Stator manufacturing method and stator manufacturing apparatus

Abstract

The stator manufacturing method includes: an insertion step of inserting a plurality of segment coils into slots of a stator core; and a bending step in which, after the insertion step, a bending member for pressing the coil end portion and bending the coil end portion in the circumferential direction is repeated to bend the coil end portion by relatively moving in the circumferential direction and in the axial direction with respect to the stator core, and then bending the coil end portion in the axial direction. Bending based on the bending member transferred to the next coil end portion adjacent to the bent coil end portion.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a stator and a device for manufacturing a stator. Background Art

[0002] Conventionally, there is known a method and apparatus for manufacturing a stator that bends segment coils disposed in slots of a stator core. Such a method and apparatus for manufacturing a stator are disclosed in, for example, Japanese Patent No. 6848130.

[0003] The Japanese Patent Gazette No. 6848130 discloses a method for manufacturing a stator, which includes a step of bending and forming the coil ends of the segmented coils arranged in the circumferential direction by pressing the coil ends of the segmented coils arranged in the circumferential direction with a plurality of forming jigs. The plurality of forming jigs are arranged in a row in the circumferential direction in a state facing the coil ends, and the number of the forming jigs is the same as the total number of the coil ends arranged in the circumferential direction. In the above-mentioned method for manufacturing a stator, the coil ends are pressed one by one by using a plurality of forming jigs, so that all the coil ends are bent and formed at the same time. That is, in the above-mentioned method for manufacturing a stator, the plurality of coil ends arranged in the circumferential shape are bent and formed at the same time by using a plurality of forming jigs arranged in a circumferential shape.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent No. 6848130 Summary of the invention

[0007] Problems to be solved by the present invention

[0008] However, in the manufacturing method (manufacturing device) of the stator disclosed in the above-mentioned Japanese Patent No. 6848130, since a plurality of coil ends arranged in a circular shape are bent and formed at the same time, the forming load during bending and forming (the reaction force from the plurality of coil ends) becomes too large, and a relatively large rigidity is required for the device that performs the bending and forming of the coil ends. Therefore, the device that performs the bending and forming of the coil ends is relatively large. In addition, in the manufacturing method (manufacturing device) disclosed in the above-mentioned Japanese Patent No. 6848130, there is a limit to the reduction in diameter of the stator to be manufactured, taking into account the interference between adjacent forming fixtures and the rigidity of the forming fixtures. As described above, it has always been desired to make improvements so that the size of the device that performs the bending and forming of the coil ends can be suppressed and the reduction in diameter of the stator can be fully coped with.

[0009] The present invention is completed to solve the above-mentioned problems. One purpose of the present invention is to provide a stator manufacturing method and a stator manufacturing device, which can suppress the size of the device for bending and forming the coil end portion and can fully cope with the reduction in the diameter of the stator.

[0010] Technical means of solving problems

[0011] In order to achieve the above-mentioned purpose, the manufacturing method of the stator according to the first aspect of the present invention comprises: an inserting step of inserting a plurality of segment coils into slots of a stator core in such a manner that coil end portions, which become coil ends, protrude from an axial end face of the stator core and a plurality of coil end portions are arranged in a circumferential direction of the stator core; and a bending step of, after the inserting step, repeatedly performing the following process to bend and form a plurality of coil end portions arranged in the circumferential direction: moving a bending member for pressing the coil end portions and bending the coil end portions in the circumferential direction and relative to the stator core in the axial direction to bend the coil end portions, and then transferring to bending of a next coil end portion adjacent to the bent coil end portion by the bending member.

[0012] In the manufacturing method of the stator of the first aspect of the present invention, as described above, a bending process is provided, and the bending process repeatedly performs the following process to perform bending forming of a plurality of the coil end portions arranged in the circumferential direction: a bending member for pressing the coil end portion and bending the coil end portion along the circumferential direction is relatively moved in the circumferential direction and in the axial direction relative to the stator core to bend the coil end portion, and then transfers to the bending of the next coil end portion adjacent to the bent coil end portion based on the bending member. Thus, after the coil end portion is bent, the bending of the next coil end portion adjacent to the bent coil end portion based on the bending member is repeated, so that the bending forming of the plurality of coil end portions can be performed using one bending member. Therefore, it is not necessary to perform bending forming of the plurality of coil end portions at once as in the past, and the rigidity required for the device for performing bending forming of the coil end portions can be reduced. In addition, since a plurality of adjacent coil end portions can be bent and formed using one bending member, the coil end portions arranged in the circumferential direction can be bent and formed without providing the same number of bending members as the total number of coil end portions arranged in the circumferential direction. Therefore, when reducing the diameter of the stator to be manufactured, it is not necessary to consider the interference between adjacent bending members as in the past. As a result, the size of the device for bending and forming the coil end portions can be reduced, and the reduction in the diameter of the stator can be fully coped with.

[0013] In the stator manufacturing method of the above-mentioned first aspect, preferably, the bending process includes: causing a bending member whose number is less than the total number of multiple coil end portions arranged in the circumferential direction to move relative to the stator core in the circumferential direction and in the axial direction, thereby bending and forming the multiple coil end portions.

[0014] According to such a structure, since the bending is performed using a bending member whose number is less than the total number of the plurality of coil end portions arranged in the circumferential direction, all the coil end portions are not bent at the same time, and the rigidity required by the device for bending the coil end portions can be effectively reduced. Therefore, the size of the device for bending the coil end portions can be effectively suppressed. In addition, for example, in the case where two bending members are arranged at an angle of 180 degrees in the circumferential direction, the interval between the two bending members can be ensured to be larger, so that interference between the bending members can be suppressed, and the bending members can be made thicker and the rigidity can be improved. As a result, it is also possible to more reliably cope with the reduction in the diameter of the stator.

[0015] In the stator manufacturing method of the above-mentioned first aspect, preferably, the bending process includes repeating the following process to perform the bending forming of multiple coil end parts: the bending member is moved relative to the stator core in the circumferential direction and in the axial direction so that the coil end part is bent along the circumferential direction and passes over the coil end part, thereby transferring to the bending of the next coil end part adjacent to the bent coil end part based on the bending member.

[0016] According to such a structure, for example, compared to a situation in which, after bending a coil end portion, the bending member is temporarily retreated axially from the stator core without crossing the coil end portion and then transferred to the bending of the next adjacent coil end portion, by bending the coil end portion along the circumferential direction and crossing the coil end portion, a plurality of circumferentially adjacent coil end portions can be bent continuously and efficiently.

[0017] In this case, preferably, the bending step includes moving the bending member relative to the stator core in both the circumferential direction and the axial direction to pass over the coil end portions, thereby spirally bending the plurality of coil end portions.

[0018] According to such a configuration, the bending member can be moved spirally only by setting the speed of the bending member in the circumferential direction and the speed of the bending member in the axial direction, thereby facilitating the bending of the plurality of coil end portions.

[0019] In the stator manufacturing method of the first aspect, the bending step preferably includes: wrapping the bending member around the stator core a plurality of times in the circumferential direction, gradually increasing the bending angle of the coil end portion relative to the axial direction, thereby performing bending forming of the plurality of coil end portions.

[0020] According to such a structure, the bending of each coil end portion can be performed in multiple steps, and the bending angle caused by one pressing of the bending member on the coil end portion can be reduced. Therefore, the bent coil end portion can be prevented from interfering with the next adjacent coil end portion.

[0021] In a structure in which the above-mentioned bending process includes performing bending forming using bending members whose number is less than the total number of the plurality of coil end parts arranged in the circumferential direction, preferably, the bending process includes: performing bending forming of the plurality of coil end parts whose number is less than the total number of the plurality of coil end parts arranged in the circumferential direction and which are arranged at equal angular intervals in the circumferential direction at the same time.

[0022] According to such a configuration, more coil end portions can be bent and shaped simultaneously compared to a case where only one bending member is used, so that a plurality of coil end portions can be bent and shaped efficiently.

[0023] The stator manufacturing device of the second aspect of the present invention comprises: a bending member, which presses and forms a plurality of coil end portions of a plurality of coil ends arranged in the circumferential direction of a stator core and bends the coil end portions along the circumferential direction; and a moving mechanism, which repeats the following process to perform bending forming of the plurality of coil end portions arranged in the circumferential direction: the bending member is moved relative to the stator core in the circumferential direction and in the axial direction of the stator core to bend the coil end portions, and then, the bending of the next coil end portion adjacent to the bent coil end portion based on the bending member is transferred; the bending members are set to be less in number than the total number of the plurality of coil end portions arranged in the circumferential direction.

[0024] In the stator manufacturing device of the second aspect of the present invention, as described above, a moving mechanism is provided, which repeats the following process to perform bending forming of a plurality of coil end portions arranged in the circumferential direction: the bending member is relatively moved in the circumferential direction relative to the stator core and in the axial direction of the stator core to bend the coil end portion, and then the bending is transferred to the next coil end portion adjacent to the bent coil end portion by the bending member, and the number of the bending members is set to be less than the total number of the plurality of coil end portions arranged in the circumferential direction. Thus, after the coil end portion is bent, the bending is repeatedly transferred to the next coil end portion adjacent to the bent coil end portion by the bending member, so that the bending forming of the plurality of coil end portions can be performed by using one bending member. Therefore, it is not necessary to perform bending forming of the plurality of coil end portions at once as in the past, and the rigidity required for the device for performing bending forming of the coil end portions can be reduced. In addition, since a plurality of adjacent coil end portions can be bent and formed using one bending member, the coil end portions arranged in the circumferential direction can be bent and formed without providing the same number of bending members as the total number of coil end portions arranged in the circumferential direction. Therefore, when reducing the diameter of the stator to be manufactured, it is not necessary to consider the interference between adjacent bending members as in the past. As a result, the size of the device for bending and forming the coil end portions can be reduced, and the reduction in the diameter of the stator can be fully coped with.

[0025] In the above-mentioned method of manufacturing the stator, the following structure is also conceivable.

[0026] (Supplementary Item 1)

[0027] That is, the bending step includes performing bending forming of the plurality of coil end portions by alternately repeating the relative movement of the bending member only in the circumferential direction and only in the axial direction with respect to the stator core.

[0028] According to such a configuration, the plurality of coil end portions arranged in the circumferential direction can be bent by the bending member while the position of the bending member in the axial direction is maintained. Therefore, the bending amounts of the plurality of coil end portions can be made uniform by the bending member. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a perspective view showing a stator according to the embodiment.

[0030] Figure 2 It is a schematic diagram for explaining the segment coil of the stator according to the embodiment.

[0031] Figure 3 It is a perspective view showing the coil end of the stator according to the embodiment.

[0032] Figure 4 It is a schematic diagram which shows the manufacturing apparatus of the stator which concerns on embodiment.

[0033] Figure 5 This is a diagram of a pressing member and a supporting member of the stator manufacturing apparatus according to the embodiment as viewed from the circumferential direction.

[0034] Figure 6 This is a schematic diagram for explaining a spiral track for moving a pressing member and a supporting member of the stator manufacturing apparatus according to the embodiment.

[0035] Figure 7 This is a diagram showing a pressing member and a supporting member of the stator manufacturing apparatus according to the embodiment as viewed from a radial direction.

[0036] Figure 8 This is a diagram showing a state where the coil end portions of the outermost row in the radial direction are bent in the circumferential direction by the pressing member of the stator manufacturing apparatus according to the embodiment.

[0037] Fig. 9 It is a perspective view showing a restriction member of the stator manufacturing apparatus according to the embodiment.

[0038] Fig.10 It is a diagram showing a manufacturing flow of a stator according to an embodiment.

[0039] Fig.11 It is a diagram for explaining a segment coil preparation step in the manufacturing flow of the stator according to the embodiment.

[0040] Fig.12 It is a diagram for explaining an insertion step in the manufacturing process of the stator according to the embodiment.

[0041] Fig.13 This is a plan view showing a state immediately before the start of bending forming of the coil end portion in the circumferential direction in a bending step in the manufacturing process of the stator according to the embodiment.

[0042] Fig.14 This is a plan view showing a state in which the coil end portions of the outermost row in the radial direction are bent in the circumferential direction in a bending step in the manufacturing process of the stator according to the embodiment.

[0043] Fig.15 This is a plan view showing a state in which coil end portions of the outermost row in the radial direction and the second row from the outer side are bent in the circumferential direction in a bending step in the manufacturing process of the stator according to the embodiment.

[0044] Fig.16 The diagram is for explaining an operation of slightly bending each of a plurality of coil end portions arranged in the circumferential direction in a bending step in the manufacturing process of the stator according to the embodiment.

[0045] Fig.17 This is a schematic diagram for explaining a zigzag track for moving a pressing member and a supporting member of a stator manufacturing apparatus according to a modified example. DETAILED DESCRIPTION

[0046] Hereinafter, embodiments of the present invention will be described based on the drawings.

[0047] Reference Figures 1 to 16 The structure of the manufacturing apparatus 200 of the stator 100 and the manufacturing method of the stator 100 according to the embodiment will be described. Hereinafter, after describing the structure of the stator 100 to be manufactured, the structure of the manufacturing apparatus 200 of the stator 100 and the manufacturing method of the stator 100 will be described in sequence.

[0048] (Structure of stator)

[0049] Reference Figure 1 to Figure 3 The structure of the stator 100 will be described.

[0050] In the following description, the stator core 10 (see Figure 1 ) are respectively defined as the Z direction, the R direction, and the C direction in the axial direction, the radial direction, and the circumferential direction. In addition, one side and the other side in the axial direction (Z direction) are respectively defined as the Z1 side and the Z2 side. In addition, the inner side and the outer side in the radial direction (R direction) are respectively defined as the R1 side and the R2 side. In addition, one side and the other side in the C direction are respectively defined as the C1 side and the C2 side. In addition, in the present embodiment, the manufacturing device 200 of the stator 100 is used to perform the coil end portion 123 (refer to Fig.12 )Bending process for bending (refer to Figure 4 ).

[0051] like Figure 1 As shown, the stator 100 and a rotor (not shown) disposed on the R1 side of the stator 100 so as to face the stator 100 constitute a part of an inner rotor type rotating electrical machine (not shown). The rotating electrical machine is, for example, a motor, a generator, or a motor-generator.

[0052] The stator 100 includes a stator core 10 having a cylindrical shape with a central axis A along the Z direction as a central axis, and a coil 20 .

[0053] The stator core 10 is formed by stacking a plurality of electromagnetic steel sheets in the Z direction. The stator core 10 includes a circular back yoke 11 and a plurality of teeth 12 protruding from the back yoke 11 toward the R1 side. Moreover, slots 13 are formed between teeth 12 adjacent to each other in the C direction. That is, the stator core 10 includes a plurality of slots 13. The plurality of slots 13 are respectively arranged in a manner extending in the Z direction.

[0054] The coil 20 is configured to generate a magnetic flux when a three-phase alternating current is supplied. As an example, the coil 20 is configured by a conductive wire mainly composed of copper, a copper alloy, aluminum, and an aluminum alloy, and an insulating film covering the conductive wire.

[0055] like Figure 2 As shown, the coil 20 is formed by joining a plurality of segment coils 20a. Each segment coil 20a includes: a pair of slot receiving portions 21 received in the slots 13; a coil end portion 22 protruding from the end face 10a on the Z1 side of the stator core 10 toward the Z1 side; and two coil end portions 23 protruding from the end face 10a on the Z2 side of the stator core 10 (the axial end face of the stator core 10) toward the Z2 side.

[0056] The pair of slot accommodating portions 21 are each accommodated (inserted) in a different slot 13. That is, the pair of slot accommodating portions 21 are each arranged to extend in the Z direction. The coil end portion 22 connects the pair of slot accommodating portions 21 to each other. Thus, in each segment coil 20a, the portion constituted by the pair of slot accommodating portions 21 and the coil end portion 22 is formed into a U shape.

[0057] The two coil ends 23 are each arranged on the Z2 side of the stator core 10. The two coil ends 23 are each connected to the opposite side of the pair of slot accommodating portions 21 to the coil end 22. The top end 23a (on the opposite side to the slot accommodating portion 21) of the two coil ends 23 is each joined (connected) to the top end 23a of the coil end 23 of the other segment coil 20a by welding on the Z2 side of the stator core 10. In one example, the total number of the coil ends 23 arranged in the circumferential direction is 48.

[0058] The figure shows a state where no insulating film is formed on each of the top ends 23a of the two coil ends 23 (conducting wire is exposed) in order to connect the top ends 23a of the two coil ends 23 to the top ends 23a of the other segment coils 20a by welding. Although not shown in the figure, the top ends 23a of the coil ends 23 are insulated by a resin member such as varnish after the top ends 23a of the coil ends 23 are connected to the top ends 23a of the coil ends 23 of the other segment coils 20a.

[0059] like Figure 3 As shown, the two coil ends 23 are bent in the direction along the C direction with respect to the slot accommodating portion 21 extending in the Z direction, with the base 23b of the coil end 23 as a bending fulcrum. Thus, the two coil ends 23 extend obliquely with respect to the Z direction.

[0060] In the stator 100, the top ends 23a of the plurality of coil ends 23 are arranged at substantially equal angular intervals in the C direction. The group of the top ends 23a of the plurality of coil ends 23 arranged in the C direction is arranged in the R direction.

[0061] The plurality of coil ends 23 arranged in the C direction in the first row from the R2 side (hereinafter referred to as the first row coil ends 23) are bent toward the C1 side in the C direction relative to the slot accommodating portion 21 extending in the Z direction. In addition, the plurality of coil ends 23 arranged in the C direction in the second row from the R2 side (hereinafter referred to as the second row coil ends 23) are bent toward the C2 side in the C direction relative to the slot accommodating portion 21 extending in the Z direction. Moreover, each of the top ends 23a of the plurality of first row coil ends 23 and each of the top ends 23a of the plurality of second row coil ends 23 face each other in the R direction and are joined to each other. In addition, the structure of the coil end 23 arranged on the R1 side of the second row coil end 23 is also substantially the same as the structure of the first row coil end 23 and the second row coil end 23.

[0062] (Stator manufacturing device)

[0063] Reference Figures 4 to 9 A manufacturing apparatus 200 for the stator 100 according to the present embodiment will be described.

[0064] like Figure 4 As shown, the manufacturing device 200 of the stator 100 includes: a pressing member 211 (an example of a "bending member" in the claims), a pressing member motor 212, a supporting member 221 (an example of a "bending member" in the claims), a supporting member motor 222, a supporting unit 231, a supporting unit motor 232, and a limiting member 241 (see Fig. 9 ), the limiting member motor 242, the stator support portion 251 and the stator support portion motor 252.

[0065] The pressing member motor 212 , the supporting member motor 222 , the supporting unit motor 232 , and the stator supporting portion motor 252 constitute a moving mechanism 200 a that moves the pressing member 211 and the supporting member 221 relative to the stator core 10 .

[0066] The moving mechanism 200a is configured to perform bending forming of a plurality of coil end portions 123 arranged in the circumferential direction by repeating the following process: the pressing member 211 and the supporting member 221 are relatively moved in the circumferential direction (C direction) and in the axial direction (Z direction) of the stator core 10 relative to the stator core 10, and after the coil end portion 123 is bent, the pressing member 211 and the supporting member 221 are used to bend the next coil end portion 123 adjacent to the bent coil end portion 123. The bending forming (bending process) will be described in detail later.

[0067] In the manufacturing device 200, a plurality of groups of pressing members 211 and supporting members 221 are provided, with one pressing member 211 and one supporting member 221 as one group. In one example, two groups of pressing members 211 and supporting members 221 are provided in the manufacturing device 200 of the present embodiment. The two groups of pressing members 211 and supporting members 221 are arranged at equal angle intervals (180 degree intervals) in the circumferential direction. In addition, in the manufacturing device 200, the pressing members 211 and supporting members 221 (one group) are provided in such a manner that the number (two groups) is less than the total number (48) of the plurality of coil end portions 123 arranged in the circumferential direction.

[0068] Thus, the manufacturing device 200 is configured to simultaneously perform bending forming of a plurality of (two) coil end portions 123, which is less in number than the total number (48) of the plurality of coil end portions 123 arranged in the circumferential direction (48), using (two groups of) the plurality of pressing members 211 and the supporting members 221, which are arranged at equal angular intervals in the circumferential direction. Furthermore, when the forming load is compared with that of a manufacturing device that simultaneously bends all 48 coil end portions, it is obvious that the manufacturing device 200 can suppress the forming load to an extremely small level.

[0069] The pressing member 211 and the supporting member 221 are configured to press the plurality of coil end portions 123 as the plurality of coil end portions 23 arranged in the circumferential direction (C direction) of the stator core 10 and bend them in the circumferential direction.

[0070] The pressing member 211 is configured to be movable in the Z direction relative to the stator core 10 by driving the pressing member motor 212. That is, the pressing member 211 is configured to be relatively movable in the Z direction relative to the stator core 10. In addition, the supporting member 221 is configured to be movable in the Z direction relative to the stator core 10 by driving the supporting member motor 222. That is, the supporting member 221 is configured to be relatively movable in the Z direction relative to the stator core 10.

[0071] The support unit 231 supports the pressing member 211 and the support member 221. The support unit 231 is configured to be movable in the R direction relative to the stator core 10 by driving the support member motor 222. That is, the pressing member 211 and the support member 221 are configured to be relatively movable in the R direction relative to the stator core 10 at the same time.

[0072] The stator support portion 251 supports the stator 100. The stator support portion 251 is configured to be able to rotate about the central axis A (see FIG. 25A ) of the stator core 100 by driving the stator support portion motor 252. Figure 1 ) rotates in the C direction. That is, the pressing member 211 and the supporting member 221 are configured to be able to move relative to the stator core 10 in the C direction at the same time.

[0073] like Figure 5 As shown, the pressing member 211 is configured to be able to protrude from the end surface 10a on the Z2 side of the stator core 10 by pressing and to be located in the plurality of slots 13 (see Figure 1 ) in each of the plurality of coil ends 23 arranged along the R direction, thereby bending the coil end portion 123 in the C direction.

[0074] Specifically, the manufacturing device 200 is configured to cause the pressing member 211 and the supporting member 221 to be wound around the stator core 10 a plurality of times (e.g., 20 times) so that the bending angle θ (refer to Figure 7 ) gradually increases, thereby performing bending forming of multiple coil end portions 123.

[0075] At this time, the manufacturing device 200 is configured to bend and shape the plurality of coil end portions 123 by repeatedly performing the following process: the pressing member 211 and the supporting member 221 are relatively moved in the circumferential direction and in the axial direction relative to the stator core 10, so that the coil end portion 123 is bent in the circumferential direction and passes over the coil end portion 123, thereby transferring to the bending of the next coil end portion 123 adjacent to the bent coil end portion 123 by the bending member. That is, the manufacturing device 200 is configured to continuously bend the plurality of adjacent coil end portions 123 after bending one coil end portion 123, without performing a restarting operation such as temporarily retreating in the axial direction in order to bend the next adjacent coil end portion 123.

[0076] The manufacturing device 200 (moving mechanism 200a) is configured to perform bending forming of the plurality of coil end portions 123 by moving the pressing member 211 and the supporting member 221 relative to the stator core 10 in the circumferential direction and in the axial direction at the same time and passing over the coil end portions 123 (see Figure 6 That is, the manufacturing device 200 (moving mechanism 200a) is configured to move the pressing member 211 and the supporting member 221 continuously on a track inclined in an inclined direction and gradually approach the stator core 10 when viewed from the C direction.

[0077] As an example, the axial moving speed and circumferential moving speed of the pressing member 211 and the supporting member 221 are respectively approximately constant. However, in the final stage when the pressing member 211 approaches the stator core 10 and completes the bending forming, the manufacturing device 200 sets the axial moving speed of the pressing member 211 to approximately zero (including zero) so that the bending angle θ (refer to Figure 7 ) are identical to each other.

[0078] like Figure 5 As shown, the support member 221 is disposed on the R2 side of the pressing member 211. The support member 221 is configured to be able to support the distal end portion 123a of the coil end portion 123 from the R2 side.

[0079] Specifically, when the pressing member 211 starts to be pressed toward the top end portion 123a of the coil end portion 123, the pressing member 211 and the supporting member 221 are arranged so that the top end 221a of the supporting member 221 on the stator core 10 side is closer to the stator core 10 side than the top end 211a of the pressing member 211 on the stator core 10 side. Figure 7 As shown, the R direction position of the support member 221 is substantially equal to the R direction position of the pressing member 211. Thus, when the top end 211b of the pressing member 211 presses the top end 123a of the coil end portion 123, the top end 123a of the coil end portion 123 is supported by the support member 221 from the R2 side.

[0080] The pressing member 211 is configured to be relatively movable in the Z direction independently of the supporting member 221 with respect to the stator core 10. That is, the relative position between the pressing member 211 and the supporting member 221 in the Z direction can be changed.

[0081] The limiting member 241 is disposed on the Z2 side of the stator core 10. Fig. 9 As shown, a plurality of limiting members 241 are provided in a manner that radially extends from the annular limiting unit 243 toward the R2 side. The plurality of limiting members 241 are arranged to be aligned with the plurality of teeth 12 (see Figure 1 ) overlapped position. Each of the plurality of limiting members 241 is configured to be movable relative to the limiting unit 243 in the R direction by driving the limiting member motor 242. That is, each of the plurality of limiting members 241 is configured to be movable relative to the stator core 10 in the R direction.

[0082] like Figure 8 As shown, the limiting member 241 is configured to limit the movement of the coil end portion 123 bent in the C direction to the R1 side. Specifically, when the coil end portion 123 is bent in the C direction, when viewed from the R direction, the end surface 241a on the R2 side of each of the plurality of limiting members 241 is adjacent to the R1 side of the coil end portion 123 where the pressing member 211 presses the top end portion 123a of the coil end portion 123, so that the limiting member 241 moves relative to the stator core 10 in the R direction.

[0083] like Fig. 9 As shown, the manufacturing device 200 of the stator 100 has a damage prevention member 261, which prevents the root 123b of the coil end portion 123 from being damaged by the corner of the slot 13 when the coil end portion 123 is bent in the C direction. The damage prevention member 261 is arranged on the Z2 side of the stator core 10. The damage prevention member 261 is arranged at the Z2 side of the plurality of teeth 12 (see Figure 1 The damage prevention member 261 has a substantially triangular shape when viewed from the R direction.

[0084] (Manufacturing method of stator)

[0085] Reference Figures 5 to 8 and Figures 9 to 16 A method for manufacturing the stator 100 according to the present embodiment will be described.

[0086] (Stator core preparation process)

[0087] like Fig.11 As shown, in step S10, a stator core preparation process is performed. The stator core preparation process (S10) is to prepare the stator core 10 (see Figure 1 ) process.

[0088] (Coil preparation process)

[0089] In step S20, a segment coil preparation process is performed. The segment coil preparation process (S20) is to prepare segment coil 120 (see Fig.11 ) process. Specifically, Fig.11 As shown in FIG. 1 , a U-shaped segment coil 120 including a pair of leg portions 121 extending in the Z direction and a connecting portion 122 connecting the pair of leg portions 121 to each other is prepared.

[0090] (Insertion process)

[0091] like Fig.10 As described above, in step S30, an insertion process is performed. Fig.12 As described above, the inserting step (S30) is a step of inserting a plurality of segment coils 120 into slots 13 in a manner that coil end portions 123 protrude from end surface 10a on the Z2 side of stator core 10 and are arranged in the R direction in each of a plurality of slots 13 of stator core 10. In the inserting step (S30), connection portion 122 of U-shaped segment coil 120 prepared in the segment coil preparing step (S20) becomes coil end portion 22 protruding from stator core 10 toward the Z1 side. In addition, a pair of leg portions 121 of segment coil 120 each become slot accommodating portion 21 and coil end portion 123.

[0092] (Bending process)

[0093] like Fig.10 As shown, a bending process is performed in step S40. The bending process (S40) is a process of performing bending forming in which each of the plurality of coil end portions 123 is bent in the C direction.

[0094] In detail, in the bending process (S40), the following process is repeated to perform bending forming of a plurality of (48) coil end portions 123 arranged in the circumferential direction: after the insertion process, the pressing member 211 and the supporting member 221 that press the coil end portion 123 to be bent in the circumferential direction are moved relative to the stator core 10 in the circumferential direction and in the axial direction, and after the coil end portion 123 is bent, the bending based on the pressing member 211 and the supporting member 221 is transferred to the next coil end portion 123 adjacent to the bent coil end portion 123.

[0095] In addition, the bending step (S40) includes: relatively moving the pressing members 211 and the supporting members 221, which are provided in a number (two groups) less than the total number (48) of the plurality of coil end portions 123 arranged in the circumferential direction and in the axial direction relative to the stator core 10, thereby performing bending and forming of the plurality of coil end portions 123. In short, the bending step (S40) is not a step of making all the pressing members 211 (supporting members 221) and all the coil end portions 123 correspond one-to-one to bend and form all the coil end portions 123 at the same time, but a step of making all the pressing members 211 (supporting members 221) correspond to a part (the same number as the pressing members 211) of the coil end portions 123 and bend and form them.

[0096] In addition, the bending process includes simultaneously performing bending forming of the plurality of (two) coil end portions 123 less than the total number (48) of the plurality of coil end portions 123 arranged in the circumferential direction using a plurality of groups (two groups) of pressing members 211 and supporting members 221 which are arranged at equal angular intervals (180 degree intervals) in the circumferential direction. That is, the bending process is a process of performing bending forming by two groups of pressing members 211 and supporting members 221 which face each other with the central axis A interposed therebetween.

[0097] In addition, the bending process includes bending the plurality of coil end portions 123 by repeatedly performing the following process: relatively moving the pressing member 211 and the supporting member 221 in the circumferential direction and in the axial direction relative to the stator core 10, so that the coil end portion 123 is bent in the circumferential direction and passes over the coil end portion 123, thereby transferring to the bending of the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221. In short, in the bending process, the plurality of adjacent coil end portions 123 are continuously bent by the pressing member 211 and the supporting member 221.

[0098] In detail, the bending process includes bending and forming the plurality of coil end portions 123 by repeatedly performing the following process: the pressing member 211 and the supporting member 221 are relatively moved in the circumferential direction and in the axial direction relative to the stator core 10 (relatively moved in the circumferential direction and in the axial direction at the same time), so that the coil end portions 123 are bent in the circumferential direction, and the coil end portions 123 are passed over, thereby transferring to the bending of the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221. In more detail, the bending process is configured to move the pressing member 211 and the supporting member 221 on a spiral track slightly inclined with respect to a direction orthogonal to the axial direction, so that the pressing member 211 and the supporting member 221 gradually approach the stator core 10.

[0099] Furthermore, the bending step includes: winding the pressing member 211 and the supporting member 221 around the stator core 10 a plurality of times (for example, 20 times) so that the coil end portion 123 is bent at an angle θ (see Figure 7 ) gradually increases, thereby performing bending forming of a plurality of coil end portions 123. At this time, the bending forming is performed using the pressing member 211 and the supporting member 221 so that the bent coil end portion 123 does not contact the next coil end portion 123 adjacent in the circumferential direction.

[0100] In the bending process, the axial moving speed of the pressing member 211 is set to substantially zero (including zero) at the final stage of the bending forming for each row of the coil end portions 123 arranged in the radial direction, so that the bending angle θ (refer to Figure 7 ) are identical to each other.

[0101] like Fig.13 and Fig.14 As shown, first, the plurality of coil end portions 123 of the plurality of first rows (outermost rows) of coil ends 23 arranged in the circumferential direction are bent in the C direction. Then, as shown in FIG. Fig.15 and Fig.16 As shown, the plurality of coil end portions 123 of the coil end portions 23 of the plurality of second rows (rows radially inward of the outermost row) arranged in the circumferential direction are bent in the C direction. Thereafter, the coil end portions 123 are bent in the C direction, sequentially for each row toward the R1 side.

[0102] (Segment coil joining process)

[0103] like Fig.10 As shown, in step S50, a segment coil joining process is performed. The segment coil joining process (S50) is to join the segment coil 20a (see Figure 2 ) are joined to each other. Specifically, Figure 2 As shown, the tip end portions 23 a of the coil end portions 23 are welded and joined (connected) to the tip end portions 23 a of the coil end portions 23 of the other segment coils 20 a on the Z2 side of the stator core 10 .

[0104] Furthermore, in the above-described flow, the order of the stator core preparation step ( S10 ) and the segment coil preparation step ( S20 ) may be reversed.

[0105] (Effects of Embodiments)

[0106] In this embodiment, the following effects can be obtained.

[0107] (Effect of the stator manufacturing method)

[0108] In the manufacturing method of the stator 100 of the present embodiment, as described above, a bending step is provided in which the following process is repeated to perform bending forming of a plurality of coil end portions 123 arranged in the circumferential direction: the pressing member 211 and the supporting member 221 that press and bend the coil end portions 123 in the circumferential direction are relatively moved relative to the stator core 10 in the axial direction, and after the coil end portion 123 is bent, the bending is transferred to the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221. Thus, since the bending process of the pressing member 211 and the supporting member 221 is repeated after the coil end portion 123 is bent, the bending is transferred to the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221, and therefore, the plurality of coil end portions 123 can be bent by using one set (one) of the pressing member 211 and the supporting member 221. Therefore, it is not necessary to bend and form the plurality of coil end portions at once as in the past, and the rigidity required for the device (manufacturing device 200) for bending and forming the coil end portions 123 can be reduced. In addition, since it is possible to bend and form the plurality of adjacent coil end portions 123 using a set (one) of pressing members 211 and supporting members 221, it is possible to bend and form the coil end portions 123 arranged in the circumferential direction without setting the pressing members 211 and supporting members 221 to be the same in number as the total number of the coil end portions 123 arranged in the circumferential direction. Therefore, when reducing the diameter of the stator 100 to be manufactured, it is not necessary to consider the interference between the adjacent pressing members 211 and the supporting members 221 as in the past. As a result of the above, the size of the device (manufacturing device 200) for bending and forming the coil end portions 123 can be suppressed, and the reduction in the diameter of the stator 100 can be fully coped with.

[0109] In the manufacturing method of the stator 100 of the present embodiment, as described above, the bending step includes: relatively moving the pressing members 211 and the supporting members 221, which are provided in a number less than the total number of the plurality of coil end portions 123 arranged in the circumferential direction, relative to the stator core 10 and in the axial direction, thereby performing bending forming of the plurality of coil end portions 123. Thus, since the bending forming is performed using the pressing members 211 and the supporting members 221, which are provided in a number less than the total number of the plurality of coil end portions 123 arranged in the circumferential direction, all the coil end portions 123 are not bent at the same time, and the rigidity required for the device (manufacturing device 200) for performing bending forming of the coil end portions 123 can be effectively reduced. Therefore, the size of the device (manufacturing device 200) for performing bending forming of the coil end portions 123 can be effectively suppressed. In addition, for example, in a case where two sets (two) of pressing members 211 and supporting members 221 are provided at an angle interval of 180 degrees in the circumferential direction, the interval between the two sets (two) of pressing members 211 and supporting members 221 can be ensured to be large, so that interference between the pressing members 211 and supporting members 221 can be suppressed, and the pressing members 211 and supporting members 221 can be made thicker and the rigidity can be improved. As a result, it is possible to more reliably cope with the reduction in the diameter of the stator 100.

[0110] In the manufacturing method of the stator 100 of the present embodiment, as described above, the bending step includes bending and forming the plurality of coil end portions 123 by repeatedly performing the following process: the pressing member 211 and the supporting member 221 are relatively moved in the circumferential direction and in the axial direction relative to the stator core 10, so that the coil end portion 123 is bent in the circumferential direction and passes over the coil end portion 123, thereby transferring to the bending of the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221. Thus, for example, compared with the case where after bending one coil end portion, the pressing member and the supporting member are temporarily retreated in the axial direction away from the stator core without passing over the one coil end portion, and then transfer to the bending of the next adjacent coil end portion, by bending the coil end portion 123 in the circumferential direction and passing over the coil end portion 123, the plurality of coil end portions 123 adjacent to each other in the circumferential direction can be bent continuously and efficiently.

[0111] In the manufacturing method of the stator 100 of the present embodiment, as described above, the bending step includes: moving the pressing member 211 and the supporting member 221 relative to the stator core 10 in the circumferential direction and in the axial direction at the same time, and passing over the coil end portions 123, thereby spirally bending and forming the plurality of coil end portions 123. Thus, by only setting the circumferential speed of the pressing member 211 and the supporting member 221 and the axial speed of the pressing member 211 and the supporting member 221, the pressing member 211 and the supporting member 221 can be moved spirally, and the plurality of coil end portions 123 can be easily bent and formed.

[0112] In the manufacturing method of the stator 100 of the present embodiment, as described above, the bending process includes: causing the pressing member 211 and the supporting member 221 to wrap around the stator core 10 plural times in the circumferential direction, so that the bending angle θ of the coil end portion 123 relative to the axial direction is gradually increased, thereby performing bending forming of the plural coil end portions 123. Thus, the bending forming of each coil end portion 123 can be divided into plural times, and the bending angle θ caused by one pressing of the pressing member 211 and the supporting member 221 relative to the coil end portion 123 can be reduced. Therefore, it is possible to avoid the coil end portion 123 after bending from interfering with the next adjacent coil end portion 123.

[0113] In the manufacturing method of the stator 100 of the present embodiment, as described above, the bending step includes: using a plurality of pressing members 211 and supporting members 221, which are arranged at equal angles in the circumferential direction and are smaller in number than the total number of the plurality of coil end portions 123 arranged in the circumferential direction, to simultaneously perform bending forming of the plurality of coil end portions 123, which is smaller in number than the total number of the plurality of coil end portions 123 arranged in the circumferential direction. Thus, compared with the case where there is only one set (one) of pressing members 211 and supporting members 221, it is possible to perform bending forming of more coil end portions 123 at the same time, and therefore, it is possible to perform bending forming of the plurality of coil end portions 123 efficiently.

[0114] (Effect of the stator manufacturing method)

[0115] In the manufacturing device 200 of the stator 100 of the present embodiment, as described above, a moving mechanism 200a is provided, which repeats the following process to perform bending forming of a plurality of coil end portions 123 arranged in the circumferential direction: the pressing member 211 and the supporting member 221 are relatively moved in the circumferential direction relative to the stator core 10 and in the axial direction of the stator core 10, and after bending the coil end portion 123, the bending based on the pressing member 211 and the supporting member 221 is transferred to the next coil end portion 123 adjacent to the bent coil end portion 123, and the pressing member 211 and the supporting member 221 are set to be less in number than the total number of the plurality of coil end portions 123 arranged in the circumferential direction. Thus, since after the coil end portion 123 is bent, the process of bending the coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the supporting member 221 is repeated, the plurality of coil end portions 123 can be bent and formed by using a set (one) of pressing members 211 and supporting members 221. Therefore, it is not necessary to bend and form the plurality of coil end portions at once as in the past, and the rigidity required for the device (manufacturing device 200) for bending and forming the coil end portions 123 can be reduced. In addition, since the plurality of adjacent coil end portions 123 can be bent and formed by using a set (one) of pressing members 211 and supporting members 221, the coil end portions 123 arranged in the circumferential direction can be bent and formed without providing the pressing members 211 and the supporting members 221 in the same number as the total number of the coil end portions 123 arranged in the circumferential direction. Therefore, when reducing the diameter of the stator 100 to be manufactured, there is no need to consider the interference between adjacent pressing members 211 and supporting members 221 as in the past. As a result, the size of the device (manufacturing device 200) for bending the coil end portion 123 can be reduced, and the reduction in the diameter of the stator 100 can be fully coped with.

[0116] (Variation Example)

[0117] The embodiments disclosed this time are to be considered in all respects as illustrative rather than restrictive. The scope of the present invention is indicated by the claims rather than the description of the embodiments above, and includes all modifications (variations) within the meaning and scope equivalent to the claims.

[0118] For example, in the above-mentioned embodiment, an example is shown in which the pressing member and the supporting member as the bending member of the present invention are moved simultaneously in the axial direction and the circumferential direction during the bending process, but the present invention is not limited thereto. Fig.17As shown in the manufacturing device 300 of the stator 100, the bending process may also include: alternately repeating the relative movement of the pressing member 211 and the supporting member 221 only in the circumferential direction and only in the axial direction relative to the stator core 10, thereby performing bending and forming of the plurality of coil end portions 123. In this case, for example, if the manufacturing device 300 has two sets of pressing members 211 and supporting members 221 arranged at intervals of 180 degrees in the circumferential direction, the relative movement is switched to the axial direction after continuing at least 180 degrees and only in the circumferential direction. With such a structure, the plurality of coil end portions 123 arranged in the circumferential direction can be bent and formed by the pressing member 211 and the supporting member 221 while maintaining the positions of the pressing member 211 and the supporting member 221 in the axial direction. Therefore, the bending amount of the plurality of coil end portions 123 can be made uniform by the pressing member 211 and the supporting member 221.

[0119] In addition, in the above-mentioned embodiment, an example is shown in which a motor is provided on the pressing member (supporting member) side in order to make the pressing member (supporting member) relatively move in the axial direction with respect to the stator core, but the present invention is not limited thereto. In the present invention, a motor may also be provided on the stator core side in order to make the pressing member (supporting member) relatively move in the axial direction with respect to the stator core.

[0120] In addition, in the above-mentioned embodiment, an example is shown in which a motor is provided on the stator core side in order to make the pressing member (support member) relatively move in the circumferential direction with respect to the stator core, but the present invention is not limited thereto. In the present invention, a motor may also be provided on the pressing member (support member) side in order to make the pressing member (support member) relatively move in the circumferential direction with respect to the stator core.

[0121] In addition, in the above-mentioned embodiment, an example in which two bending members (a group of a pressing member and a supporting member) of the present invention are provided is shown, but the present invention is not limited thereto. In the present invention, one or more than three bending members may also be provided. However, the maximum number of bending members is set to a number less than the total number of coil end portions arranged in the circumferential direction.

[0122] In addition, in the above-mentioned embodiment, an example is shown in which the bending member of the present invention is composed of two separate components, namely, a pressing component and a supporting component, but the present invention is not limited thereto. In the present invention, the bending member may also be composed of one component. That is, the pressing component and the supporting component may also be integrally formed.

[0123] In the above embodiment, an example is shown in which the stator manufacturing device is configured to manufacture two stators simultaneously, but the present invention is not limited thereto. In the present invention, the stator manufacturing device may be configured to manufacture only one stator or three or more stators simultaneously.

[0124] In addition, in the above-mentioned embodiment, an example is shown in which the bending member (pressing member and supporting member) of the present invention is relatively moved in the circumferential direction and in the axial direction relative to the stator core so that the coil end portion is bent in the circumferential direction and passes over the coil end portion, but the present invention is not limited to this. In the present invention, the bending member may not pass over the coil end portion, for example, the bending member is kept in contact with only a predetermined portion of one coil end portion, and after one coil end portion is bent, the bending member is temporarily retreated in the axial direction away from the stator core without passing over the one coil end portion, and then the bending member is transferred to the bending of the next adjacent coil end portion.

[0125] In the above embodiment, the example of the present invention in which a plurality of bending members (pressing members and supporting members) are arranged at equal angular intervals in the circumferential direction is shown, but the present invention is not limited thereto. In the present invention, the bending members may not be arranged at equal angular intervals in the circumferential direction.

[0126] In addition, in the above embodiment, an example is shown in which the bent member (pressing member and supporting member) of the present invention is wound around the circumference of the stator core 20 times, but the present invention is not limited to this. In the present invention, the bent member (pressing member and supporting member) may be wound around the circumference of the stator core a number of times different from 20 times.

[0127] Description of Reference Numerals

[0128] 10 stator core

[0129] 10a (axial end face of stator core)

[0130] 13 slots

[0131] 23 Coil end

[0132] 100 stator

[0133] 120 segment coil

[0134] 123 Coil end part

[0135] 200, 300 stator manufacturing equipment

[0136] 200a mobile mechanism

[0137] 211 Pressing member (bending member)

[0138] 221 Support member (bend member)

[0139] θ (bending angle of the coil end portion relative to the axial direction)

Claims

1. A method for manufacturing a stator, wherein: have: an inserting step of inserting a plurality of segment coils into slots of the stator core in such a manner that coil end portions, which become coil ends, protrude from an axial end surface of the stator core and a plurality of the coil end portions are arranged in a circumferential direction of the stator core; as well as A bending process, after the insertion process, repeating the following process to perform bending forming of a plurality of coil end portions arranged in the circumferential direction: causing a bending member used to press the coil end portions and bend the coil end portions along the circumferential direction to move relative to the stator core in the circumferential direction and in the axial direction to bend the coil end portions, and then transferring to the bending of the next coil end portion adjacent to the bent coil end portion based on the bending member.

2. The method for manufacturing a stator according to claim 1, wherein: The bending step includes: moving the bending member, whose number is less than the total number of the plurality of coil end portions arranged in the circumferential direction, relative to the stator core in the circumferential direction and in the axial direction, thereby performing the bending forming of the plurality of coil end portions.

3. The method for manufacturing a stator according to claim 1, wherein: The bending process includes repeating the following process to perform the bending forming of multiple coil end portions: causing the bending member to move relative to the stator core in the circumferential direction and in the axial direction so that the coil end portion is bent along the circumferential direction and passes over the coil end portion, thereby transferring to the bending of the next coil end portion adjacent to the bent coil end portion based on the bending member.

4. The method for manufacturing a stator according to claim 3, wherein: The bending step includes moving the bending member relative to the stator core in the circumferential direction and the axial direction simultaneously and passing over the coil end portions to perform the spiral bending of the plurality of coil end portions.

5. The method for manufacturing a stator according to claim 1, wherein: The bending step includes: causing the bending member to wrap around the stator core a plurality of times in the circumferential direction, gradually increasing the bending angle of the coil end portion with respect to the axial direction, thereby performing the bending forming of the plurality of coil end portions.

6. The method for manufacturing a stator according to claim 2, wherein: The bending process includes: using a plurality of bending members whose number is less than the total number of the plurality of coil end portions arranged in the circumferential direction and are arranged at equal angular intervals in the circumferential direction, and simultaneously performing the bending forming of the plurality of coil end portions whose number is less than the total number.

7. A stator manufacturing device, wherein: have: a bending member that presses a plurality of coil end portions that become a plurality of coil ends arranged in a circumferential direction of a stator core and bends the coil end portions along the circumferential direction; as well as a moving mechanism that repeatedly performs the following process to bend and form a plurality of the coil end portions arranged in the circumferential direction: relatively moving the bending member relative to the stator core in the circumferential direction and in the axial direction of the stator core to bend the coil end portions, and then transferring to the bending of the next coil end portion adjacent to the bent coil end portion by the bending member; The number of the bent members provided is smaller than the total number of the plurality of coil end portions arranged in the circumferential direction.

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