediate part 26, a second part 22, a second intermediate part 28, and a third part 23. The first part 21, the first intermediate part 26, the second part 22, the second intermediate part 28, and the third part 23 are arranged sequentially from end face 20a toward end face 20b.

[0039] The axial thickness of the first intermediate portion 26 and the second intermediate portion 28 is thinner than the axial thickness of the first portion 21, the second portion 22, and the third portion 23. The first portion 21 includes the first end face 20a. The first intermediate portion 26 is disposed on the side relative to the first portion 21 and closer to the second end face 20b. The second portion 22 is disposed on the side relative to the first intermediate portion 26 and closer to the second end face 20b. The second intermediate portion 28 is disposed on the side relative to the second portion 22 and closer to the second end face 20b. The third portion 23 is disposed on the side relative to the second intermediate portion 28 and closer to the second end face 20b. The third portion 23 includes the second end face 20b. The first intermediate portion 26 is axially disposed between the first portion 21 and the second portion 22. The second intermediate portion 28 is axially disposed between the second portion 22 and the third portion 23. The interfaces between the portions constituting the stator core 20 extend along a plane perpendicular to the axis Z1. Three fastening holes 29 are provided on the outer periphery of the stator core 20. Each fastening hole 29 extends axially through the first portion 21, the first intermediate portion 26, the second portion 22, the second intermediate portion 28, and the third portion 23. Although not shown, fastening components (e.g., bolts and nuts) are installed in each fastening hole 29. The first portion 21, the first intermediate portion 26, the second portion 22, the second intermediate portion 28, and the third portion 23 are fixed to each other by the fastening components provided in each fastening hole 29.

[0040] A plurality of grooves 30 are provided on the inner circumferential surface 24 of the stator core 20. Each groove 30 is a recess provided on the inner circumferential surface 24. Each groove 30 extends axially from end face 20a to end face 20b. Therefore, each groove 30 extends axially across the first portion 21, the first intermediate portion 26, the second portion 22, the second intermediate portion 28, and the third portion 23. Figure 3 As shown, in a section perpendicular to axis Z1, each slot 30 extends radially along the stator core 20. In the section perpendicular to axis Z1, each slot 30 has two side surfaces 34a and 34b. Side surfaces 34a and 34b face each other in the circumferential direction. The width of the slot 30 narrows at its inner circumferential end.

[0041] like Figure 1 As shown, the coil 40 is fixed to the stator core 20 by passing through the slots 30 of the stator core 20. The coil 40 is composed of multiple coil wires 42. Figure 4represents a coil wire 42. As shown in Figure 4 The coil wire 42 has a wave shape. More specifically, the coil wire 42 undulates in the axial direction while extending in the circumferential direction. The coil wire 42 is configured by connecting a plurality of Figure 5 segment conductors 50 as shown. As shown in Figure 5 The segment conductor 50 has a U shape. That is, the segment conductor 50 has two linear portions 51 and a connecting portion 54. The two linear portions 51 extend in a substantially straight line. The two linear portions 51 extend substantially in parallel. The connecting portion 54 connects the two linear portions 51. On each linear portion 51, a recess 51c is formed. The recess 51c is formed on the inner side surface of the linear portion 51. The recess 51c is provided in a range including the front end of the linear portion 51. Thus, in the range including the front end of the linear portion 51, a thin plate portion 51a having a small thickness is formed. Hereinafter, a portion of the linear portion 51 other than the thin plate portion 51a will be referred to as a thick plate portion 51b. The thin plate portion 51a has a smaller thickness than the thick plate portion 51b. Figure 5 The diagonal line represents an insulating coating film. In the surface of the segment conductor 50, except for the thin plate portion 51a, is covered with the insulating coating film. As shown in Figure 4 The coil wire 42 having a wave shape is configured by connecting a plurality of segment conductors 50 having a U shape to each other.

[0042] Figure 6 is a plan view of one coil wire 42a in a state of being fixed to the stator core 20, viewed from the center side of the stator core 20. Figure 6 The left-right direction of Figure 6 The up-down direction of Figure 6As shown, a portion of the segmented conductors 50 constituting the coil wire 42a are inserted into the groove 30 from the end face 20a. The front end of each segmented conductor 50a is located within the groove 30. The remaining segmented conductors 50b constituting the coil wire 42a are inserted into the groove 30 from the end face 20b. The front end of each segmented conductor 50b is located within the groove 30. Furthermore, in the coil wire 42a, each linear portion 51 of the segmented conductors 50a is shorter than each linear portion 51 of the segmented conductors 50b. The linear portion 51 of the segmented conductors 50a extends within the groove 30 from the range of the first portion 21, through the range of the first intermediate portion 26, to the range of the second portion 22. The front end of the linear portion 51 of the segmented conductors 50a is located within the groove 30 of the second portion 22. The linear portion 51 of segmented conductor 50b extends within the groove 30 from the range of the third portion 23, through the range of the second intermediate portion 28, the range of the second portion 22, and the range of the first intermediate portion 26, to the range of the first portion 21. The leading edge of the linear portion 51 of segmented conductor 50b is located within the groove 30 of the first portion 21. Within the groove 30 of the first intermediate portion 26, the linear portions 51 of segmented conductor 50a and segmented conductor 50b overlap circumferentially. Figure 6 As shown in ranges A and B, the connecting portion 49 within the groove 30 located in the range of the first intermediate portion 26 connects the linear portion 51 of the segmented conductor 50a and the linear portion 51 of the segmented conductor 50b.

[0043] Figure 7 Indicates that it is located at Figure 6 The connecting portion 49a within range A. For example... Figure 7 As shown, within the groove 30 within range A, with the recesses 51c of segmented conductor 50a and segmented conductor 50b facing each other, the thin plate portions 51a and 51a of segmented conductor 50a overlap circumferentially in the stator core 20. The thin plate portions 51a of segmented conductor 50a extend from the range of the first portion 21, through the range of the first intermediate portion 26, to the range of the second portion 22 within the groove 30. The thin plate portions 51a of segmented conductor 50b extend from the range of the second portion 22, through the range of the first intermediate portion 26, to the range of the first portion 21 within the groove 30. Therefore, within the range of the first intermediate portion 26 and its periphery, the thin plate portions 51a of segmented conductor 50a and 50b overlap circumferentially. The thin plate portions 51a of segmented conductor 50a are positioned closer to the side 34a than the thin plate portions 51a of segmented conductor 50b.

[0044] like Figure 7As shown, on the side surface 34a, the first intermediate portion 26 protrudes from the first portion 21 and the second portion 22. Hereinafter, the portion in which the first intermediate portion 26 protrudes on the side surface 34a is referred to as a protruding portion 38a. The protruding portion 38a is in contact with the thin plate portion 51a of the segment conductor 50a. The protruding portion 38a is not in contact with the thick plate portion 51b of the segment conductor 50a. Further, the protruding portion 38a is not in contact with the segment conductor 50b. Between the side surface 34a in the range of the first portion 21 and the segment conductor 50a, there is a gap. However, the side surface 34a in the range of the first portion 21 can also be partially in contact with the segment conductor 50a. Between the side surface 34a in the range of the second portion 22 and the segment conductor 50a, there is a gap. Between the side surface 34a in the range of the second portion 22 and the segment conductor 50b, there is a gap. However, the side surface 34a in the range of the second portion 22 can also be partially in contact with the segment conductor 50b. On the side surface 34b, the first intermediate portion 26 is recessed with respect to the first portion 21 and the second portion 22. Hereinafter, the portion in which the first intermediate portion 26 is recessed on the side surface 34b is referred to as a recessed portion 38b. The recessed portion 38b is not in contact with the segment conductors 50a and 50b. The side surface 34b in the range of the first portion 21 is in contact with the thick plate portion 51b of the segment conductor 50a and the leading end of the thin plate portion 51a of the segment conductor 50b. The side surface 34b in the range of the second portion 22 is in contact with the thick plate portion 51b of the segment conductor 50b and the base of the thin plate portion 51a of the segment conductor 50b.

[0045] The thin plate portion 51a of the segment conductor 50a and the thin plate portion 51a of the segment conductor 50b are connected to each other by being sandwiched by the protruding portion 38a and the side surface 34b (more specifically, the side surface 34b in the range of the first portion 21 and the side surface 34b in the range of the second portion 22). That is, the protruding portion 38a presses the thin plate portion 51a of the segment conductor 50a toward the thin plate portion 51a of the second segment conductor 50b. Further, the side surface 34b in the range of the first portion 21 and the side surface 34b in the range of the second portion 22 support the thin plate portion 51a of the second segment conductor 50b from the opposite side of the protruding portion 38a. Therefore, the surface of the recessed portion 51c of the segment conductor 50a is in contact with the surface of the recessed portion 51c of the segment conductor 50b in a state in which the surface of the recessed portion 51c of the segment conductor 50a is pressed. That is, the thin plate portion 51a of the segment conductor 50a and the thin plate portion 51a of the second segment conductor 50b are connected to each other by the pressure applied by the protruding portion 38a and the side surface 34b. As described above, each thin plate portion 51a is not covered with the insulating protective film. Therefore, in the connection portion 49a shown in FIG. 6, the segment conductor 50a and the segment conductor 50b are electrically connected. Figure 7 In the connection portion 49a shown in FIG. 6, the segment conductor 50a and the segment conductor 50b are electrically connected.

[0046] Further, in the connection portion 49a shown in FIG. 6, the segment conductor 50a and the segment conductor 50b are electrically connected. Figure 8 indicates that the segment conductor 50a and the segment conductor 50b are electrically connected. Figure 6The connecting portion 49b is within range B. In the connecting portion 49b, the thin plate portion 51a of the segmented conductor 50b is positioned closer to the side surface 34a than the thin plate portion 51a of the segmented conductor 50a. The other structures of the connecting portion 49b are the same as those of the connecting portion 49a. In the connecting portion 49b, the thin plate portions 51a of the segmented conductor 50a and the thin plate portions 51a of the segmented conductor 50b are also connected by being clamped by the protrusion 38a and the side surface 34b.

[0047] In this manner, the segmented conductors 50a and 50b of the coil wire 42a are fixed to each other by being clamped by the protrusion 38a and the side 34b. Therefore, no bonding material is provided at the contact interface 47 between the segmented conductors 50a and 50b. That is, the contact interface 47 is physically and electrically connected without bonding material. Through the same structure, all the segmented conductors 50 constituting the coil wire 42a are interconnected. Furthermore, the segmented conductors 50 of other coil wires 42 are also connected using the same connection structure as the segmented conductors 50 of the coil wire 42a.

[0048] like Figure 9 As shown, multiple coil wires 42 are inserted into a slot 30. Within a slot 30, the multiple coil wires 42 are stacked radially on the stator core 20. Figure 9 As shown, coil wire 42b is arranged adjacent to coil wire 42a. Figure 10 This is a top view of the coil wire 42b fixed to the stator core 20, viewed from the center side of the stator core 20. (See attached image.) Figure 10 As shown, in the coil wire 42b, each linear portion 51 of the segmented conductor 50a is longer than each linear portion 51 of the segmented conductor 50b. For example... Figure 10 As shown, the linear portion 51 of the segmented conductor 50a extends within the groove 30 from the range of the first portion 21, through the range of the first intermediate portion 26, the range of the second portion 22, and the range of the second intermediate portion 28, to the range of the third portion 23. (As shown...) Figure 10 As shown, the front end of the linear portion 51 of the segmented conductor 50a is located within the groove 30 of the third portion 23. (As indicated...) Figure 10 As shown, the linear portion 51 of the segmented conductor 50b extends within the groove 30 from the range of the third portion 23, through the range of the second intermediate portion 28, to the range of the second portion 22. As... Figure 10 As shown, the front end of the linear portion 51 of the segmented conductor 50b is located within the groove 30 of the second portion 22. (As indicated...) Figure 10 As shown, within the groove 30 of the second intermediate portion 28, the linear portions 51 of segmented conductor 50a and segmented conductor 50b overlap circumferentially. Figure 10range C, D, etc., the connecting portion 49 in the groove 30 in the range of the second intermediate portion 28 connects the linear portion 51 of the segment conductor 50a and the linear portion 51 of the segment conductor 50b. The connecting portion 49c in the range C has substantially the same structure as the connecting portion 49a in the range A. That is, as shown in Figure 11 FIG. 6, in the range C, the second intermediate portion 28 is formed with a protrusion 39a on the side surface 34a that protrudes more than the second portion 22 and the third portion 23. In the connecting portion 49c, the thin plate portion 51a of the segment conductor 50a and the thin plate portion 51a of the segment conductor 50b are physically and electrically connected by being sandwiched by the protrusion 39a and the side surface 34b. Figure 12 FIG. 7 shows the positional relationship of the connecting portion 49a and the connecting portion 49c in the axial direction. As shown in Figure 12 FIG. 7, the segment conductor 50a of the coil wire 42b is inserted into the groove 30 at a position that is radially offset with respect to the segment conductor 50a of the coil wire 42a. The segment conductor 50b of the coil wire 42b is inserted into the groove 30 at a position that is radially offset with respect to the segment conductor 50b of the coil wire 42a. As shown in Figure 12 FIG. 7, the axial position of the connecting portion 49a and the connecting portion 49c differs between adjacent coil wires 42a, 42b. As described above, the thin plate portion 51a of each segment conductor 50 is not covered by the insulating coating. Therefore, when the positions of the connecting portions 49a, 49c overlap in the axial direction between adjacent coil wires 42a, 42b, a leakage current occurs between the connecting portions 49a, 49c. As shown in Figure 12 FIG. 7, by making the positions of the connecting portions 49a, 49c different in the axial direction, it is possible to prevent a leakage current. Furthermore, in the coil wire 42 that includes all of the coil wires 42a, 42b, each connecting portion 49 is configured so that the positions of the connecting portions 49 do not overlap between adjacent coil wires 42.

[0049] In the connecting portion 49d in the range D of Figure 10 the connecting portion 49d, the thin plate portion 51a of the segment conductor 50b is disposed at a position closer to the side surface 34a than the thin plate portion 51a of the segment conductor 50a. The other structure of the connecting portion 49d is the same as the connecting portion 49c. With respect to the connecting portions 49b, 49d, as with the connecting portions 49a, 49c shown in Figure 12 FIG. 7, the connecting portions are configured so that the positions do not overlap between adjacent coil wires 42. Therefore, a leakage current is prevented from occurring between the connecting portion 49b and the connecting portion 49d.

[0050] Next, the manufacturing method of the stator 10 will be described. Before the coil 40 is fixed, in the stator core 20, the first intermediate portion 26 and the second intermediate portion 28 are relatively rotatable about the axis Zl with respect to the first portion 21, the second portion 22, and the third portion 23. The intermediate portions 26, 28 can be rotated in Figure 13 14 ​The position shown is the same as Figure 15 , 16 The positions shown are rotated relative to portions 21-23. Figure 13 , 14 In this groove 30, no protrusion is formed on either of the sides 34a or 34b. Furthermore, at this location, such as... Figure 14 As shown, the positions of the intermediate portions 26, 28, and portions 21-23 are offset on the outer peripheral surface of the stator core 20. Furthermore, at this position, the positions of the intermediate portions 26, 28, and portions 21-23 are also offset on the inner peripheral surface of the fastening hole 29. Therefore, at this position, the fastening component cannot be installed in the fastening hole 29. When the intermediate portions 26, 28 are moved from... Figure 13 , 14 When the positions shown are rotated counterclockwise, the middle parts 26 and 28 move to... Figure 15 , 16 The position shown. In this state, protrusions 38a and 39a are formed on the side surface 34a of the groove 30. In this position, as shown... Figure 16 As shown, the middle portions 26, 28, and portions 21-23 are positioned at the same location on the outer peripheral surface of the stator core 20. Furthermore, at the same location, the middle portions 26, 28, and portions 21-23 are also positioned at the same location on the inner peripheral surface of the fastening hole 29. Therefore, at this location, a fastening component can be installed in the fastening hole 29.

[0051] The manufacturing method of stator 10 includes a step of fixing coil 40 onto stator core 20. The step of fixing coil 40 onto stator core 20 includes a step of inserting segmented conductors 50a and 50b into slots 30, and a step of rotating intermediate portions 26 and 28.

[0052] In the process of inserting the segmented conductors 50a and 50b into the slot 30, firstly, the angles of the middle portions 26 and 28 are adjusted to... Figure 13 , 14 The angle shown. Therefore, the process of inserting the segmented conductors 50a and 50b into the slot 30 is performed when there is no protrusion 38a on the side surface 34a of the slot 30. Next, all the segmented conductors 50 constituting the coil 40 are inserted into the corresponding slots 30. Each segmented conductor 50a is inserted into the corresponding slot 30 from the end face 20a side, and each segmented conductor 50b is inserted into the corresponding slot 30 from the end face 20b side. Since no protrusion 38a is formed in each slot 30, each segmented conductor 50 can be easily inserted into the slot 30. Figure 6 As shown, when the segmented conductors 50a and 50b constituting the coil wire 42a are inserted into the corresponding slots 30, within the first intermediate portion 26, the thin plate portion 51a of the segmented conductor 50a and the thin plate portion 51a of the segmented conductor 50b overlap in the circumferential direction. Figure 10As shown, when the segmented conductors 50a and 50b constituting the coil wire 42b are inserted into the corresponding slots 30, within the second intermediate portion 28, the thin plate portion 51a of the segmented conductor 50a and the thin plate portion 51a of the segmented conductor 50b overlap in the circumferential direction. In this way, all the segmented conductors 50 constituting the coil 40 are inserted into the corresponding slots 30.

[0053] Next, rotate the middle portions 26 and 28 relative to portions 21 to 23. Here, rotate the middle portions 26 and 28 to... Figure 15 , 16 The positions are shown. Thus, on the side 34a of the groove 30, the middle portions 26 and 28 protrude, forming convex portions 38a and 39a. The result is as follows: Figure 7 , 8 As shown in Figure 11, each connecting portion 49 is pressurized by protrusions 38a and 39a. That is, the thin plate portion 51a of segmented conductor 50a and the thin plate portion 51a of segmented conductor 50b are pressurized by being clamped by protrusions 38a and side surfaces 34b (more specifically, side surfaces 34b within the range of portions 21-23). ​​Thus, the thin plate portions 51a of segmented conductor 50a and the thin plate portions 51a of segmented conductor 50b are physically and electrically connected. Figure 7 In the connecting portion 49a shown, the protrusion 38a contacts the thin plate portion 51a of the segmented conductor 50, but does not contact the thick plate portion 51b of the segmented conductor 50a and the thick plate portion 51b of the segmented conductor 50b. Therefore, the protrusion 38a can effectively pressurize the thin plate portion 51a of the segmented conductor 50. Furthermore, in the connecting portion 49a, the side surface 34b within the range of the first portion 21 contacts the front end of the thin plate portion 51a of the segmented conductor 50b. Furthermore, the side surface 34b within the range of the second portion 22 contacts the base end of the thin plate portion 51a of the segmented conductor 50b. Therefore, both ends of the thin plate portion 51a of the segmented conductor 50b are supported by the side surface 34b within the range of the first portion 21 and the side surface 34b within the range of the second portion 22. Therefore, the laminate of the thin plate portions 51a of the segmented conductor 50a and the thin plate portions 51a of the segmented conductor 50b can be effectively pressurized. In this manner, because the laminate can be effectively pressurized through the protrusion 38a and the side 34b, segment conductors 50a and 50b can be securely connected, and the connection between segment conductors 50a and 50b can be achieved with low resistance. Furthermore, other connecting portions 49 also connect segment conductors 50a and 50b in the same way. By interconnecting the segment conductors 50, a... Figure 1 The coil 40 is shown. That is, the coil 40 is fixed to the stator core 20. The middle parts 26 and 28 are rotated to... Figure 15 , 16The intermediate portions 26, 28 are fixed to the portions 21 to 23 by installing fastening members in the fastening holes 29, thereby fixing the intermediate portions 26, 28 to the portions 21 to 23 to each other. Thus, the stator core 20 is completed. Figure 1 The stator 10 is shown.

[0054] In this way, in the manufacturing method, the segmented conductors 50 are connected to each other by inserting the segmented conductors 50 into the slots 30 and then rotating the intermediate portions 26, 28 with respect to the portions 21 to 23. The segmented conductors 50 can be easily connected, and the coils 40 can be easily fixed to the stator core 20. Further, the segmented conductors 50 are not pressed by a jig in the slots 30, and thus a pressing jig is not required. Therefore, even in the case of manufacturing a plurality of stators having different shapes of stator cores 20, the pressing jig does not need to be changed, and a plurality of stators can be efficiently manufactured. Further, in the manufacturing method, the segmented conductors 50 are connected to each other by being clamped by the protrusions 38a and the side surfaces 34b, and thus a bonding material is not required on the contact interface of the segmented conductors 50. Therefore, the stator 10 can be more efficiently manufactured. Further, by connecting the segmented conductors 50 in the slots 30 in this way, the connection portions of the segmented conductors outside the slots 30 can be eliminated. Thus, the coils 40 can be downsized and lightened, and copper loss generated in the coils 40 can be reduced. Further, in other embodiments, a bonding material can be provided on the contact interface of the segmented conductors.

[0055] Further, in the above-described embodiments, the protrusions 38a, 39a are formed on the side surfaces 34a of the slots 30, but the protrusions can be formed on the side surfaces 34b protruding from the intermediate portions 26, 28 instead of the side surfaces 34a.

[0056] Further, in the above-described embodiments, the coils 40 are wave-shaped. However, the technology disclosed in the present specification can be applied to a lap-wound coil. Further, the lap-wound coil refers to a coil wound on a stator core in such a manner that a coil wire is wound around a common slot multiple times.

[0057] The end surface 20a of the above embodiment is an example of a first end surface. The end surface 20b of the above embodiment is an example of a second end surface. The side surface 34a of the above embodiment is an example of a first side surface. The side surface 34b of the above embodiment is an example of a second side surface. The segment conductor 50a of the above embodiment is an example of a first segment conductor and a third segment conductor. The segment conductor 50b of the above embodiment is an example of a second segment conductor and a fourth segment conductor. The protrusion 38a of the above embodiment is an example of a first protrusion. The protrusion 39a of the above embodiment is an example of a second protrusion. The thin plate portion 51a of the segment conductor 50a of the above embodiment is an example of a first thin plate portion. The thick plate portion 51b of the segment conductor 50a of the above embodiment is an example of a first thick plate portion. The thin plate portion 51a of the segment conductor 50b of the above embodiment is an example of a second thin plate portion. The thin plate portion 51a of the segment conductor 50b of the above embodiment is an example of a second thick plate portion. The recess 51c of the above embodiment is an example of a recessed portion.

[0058] The above detailed description illustrates the implementation, but these are only examples and do not limit the scope of the claims. In the technology recited in the claims, technologies of various modifications and changes to the above examples are included. The technical elements described in the specification or drawings are elements that exhibit technical utility by themselves or in various combinations, and are not limited to the combinations recited in the claims at the time of filing. Furthermore, the technology exemplified in the specification or drawings is a technology that achieves multiple objects, and achieving one of the objects itself has technical utility.

Claims

1. A stator, comprising: a stator core having a cylindrical shape; and a coil fixed to the stator core, the stator core has a first end surface and a second end surface disposed on both sides in an axial direction of the stator core, the stator core has a first portion, a second portion disposed at a position closer to the second end surface than the first portion, and a first intermediate portion sandwiched between the first portion and the second portion in the axial direction, a slot extending across the first portion, the first intermediate portion, and the second portion in the axial direction is provided on an inner peripheral surface of the stator core, the slot has a first side surface and a second side surface facing the first side surface in a circumferential direction of the stator core, the coil has a first sub-conductor and a second sub-conductor, the first sub-conductor is inserted into the slot from the first end surface, the first sub-conductor extends in the slot from a range of the first portion to a range of the first intermediate portion, a leading end of the first sub-conductor is located in the slot, the second sub-conductor is inserted into the slot from the second end surface, the second sub-conductor extends in the slot from a range of the second portion to a range of the first intermediate portion, a leading end of the second sub-conductor is located in the slot, the first sub-conductor and the second sub-conductor overlap each other in the circumferential direction of the stator core in the slot in the range of the first intermediate portion, a first protrusion in which the first intermediate portion protrudes with respect to the first portion and the second portion is provided on the first side surface, the first sub-conductor and the second sub-conductor are connected to each other by being sandwiched by the first protrusion and the second side surface.

2. The stator of claim 1, wherein a recess in which the first intermediate portion is recessed with respect to the first portion and the second portion is provided on the second side surface.

3. A stator according to claim 1 or 2, characterised in that the first sub-conductor has a first thick plate portion and a first thin plate portion thinner than the first thick plate portion, the first thin plate portion is formed by a recessed portion provided in a side surface of the first sub-conductor including a range of the leading end of the first sub-conductor, the second sub-conductor has a second thick plate portion and a second thin plate portion thinner than the second thick plate portion, the second thin plate portion is formed by a recessed portion provided in a side surface of the second sub-conductor including a range of the leading end of the second sub-conductor, in the slot in the range of the first intermediate portion, the first thin plate portion and the second thin plate portion overlap each other in the circumferential direction of the stator core in a state in which the recessed portion of the first sub-conductor and the recessed portion of the second sub-conductor face each other.

4. A stator according to claim 3, characterised in that the first protrusion does not contact the first thick plate portion and the second thick plate portion.

5. A stator according to claim 3 or 4, characterised in that the first protrusion contacts one of the first thin plate portion and the second thin plate portion, both the second side surface in the range of the first portion and the second side surface in the range of the second portion contact the other of the first thin plate portion and the second thin plate portion.

6. The stator of any one of claims 1 to 5, characterized in that, the stator core has a third portion disposed at a position closer to the second end face than the second portion, and a second intermediate portion sandwiched in the axial direction between the second portion and the third portion, the slot extends across the first portion, the first intermediate portion, the second portion, the second intermediate portion, and the third portion in the axial direction, the coil has a third segment conductor and a fourth segment conductor, the third segment conductor is inserted into the slot from the first end face at a position offset in a radial direction of the stator core with respect to the first segment conductor, the third segment conductor extends within the slot from a range of the second portion to a range of the second intermediate portion, a leading end of the third segment conductor is located within the slot, the fourth segment conductor is inserted into the slot from the second end face at a position offset in the radial direction of the stator core with respect to the second segment conductor, the fourth segment conductor extends within the slot from a range of the third portion to a range of the second intermediate portion, a leading end of the fourth segment conductor is located within the slot, the third segment conductor and the fourth segment conductor overlap in a circumferential direction of the stator core within the slot in the range of the second intermediate portion, a second protrusion protruding from the second intermediate portion with respect to the second portion and the third portion is provided on the first side face, the third segment conductor and the fourth segment conductor are connected to each other by being sandwiched by the second protrusion and the second side face.

7. A manufacturing method of a stator, comprising: a process of fixing a coil on a stator core having a cylindrical shape, the stator core has a first end face and a second end face disposed on both sides in an axial direction of the stator core, the stator core has a first portion, a second portion disposed at a position closer to the second end face than the first portion, and a first intermediate portion sandwiched in the axial direction between the first portion and the second portion, a slot extending across the first portion, the first intermediate portion, and the second portion in the axial direction is provided on an inner peripheral surface of the stator core, the slot has a first side face and a second side face facing the first side face in a circumferential direction of the stator core, the coil has a first segment conductor and a second segment conductor, the process of fixing the coil on the stator core includes: a process of inserting the first segment conductor into the slot from the first end face; a process of inserting the second segment conductor into the slot from the second end face; and a process of rotating the first intermediate portion with respect to the first portion and the second portion, the process of inserting the first segment conductor into the slot is performed in such a manner that the first segment conductor extends within the slot from a range of the first portion to a range of the first intermediate portion, and a leading end of the first segment conductor is located within the slot, The second segment conductor is inserted into the slot in such a manner that the second segment conductor extends in the slot from a range of the second portion to a range of the first intermediate portion, with a leading end of the second segment conductor being positioned in the slot, The first segment conductor and the second segment conductor are overlapped in the circumferential direction of the stator core in the slot in a range of the first intermediate portion, In the process of rotating the first intermediate portion, a first protrusion is formed on the first side surface by the first intermediate portion protruding relative to the first portion and the second portion, and the first segment conductor and the second segment conductor are connected to each other by being clamped by the first protrusion and the second side surface.

8. The manufacturing method according to claim 7, wherein In the process of rotating the first intermediate portion, a recess is formed on the second side surface by the first intermediate portion being recessed relative to the first portion and the second portion.

9. The production method according to claim 7 or 8, characterized by, The first segment conductor has a first thick plate portion and a first thin plate portion that is thinner than the first thick plate portion, The first thin plate portion is formed by a recessed portion provided in a side surface of the first segment conductor in a range including the leading end of the first segment conductor, The second segment conductor has a second thick plate portion and a second thin plate portion that is thinner than the second thick plate portion, The second thin plate portion is formed by a recessed portion provided in a side surface of the second segment conductor in a range including the leading end of the second segment conductor, The first segment conductor and the second segment conductor are overlapped in the circumferential direction of the stator core in the slot in a range of the first intermediate portion, with the recessed portion of the first segment conductor and the recessed portion of the second segment conductor facing each other.

10. The manufacturing method according to claim 9, wherein The process of rotating the first intermediate portion is performed in such a manner that the first protrusion does not contact the first thick plate portion and the second thick plate portion.

11. The production method according to claim 9 or 10, characterized by, The process of rotating the first intermediate portion is performed in such a manner that the first protrusion contacts one of the first thin plate portion and the second thin plate portion, and the second side surface in a range of the first portion and the second side surface in a range of the second portion both contact the other of the first thin plate portion and the second thin plate portion.

12. The production method according to any one of claims 7 to 11, characterized by, The stator core has a third portion disposed closer to the second end surface than the second portion, and a second intermediate portion sandwiched in the axial direction between the second portion and the third portion, The slot extends across the first portion, the first intermediate portion, the second portion, the second intermediate portion, and the third portion in the axial direction, The coil has a third segment conductor and a fourth segment conductor, The process of fixing the coil to the stator core has: a step of inserting the third segment conductor into the slot from the first end face at a position offset in a radial direction of the stator core with respect to the first segment conductor; a step of inserting the fourth segment conductor into the slot from the second end face at a position offset in the radial direction of the stator core with respect to the second segment conductor; and a step of rotating the second intermediate portion with respect to the second portion and the third portion, the step of inserting the third segment conductor into the slot is performed in such a manner that the third segment conductor extends in the slot from a range of the second portion to a range of the second intermediate portion, a leading end of the third segment conductor being located in the slot, the step of inserting the fourth segment conductor into the slot is performed in such a manner that the fourth segment conductor extends in the slot from a range of the third portion to a range of the second intermediate portion, a leading end of the fourth segment conductor being located in the slot, the step of inserting the third segment conductor into the slot and the step of inserting the fourth segment conductor into the slot are performed in such a manner that the third segment conductor and the fourth segment conductor overlap in the circumferential direction of the stator core in the slot in a range of the second intermediate portion, in the step of rotating the second intermediate portion, a second protrusion is formed by the second intermediate portion protruding on the first side face with respect to the second portion and the third portion, the third segment conductor and the fourth segment conductor being connected to each other by being clamped by the second protrusion and the second side face.

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