Stator for rotating electrical machine, method for manufacturing stator for rotating electrical machine, and device for manufacturing stator for rotating electrical machine

Abstract

A stator for a rotating electrical machine is provided with: a stator core provided with a plurality of grooves in the circumferential direction extending substantially parallel to the axis; a segment coil disposed in the slot; and a resin portion that fixes the segment coil to the stator core in a state in which the axial end portion of the segment coil protrudes from the axial end surface of the stator core. The resin portion has a groove resin portion provided in the groove, and an end surface resin portion connected to the groove resin portion and provided on an axial end surface of the stator core, and the end surface resin portion is a plurality of end surface resin portions in the circumferential direction that correspond to the plurality of grooves in the circumferential direction and are provided apart from each other.

Description

Technical Field

[0001] This invention relates to a stator for a rotating electric motor, a method for manufacturing a stator for a rotating electric motor, and an apparatus for manufacturing a stator for a rotating electric motor. Background Technology

[0002] Conventionally, there are known stators for rotating electric machines in which a winding tube is inserted into a slot in the stator core to insulate the stator core from the coil, a flat wire coil is inserted into the winding tube, and the stator core, coil, and winding tube are fixed with resin. Such a stator for a rotating electric machine is described, for example, in Patent Document 1.

[0003] However, as described in Patent Document 1 for a rotating electric stator, when a winding tube is inserted into the stator core slot from the viewpoint of improving insulation, the occupancy rate of the coil in the slot will decrease.

[0004] Existing technical documents Patent documents Patent document 1: Japanese Patent Application Publication No. 2023-57947 (JP2023-057947A). Summary of the Invention

[0005] A stator for a rotary electric motor according to one embodiment of the present invention comprises: a stator core having a plurality of circumferentially extending slots substantially parallel to an axis; segmented coils disposed in the slots; and resin portions that fix the segmented coils to the stator core with the axial ends of the segmented coils protruding from the axial end faces of the stator core. The resin portions include slot resin portions disposed within the slots and end face resin portions connected to the slot resin portions and disposed on the axial end faces of the stator core. The end face resin portions are a plurality of circumferentially separated end face resin portions corresponding to the plurality of slots.

[0006] Another technical solution of the present invention is a method for manufacturing a stator for a rotary electric motor, wherein the segmented coil has a pair of legs inserted into a pair of different slots in a plurality of circumferential slots and a connecting portion connecting the pair of legs. The method for manufacturing a stator for a rotary electric motor includes: a step of setting a stator core in a lower mold having a recess facing the lower end face of the slot; a step of inserting the legs of the segmented coil into the interior of the slot from above the stator core; a step of inserting a plurality of upper molds having a recess facing the upper end face of the slot in a circumferential direction from the radially outer side along the upper end face of the stator core, forming a space through the slot from the recess of the lower mold to the recess of the upper mold; and a step of supplying resin into the space to form a resin portion.

[0007] Another technical solution of the present invention is a manufacturing apparatus for a stator of a rotary electric machine, comprising: a lower mold disposed facing the lower end face of the stator core; an upper mold disposed facing the upper end face of the stator core; and a guide member inserted through the lower mold from below into a plurality of circumferential slots. The guide member has a coil receiving portion forming a space for inserting segmented coils. Attached Figure Description

[0008] The objectives, features, and advantages of the present invention are further illustrated by the following description of embodiments in conjunction with the accompanying drawings.

[0009] Figure 1 This is a cross-sectional view showing the main structural components of a rotary electric motor including a stator for a rotary electric motor according to an embodiment of the present invention; Figure 2 yes Figure 1 Enlarged view of the main parts of the stator core; Figure 3 It is shown Figure 1 A perspective view of an example of the insertion process of a conductor segment contained in the stator of a rotating electric motor; Figure 4 This is a perspective view showing the overall structure of the stator for a rotary electric machine constituting an embodiment of the present invention; Figure 5 It is shown in general terms. Figure 4 A cross-sectional view of the main structural components of the stator; Figure 6A It is shown in Figure 4 A perspective view of the main parts of the stator with the structure of the end face resin part set on the upper end face of the stator core; Figure 6B It is shown in Figure 4 A perspective view of the main parts of the stator with a resin section set on the lower end face of the stator core; Figure 7 Viewed from above Figure 6A A top view of the main part of the stator obtained from the upper end face of the stator core; Figure 8A It is shown Figure 7 A comparative example diagram; Figure 8B It is shown Figure 7 A diagram of another comparative example; Figure 9 This is a diagram illustrating the effect of the stator for a rotary electric motor according to an embodiment of the present invention; Figure 10 This is a flowchart illustrating an example of a method for manufacturing a stator for a rotary electric machine according to an embodiment of the present invention; Figure 11 This is an explanation Figure 10A diagram of the process in step S1; Figure 12 This is an explanation Figure 10 A diagram of the process in step S3; Figure 13 It is a schematic cross-sectional view showing the structure of the slot after the guide plate is inserted; Figure 14 This is a three-dimensional view of the upper mold unit obtained by observing the upper mold from an oblique angle above; Figure 15 This is an explanation Figure 10 A diagram of the process in step S6; Figure 16A This is an explanation Figure 10 A diagram of the process in step S8; Figure 16B This is an explanation Figure 10 A diagram of the process in step S9; Figure 17 This is a bottom view of the lower mold, obtained by observing the mold from below. Detailed Implementation

[0010] The following is for reference Figures 1 to 17 The embodiments of the present invention will be described. Figure 1 This is a cross-sectional view showing the schematic structure of a rotary motor 100 including a stator for a rotary motor according to an embodiment of the present invention. The rotary motor 100 is mounted in hybrid vehicles and electric vehicles, and can be used as a motor for driving vehicles or as a generator. It should be noted that the rotary motor 100 can also be mounted in non-vehicle applications for various purposes.

[0011] like Figure 1 As shown, the rotary electric motor 100 includes a rotor 1 that rotates around an axis CL0 and a stator 2 disposed outside the rotor 1 such that it surrounds the outer peripheral surface 1a of the rotor 1. A housing 3 is disposed around the stator 2, and the stator 2 is fixed to the housing 3. For convenience, in Figure 1 The housing 3 is shown in a roughly cylindrical shape. Hereinafter, the direction of extension of the axis CL0 is defined as the axial direction, the direction extending radially from the axis CL0 is defined as the radial direction, and the direction along the circumference of the circle centered on the axis CL0 is defined as the circumferential direction.

[0012] The rotary electric motor 100 is configured, for example, as a built-in permanent magnet synchronous motor. Therefore, the rotor 1 has a rotor core 10 in a generally annular shape centered on an axis CL0 and multiple magnetic pole portions (not shown) formed circumferentially on the rotor core 10. Permanent magnets are embedded in the magnetic pole portions. A rotor shaft (not shown), for example constituting the output shaft of the rotary electric motor 100, is fitted into the inner circumferential surface 10a of the rotor core 10, and the rotor 1 rotates integrally with the rotor shaft. The rotor core 10 is formed by stacking multiple (e.g., dozens) sheets of electromagnetic steel, which serve as magnetic materials, axially.

[0013] The stator 2 has a roughly annular stator core 20 centered on the axis CL0, and the stator core 20 has an inner circumferential surface 2a arranged radially at predetermined intervals from the outer circumferential surface 1a of the rotor 1. The stator core 20 is constructed by stacking multiple sheets of electromagnetic steel, which are magnetic materials, in the axial direction.

[0014] Figure 2 yes Figure 1 Enlarged view of the main parts of the stator core 20. (See attached image.) Figure 2 As shown, the stator core 20 has a plurality of circumferentially spaced teeth 23 that protrude radially inward from a generally annular yoke 24. Between adjacent circumferentially spaced teeth 23, a plurality of circumferentially spaced grooves 22 are provided from the inner circumferential surface 2a toward the radially outer side. It should be noted that the grooves 22 are provided at equal intervals along the entire circumference of the inner circumferential surface 2a, but for convenience, they are not shown in the diagram. Figure 1 In the image, only the slot 22 near the top of the stator core 20 is shown.

[0015] The stator 2 has multiple coils 21 arranged in each slot 22. Each coil 21 is a segmented coil composed of conductor segments with a generally rectangular cross-section. Alternatively, each coil 21 may be composed of conductor segments with a circular cross-section. For example, the coils 21 may include a U-phase coil, a V-phase coil, and a W-phase coil, forming a three-phase coil. The motor may also be configured as a motor other than three-phase (e.g., a two-phase motor) instead of a three-phase motor.

[0016] exist Figure 1 In this configuration, when the rotary motor 100 is used as an electric motor, alternating current (AC) is supplied to each coil 21 by a power conversion device (not shown). This generates a magnetic field in the stator 2, which interacts with the magnetic field generated by the permanent magnets at the poles of the rotor 1, causing the rotor 1 to rotate. As a result, a driving force is generated, and the vehicle moves. When the rotary motor 100 is used as a generator, the AC power generated by driving the rotary motor 100 is supplied to the power conversion device, etc.

[0017] like Figure 2As shown, the slot 22 has an opening 221 on the inner circumferential surface 2a of the stator core 20 and a receiving portion 222 on the radially outer side of the opening 221. The receiving portion 222 has a pair of side surfaces 222a and 222b extending radially and facing each other, and a bottom surface 222c connecting the radially outer sides of the pair of side surfaces 222a and 222b. The width of the receiving portion 222, i.e., the distance (circumferential length) between the pair of side surfaces 222a and 222b, is constant in the radial direction, and the receiving portion 222 is formed with a roughly rectangular cross-section that is slender in the radial direction. The tooth 23 has a protrusion 231 at its radially inner top end that protrudes circumferentially to both sides, and an opening 221 is provided between the pair of protrusions 231. The width (circumferential length) of the receiving portion 222 is larger than the width of the opening 221.

[0018] Eight conductor segments 210 for forming the coil 21 are arranged radially in the receiving portion 222. It should be noted that the number of conductor segments 210 in the receiving portion 222 can be more or less than eight. For example, the number of conductor segments 210 in the receiving portion 222 can be four. The conductor segments 210 in the slot 22 are surrounded by insulating resin 31, and the conductor segments 210 are fixed to the stator core 20 by the resin 31. For convenience, the resin 31 in such a slot 22 is referred to as the slot resin portion.

[0019] The conductor segment 210 is inserted into the slot 22 from one axial end face of the stator core 20. Figure 3 This is a perspective view illustrating an example of the insertion process of conductor segment 210. (See diagram below.) Figure 3 As shown, the conductor segment 210 is generally U-shaped, with a pair of legs 211, 211 extending parallel to each other, and a top 213 connecting the ends of the pair of legs 211, 211 that are bent through bends 212, 212. The pair of legs 211, 211 are inserted into circumferentially different slots 22.

[0020] The pair of legs 211, 211 each include straight portions 214, 214 connected to the top 213, inclined portions 215, 215 bent as shown by dashed lines after being inserted into the slot 22, and joint portions 216, 216 at the top ends of the inclined portions 215, 215. The conductor segment 210 is formed using a flat wire made of a conductive material such as copper, and is covered by an insulating film except for the pair of joint portions 216, 216.

[0021] The straight section 214 is located at one end face along the axial direction of the stator core 20. Figure 4 (upper end face) 200a to the other end face ( Figure 4The length of the lower end face 200b is the axial length of the slot 22. Therefore, with the conductor segment 210 inserted into the slot 22, the top 213 protrudes from one end face 200a of the stator core 20, and the inclined portion 215 protrudes from the other end face 200b of the stator core 20. One end side (top side) of the conductor segment 210 protruding from the stator core 2 becomes the closed-side coil end, and the other end side (top side) becomes the open-side coil end.

[0022] After the conductor segment 210 is inserted into the slot 22, the joint 216 at the top of the conductor segment 210 is electrically and physically connected to the joint 216 at the top of other conductor segments 210 constituting the same phase (see reference). Figure 5 By connecting multiple conductor segments 210 in this manner, a coil 21 is formed by winding multiple teeth 23 in the circumferential direction. It should be noted that conductor segments 210 are sometimes simply referred to as coil 21.

[0023] Figure 4 This is a perspective view showing the overall structure of stator 2. The following is an example... Figure 4 As shown, the direction along axis CL0 is defined as the up-down direction, and the structure of each part of stator 2 will be described according to this definition. The up-down direction corresponds to the direction during the manufacture of stator 2. Figure 3 The difference lies in Figure 4 In this design, a flange 200c for fixing the stator 2 to the housing 3 is provided on the outer peripheral surface of the stator core 20. A conductor segment 210 protrudes from the upper end face 200a and lower end face 200b of the stator core 20, and a protrusion 21a is provided on the conductor segment 210. It should be noted that... Figure 4 In the figure, except for a portion, detailed illustrations of the protrusion 21a of coil 21 are omitted.

[0024] Figure 5 This is a cross-sectional view of the stator 2 along conductor segment 210, which schematically shows the main part structure of the stator 2. Figure 5 The diagram shows a single conductor segment 210 with a pair of legs 211, 211 inserted into a pair of slots 22, 22, respectively. Figure 5 A pair of legs 211, 211 are inserted into a pair of slots 22, 22, spanning a predetermined number of slots 22 in the circumferential direction. Therefore, although the illustration is omitted, Figure 5 A specified number of slots 22 exist between a pair of slots 22, 22.

[0025] like Figure 4 , 5 As shown, an insulating resin portion 32 is provided on the upper end face 200a of the stator core 20, and the upper end of the conductor segment 210 (more specifically, the upper end of the straight portion 214) is fixed to the stator core 20 via the resin portion 32. Figure 5As shown, an insulating resin portion 33 is provided on the lower end face 200b of the stator core 20, and the lower end of the conductor segment 210 (more specifically, the lower end of the straight portion 214) is fixed to the stator core 20 via the resin portion 33. For convenience, the resin portion along the upper end face 200a and the lower end face 200b of the stator core 20 in this manner is referred to as the end face resin portion.

[0026] The structures (shapes viewed axially and shapes viewed radially) of the end-face resin portions 32 and 33 of the upper end face 200a and lower end face 200b of the stator core 20 are identical. The end-face resin portions 32 and 33 are formed using a mold described later. The upper surface of the end-face resin portion 32 is a flat surface, and the height (vertical length) H1 of the end-face resin portion 32 is less than or equal to the length H2 from the upper end face 200a of the stator core 20 to the upper end (bent portion 212) of the straight section 214 of the conductor segment 210. The lower surface of the end-face resin portion 33 is a flat surface, and the height H3 of the end-face resin portion 33 is less than or equal to the length H4 from the lower end face 200b of the stator core 20 to the lower end of the straight section 214 of the conductor segment 210. The end-face resin portions 32 and 33 are connected via a groove resin portion 31, and these resin portions 31 to 33 are integrally formed.

[0027] A recess 210a is provided on the surface of the straight portion 214 of the conductor segment 210, for example, the central portion facing the groove resin portion 31 in the vertical direction. This increases the contact area between the conductor segment 210 and the groove resin portion 31, and can reduce the stress (e.g., the stress during heat shrinkage) when the conductor segment 210 is subjected to a relative force in the axial or radial direction relative to the groove resin portion 31.

[0028] Figure 6A This is a perspective view showing the structure of the end face resin portion 32 provided on the upper end face 200a of the stator core 20, and a perspective view of the main part of the stator 2 obtained by viewing the upper end face 200a obliquely from above. Figure 6A Show coil 21 along Figure 5 The diagram shows the horizontal plane PL1, indicated by the double-dotted line, which is cut off along the upper end (bend 212) of the straight section 214. The top 213 of the conductor segment 210 is omitted.

[0029] like Figure 6A As shown, the end-face resin portions 32 are provided in multiple circumferential directions corresponding to the multiple grooves 22, each individually covering the entire upper end surface of the grooves 22. That is, the number of end-face resin portions 32 is the same as the number of grooves 22. Adjacent end-face resin portions 32, 32 in the circumferential direction are separated from each other by a gap CL1 of a predetermined width. The end-face resin portions 32 alternately have rectangular resin portions 321 that are generally rectangular in shape when viewed from above and trapezoidal resin portions 322 that are generally trapezoidal in shape when viewed from above.

[0030] More specifically, the rectangular resin portion 321 has a pair of radially extending side surfaces 321a, 321a, a generally arc-shaped inner circumferential surface 321b connecting the inner diameter ends of the pair of side surfaces 321a, 321a, and a generally arc-shaped outer circumferential surface 321c connecting the outer diameter ends of the pair of side surfaces 321a, 321a. The width (circumferential length) of the rectangular resin portion 321, i.e., the distance between the pair of side surfaces 321a, 321a, is greater than the width of the groove 22. Figure 2 The distance between a pair of side surfaces 222a and 222b is long and constant in the radial direction.

[0031] The trapezoidal resin portion 322 has a pair of radially extending side surfaces 322a, 322a, a generally arcuate inner circumferential surface 322b connecting the inner diameter ends of the pair of side surfaces 322a, 322a, and a generally arcuate outer circumferential surface 322c connecting the outer diameter ends of the pair of side surfaces 322a, 322a. The width of the trapezoidal resin portion 322, i.e., the distance between the pair of side surfaces 322a, 322a, gradually increases from the inner diameter side to the outer diameter side. The width of the inner circumferential surface 322b is larger than the width of the groove 22, for example, the same as or approximately the same as the width of the inner circumferential surface 321b of the rectangular resin portion 321. The side surfaces 321a of the adjacent rectangular resin portions 321 in the circumferential direction are generally parallel to the side surfaces 322a of the trapezoidal resin portion 322, and radially spaced gaps CL1 of a certain width are distributed between the rectangular resin portions 321 and the trapezoidal resin portions 322.

[0032] The inner circumferential surfaces 321b of the rectangular resin section 321 and 322b of the trapezoidal resin section 322 are located on the same cylindrical surface centered on the axis CL0 as the inner circumferential surface 2a of the stator core 20. The inner circumferential surface 31a of the groove resin section 31 (along...) Figure 2 The opening 221 of the groove 22 is also located on the same cylindrical surface as the inner circumferential surface 2a of the stator core 20. The outer circumferential surface 321c of the rectangular resin part 321 and the outer circumferential surface 322c of the trapezoidal resin part 322 are located on the same cylindrical surface centered on the axis CL0.

[0033] Figure 6B This is a perspective view showing the structure of the end face resin portion 33 provided on the lower end face 200b of the stator core 20. It is a perspective view of the main part of the stator 2 obtained by viewing the lower end face 200b obliquely from below. Figure 6B Show coil 21 along Figure 5 The horizontal plane PL2 shown by the double-dotted line is cut off along the horizontal plane PL2 passing through the lower end of the straight section 214. The inclined section 215 of the conductor section 210 is omitted from the illustration.

[0034] like Figure 6B As shown, the end-face resin portions 33 are provided in multiple circumferential directions corresponding to the multiple grooves 22, each individually covering the entire lower end face of the grooves 22. That is, the number of end-face resin portions 33 is the same as the number of grooves 22. Adjacent end-face resin portions 33, 33 in the circumferential direction are separated from each other by a gap CL1 of a predetermined width. The end-face resin portions 33 alternately have rectangular resin portions 331 that are generally rectangular in shape when viewed from below and trapezoidal resin portions 332 that are generally trapezoidal in shape when viewed from below.

[0035] The lower rectangular resin portion 331 and trapezoidal resin portion 332 have the same shape as the upper rectangular resin portion 321 and trapezoidal resin portion 322. A single rectangular resin portion 331 is positioned below a single rectangular resin portion 321, and a single trapezoidal resin portion 332 is positioned below a single trapezoidal resin portion 322. Therefore, the rectangular resin portions 321 and 331 are connected via grooved resin portions 31, and the trapezoidal resin portions 322 and 332 are connected via grooved resin portions 31. It should be noted that a single trapezoidal resin portion 332 can also be positioned below a single rectangular resin portion 321, and a single rectangular resin portion 331 can be positioned below a single trapezoidal resin portion 322.

[0036] Figure 7 This shows the view from above. Figure 6A A top view of the main structure of the stator 2 obtained from the upper end face 200a of the stator core 20. Figure 7 In this context, a line extending radially outward from the center of the groove 22 covered by the rectangular resin part 321 through the axis CL0 is defined as reference line L1 (second reference line), and a line extending radially outward from the center of the groove 22 covered by the trapezoidal resin part 322 through the axis CL0 is defined as reference line L2 (first reference line).

[0037] In this embodiment, an end-face resin portion 32 is formed in each of a plurality of regions AR1 in the circumferential direction from the reference line L1 to the reference lines L2 on both sides of L2. Therefore, in order to form the end-face resin portion 32, a plurality of molds (upper molds) 50 are arranged in the circumferential direction on the upper end surface 200a. In addition, as Figure 7 As shown in the shaded area, a pair of portions 322d of the entire rectangular resin portion 321 and trapezoidal resin portion 322 within region AR1 are formed in one step using a single upper mold 50, located circumferentially inward (on the side of reference line L1) from reference line L2. That is, multiple end-face resin portions 32 are formed using a single upper mold 50. Therefore, the number of upper molds 50 (the number of regions AR1) is less than the number of end-face resin portions 32 (the number of grooves 22), specifically half the number of end-face resin portions 32.

[0038] The side surfaces 321a of the rectangular resin portion 321 and 322a of the trapezoidal resin portion 322, which are adjacent in the circumferential direction, extend parallel to the reference line L1. Therefore, after the upper mold 50 is placed on the upper end face 200a to form the end face resin portion 32, by moving the upper mold 50 radially outward parallel to the reference line L1, a gap CL can be provided between the side surfaces 321a and 322a, and the upper mold 50 can be easily removed.

[0039] In contrast, for example, as Figure 7 Comparative examples Figure 8A As shown, when the end face resin portion 32 is entirely composed of rectangular resin portions 321, that is, when the rectangular resin portions 321 are centered not only on the reference line L1 but also on the reference line L2, it is impossible to make the side surface 321a of the rectangular resin portion 321 facing the gap CL1 parallel to the reference line L1. Therefore, it is impossible to move the upper mold 50 radially outward along the reference line L1 after the end face resin portion 32 is molded.

[0040] Additionally, for example, as Figure 7 Comparative examples Figure 8B As shown, when the end face resin portion 32 is entirely composed of trapezoidal resin portions 322, that is, when the trapezoidal resin portion 322 is centered not only on the reference line L2 but also on the reference line L1, the side surface 322a of the trapezoidal resin portion 322 on the reference line L2 side will not be parallel to the reference line L1. Therefore, the upper mold 50 cannot be moved radially outward along the reference line L1.

[0041] Figure 9 This diagram illustrates the effect of the stator 2 for the rotary electric motor in this embodiment. (See diagram for example.) Figure 9 As shown, in this embodiment, end-face resin portions 32 and 33 are provided along the upper end surface 200a and lower end surface 200b of the stator core 20, respectively, and the upper end surface 200a and lower end surface 200b of the stator core 20 are covered by insulating end-face resin portions 32 and 33. This extends the creepage distance L11 from the surface of the coil 21 (e.g., the part where the insulating film on the surface is damaged) to the stator core 20, thus achieving good insulation performance of the stator 2.

[0042] Conversely, assuming the end-face resin portions 32 and 33 are not provided, the creepage distance L12 between the coil 21 and the stator core 20 is shortened. Therefore, in order to ensure sufficient insulation performance of the stator 2, additional insulating components need to be inserted between the slot 22 and the coil 21. As a result, the occupancy rate of the coil 21 in the slot decreases, leading to increased costs.

[0043] In this respect, in this embodiment, it is not necessary to insert insulating members into the slots, thus increasing the occupancy rate of the coils 21 within the slots. This improves the performance of the rotary motor 100 and allows for efficient heat dissipation from the coils 21 to the outside via the stator core 20. Furthermore, in this embodiment, the upper and lower end-face resin portions 32 and 33 are connected via the slot resin portion 31, thus preventing axial displacement of the resin portions 31-33. Additionally, in this embodiment, the end-face resin portions 32 and 33 are separately provided in each slot, thereby reducing stress during resin thermal shrinkage. The molding time of the resin in each slot 22 can also be shortened.

[0044] The manufacturing method of the stator 2 for the rotary electric machine configured as described above will be explained. The stator 2 is manufactured using various manufacturing equipment. Figure 10 This is a flowchart illustrating an example of a method for manufacturing the stator 2 for a rotary electric machine. For example... Figure 10 As shown, firstly, in step S1, the stator core 20 is installed in the lower mold. Figure 11 This is a diagram illustrating the process of step S1. For example... Figure 11 As shown, the lower mold 55 has a generally annular core mounting portion 56 that bulges upward from the upper surface 55a.

[0045] In the core mounting section 56, multiple through holes 57 are formed circumferentially. These through holes 57 penetrate the lower mold 55 vertically and have the same shape as the groove 22. Also in the core mounting section 56, around the through holes 57, [the following is a description of a groove 22]. Figure 6B The rectangular resin portion 331 and the trapezoidal resin portion 332 have corresponding recesses 58. The stator core 20 is provided on the upper surface of the core mounting portion 56 with the slot 22 aligned with the through hole 57. At this time, the recesses 58 of the core mounting portion 56 are covered by the lower end face 200b of the stator core 20.

[0046] Next, in Figure 10 In step S2, with the stator core 20 installed in the lower mold 55, the stator core 20 and the lower mold 55 are placed in a preheating furnace and heated to a specified temperature. That is, the stator core 20 is preheated. After preheating, the stator core 20 is removed from the preheating furnace, and the stator core 20 and the lower mold 55 are placed together into the forming equipment. Steps S3 and later are performed within the forming equipment.

[0047] In step S3, the guide plate is inserted into the slot 22 of the stator core 20. Figure 12 This is a diagram illustrating the process in step S3. For example... Figure 12 As shown, the guide plate 60 protrudes upward from the plate-shaped base 61, corresponding to a plurality of grooves 22 in the circumferential direction, and a plurality of grooves 22 are arranged at equal intervals in the circumferential direction, the same number as the grooves 22. Figure 12As shown in the enlarged view of part A, the guide plate 60 has a pair of side surfaces 222a and 222b that correspond to the groove 22. Figure 2 A pair of opposing sidewalls 62, 62 and a connecting wall 63 connecting the radially outer ends of the pair of sidewalls 62, 62 to each other. The guide plate 60 is generally U-shaped when viewed from above, and a space SP3 is formed on the inner side of the guide plate 60. The guide plate 60 is inserted into the groove 22 from below the lower mold 55 through the through hole 57.

[0048] Next, in Figure 10 In step S4, the conductor segment 210 is inserted into the slot 22 from above the stator core 20. At this time, the lower end of the conductor segment 210 passes through the through hole 57 of the lower mold 55 and protrudes downward from the lower mold 55. Figure 13 This is a schematic cross-sectional view showing the structure of the slot 22 after the guide plate 60 is inserted. (See diagram below.) Figure 13 As shown, with the guide plate 60 inserted into the slot 22, the upper end of the guide plate 60 is positioned above the upper end face 200a of the stator core 20, and the lower end of the guide plate 60 is positioned below the lower end face 200b of the stator core 20.

[0049] Therefore, as Figure 13 As indicated by the arrow, the conductor segment 210 can be inserted into the space SP3 inside the guide plate 60 without contacting the side surface of the slot 22. The stator core 20 is a stack of multiple electromagnetic steel plates, therefore the side surface of the slot 22 is uneven. Therefore, when the conductor segment 210 contacts the side surface of the slot 22, the surface (insulating coating) of the conductor segment 210 may be damaged. This is prevented by clamping the guide plate 60 and inserting the conductor segment 210 inside the guide plate 60.

[0050] Next, in Figure 10 In step S5, the guide plate 60 is moved downward relative to the lower mold 55, and the guide plate 60 is pulled out from the slot 22. For example, the guide plate 60 is moved downward or the lower mold 55 and the stator core 20 are moved upward together to pull out the guide plate 60.

[0051] Next, in step S6, a mold 50 is installed on the upper end face 200a of the stator core 20. Figure 7 ). Figure 14 This is a three-dimensional view of the upper mold 50 as seen from an obliquely upward perspective. Figure 15 This is a diagram illustrating the process of step S6. Figure 15 This is a perspective view, viewed from a slightly below-slant angle, showing the upper mold 50 inserted radially outward between adjacent coils 21, 21, and multiple upper molds 50 during the insertion process. It should be noted that, for convenience, in... Figure 15 In the diagram, conductor segment 210 is shown with a double-dotted line, and the stator core 20 is omitted.

[0052] like Figure 14 , 15 As shown, the upper mold 50 has a base 51 extending in the circumferential direction and a pair of legs 52, 52 extending radially inward from the base 51. The upper mold 50 has an axis CL2 extending radially through the center of the base 51. Figure 14 Centered on the base 51, the overall structure is symmetrical. More specifically, the base 51 has an upper surface 511 and a lower surface 512, a pair of circumferentially outward end faces 513 and 514, and radially inward and outward inner and outer circumferential surfaces 515 and 516. The leg 52 has an upper surface 521 and a lower surface 522, a pair of circumferentially outward and inward side surfaces 523 and 524, and radially inward inner circumferential surface 525.

[0053] The upper surface 511 of the base 51 and the upper surface 521 of the leg 52 are located on the same surface, and the lower surface 512 of the base 51 and the lower surface 522 of the leg 52 are located on the same surface. Therefore, the height from the lower surface 512 of the base 51 to the upper surface 511 is equal to the height from the lower surface 522 of the leg 52 to the upper surface 521. Figure 14 As shown, the leg 52 extends radially from the inner circumferential surface 515 of the base 51 on the circumferentially outer side of the axis CL2 and the circumferentially inner side of the end face 514. Therefore, the inner circumferential surface 515 of the base 51 has a circumferentially central inner circumferential surface 515a and a pair of circumferentially outer inner circumferential surfaces 515b, 515b.

[0054] An inner space SP1 is formed on the inner side of a pair of legs 52, 52, surrounded by a pair of side surfaces 524, 524 and an inner circumferential surface 515a. For example... Figure 15 As shown, conductor segment 210 is housed in inner space SP1. With the upper mold 50 installed, the end faces 514 of adjacent upper molds 50 in the circumferential direction abut against each other. At this time, an end space SP2 is formed, surrounded by the side surface 523 and inner circumferential surface 515b of the leg 52 of one upper mold 50 and the side surface 523 and inner circumferential surface 515b of the leg 52 of the other upper mold 50. Conductor segment 210 is housed in end space SP2. Inner space SP1 and end space SP2 have the same shape.

[0055] A recess 53 of a predetermined depth is provided on the lower surface of the upper mold 50. The recess 53 has an inner recess 531 disposed around the inner space SP1 and a pair of end recesses 532, 532 disposed around the end space SP2. More specifically, the inner recess 531 generally corresponds to the rectangular resin portion 321, and is approximately rectangular in shape, having a shape similar to... Figure 6AThe rectangular resin portion 321 has a pair of side surfaces 321a, 321a corresponding to a pair of side surfaces 531a, 531a and an outer peripheral surface 531c corresponding to the outer peripheral surface 321c. The end recess 532 has a... Figure 6A The trapezoidal resin portion 322 has a side surface 532a corresponding to the side surface 322a and an outer peripheral surface 532c corresponding to the outer peripheral surface 322c. The end recesses 532, 532 of a pair of adjacent upper molds 50, 50 in the circumferential direction are generally in a trapezoidal shape and correspond to the trapezoidal resin portion 322.

[0056] A pair of radially extending partition walls 54, 54 are disposed between the inner recess 531 and the end recess 532 of the upper mold 50. The pair of partition walls 54, 54 and... Figure 14 The axis CL2 extends approximately parallel to the axis and is formed by partitions 54 and 54. Figure 6A The gap CL1.

[0057] In step S6, while sliding the lower surfaces 512 and 522 of the upper mold 50 along the upper end face 200a of the stator core 20, the process is as follows: Figure 7 With the reference line L1 aligned with the axis CL2, the upper mold 50 is inserted radially outward from the stator core 20. More specifically, the legs 52 of the upper mold 50 are inserted between adjacent conductor segments 210, 210 in the circumferential direction. The height of the legs 52 is the same as or approximately the same as the height from the upper end face 200a of the stator core 20 to the bend 212 of the conductor segment 210. Figure 14 As shown, arc-shaped curved surfaces 526 and 526 are respectively provided at the intersection of the upper surface 521 and the side surfaces 523 and 524 of the leg 52. The curvatures of the curved surfaces 526 and the bending portions 212 are the same or approximately the same, and the curved surfaces 526 and the bending portions 212 fit tightly together when the leg 52 is inserted.

[0058] Next, in Figure 10 In step S7, along the inner circumferential surface 2a of the stator core 20, a component is installed with axis CL0 ( Figure 1 The inner diameter mold is a roughly cylindrical mold centered on the resin section 31. The inner diameter mold is used to define the inner circumferential surface 31a of the resin section 31. Figure 6A The inner circumferential surfaces 321b and 331b of the rectangular resin portions 321 and 331 on the upper and lower sides, and the inner circumferential surfaces 322b and 332b of the trapezoidal resin portions 322 and 332 on the upper and lower sides are provided. Therefore, although the figure is omitted, the upper end of the inner diameter mold protrudes upward beyond the upper end surface 200a of the stator core 20, and the lower end protrudes downward beyond the lower end surface 200b of the stator core 20.

[0059] The inner diameter mold is configured to expand and contract radially. This allows the outer circumferential surface of the inner diameter mold to easily and tightly fit against the inner circumferential surface 2a of the stator core 20. With the inner diameter mold installed, the inner circumferential surface 525 of the leg 52 of the upper mold 50 abuts against the outer circumferential surface of the inner diameter mold. This forms a space SP0 for resin supply from the recess 58 of the lower mold through the groove 22 to the recess 53 of the upper mold 50. Figure 16A ).

[0060] Next, in Figure 10 In step S8, the resin material that serves as the base of the resin section (groove resin section 31, end face resin section 32, 33) is installed in the lower mold 55. Figure 16A This is a diagram illustrating the process of step S8. The main part of the lower mold 55, along with multiple conductor segments 210 and the stator core 20, is shown simplified. Figure 16A As shown, a recess 59 is provided on the lower surface of the lower mold 55, and resin material 70 is provided in the recess 59.

[0061] Figure 17 This is a bottom view of the lower mold 55, taken from below. (See attached image.) Figure 17 As shown, in the core mounting section 56 ( Figure 11 A plurality of recesses 59 are provided circumferentially on the radially outer side of the portion. The recesses 59 are, for example, generally cylindrical in shape, and a resin material 70, for example, generally cylindrical in shape, is provided in each of the plurality of recesses 59. Figure 17 As shown in the enlarged view of part A, one end of the flow channel 591, which serves as a flow channel for the molten resin material 70, is connected to the recess 59. The other end of the flow channel 591 passes through the lower mold 55 and is connected to the upper recess 58. Thus, the recess 59 and the recess 58 are connected via the flow channel 591.

[0062] Next, as Figure 10 As shown in step S9, the resin material 70 is pressurized to form a resin section (groove resin section 31, end face resin sections 32, 33). Figure 16B This is a diagram illustrating the process of step S9, and... Figure 16A Similarly, the main parts of the lower mold 55 are briefly shown. (e.g.) Figure 16B As shown, a pressurizing device 71 (e.g., a cylinder) is provided below the recess 59. The resin material 70 is pressurized upward by the pressurizing device 71.

[0063] Thus, the molten resin material 70 flows upward through the recess 58 and the groove 22, reaching the recess 53 on the lower side of the upper mold 50. As a result, the space SP0 from the recess 58 to the recess 53... Figure 16AThe resin is filled with resin, which can form the groove resin portion 31 and the end face resin portions 32 and 33. In this case, a plurality of recesses 59 for providing the resin material 70 are provided around the core setting portion 56. Figure 17 Therefore, the length of the flow channel 591 can be shortened. This improves the utilization rate of the resin.

[0064] Although Figure 10 The diagram is omitted, but after the resin sections 31-33 are molded, the pressure device 71 is lowered, and the lower mold 55 is further lowered, and the lower mold 55 is removed from the stator 2. Next, the lower end of the conductor section 210 is bent to form an inclined section 215. Figure 5 Multiple conductor segments are welded together via the joint 216 at the top of the inclined portion 215. This completes the manufacture of the stator 2.

[0065] The following effects can be achieved by adopting this implementation method.

[0066] (1) The stator 2 for a rotary electric motor comprises: a stator core 20 having a plurality of circumferential slots 22 extending substantially parallel to the axis CL0; a coil 21, more specifically a conductor segment (segmented coil) 210, disposed in the slots 22; and a resin portion that fixes the coil 21 to the stator core 20 in a state where the axial ends of the coil 21 protrude from the axial end faces 200a and 200b of the stator core 20. Figure 1 , Figure 2 , Figure 5 The resin section includes a groove resin section 31 disposed within a groove and end face resin sections 32 and 33 connected to the groove resin section 31 and disposed on end faces 200a and 200b along the axial direction of the stator core 20. Figure 5 The end-face resin portion 32 is a plurality of end-face resin portions 32 disposed separately in the circumferential direction corresponding to a plurality of grooves 22 in the circumferential direction. Figure 4 , Figure 6A ).

[0067] Thus, by providing end-face resin portions 32 and 33 on the end faces 200a and 200b of the stator core 20 in the manner of covering grooves 22, the creepage distance L11 from the coil 21 to the stator core 20 can be extended. Figure 9 Therefore, the occupancy rate of the coil 21 in the slot can be increased without compromising the insulation of the coil 21. As a result, the performance of the rotary motor 100 can be improved, and the cooling performance of the coil 21 can be enhanced. In addition, end-face resin portions 32 and 33 are provided on both axial sides of the stator core 20, thus preventing axial displacement of the slot resin portion 31. Furthermore, resin molding can be performed in each slot 22, thereby shortening the molding time.

[0068] (2) The multiple end face resin portions 32 in the circumferential direction have a trapezoidal resin portion 322 that is generally trapezoidal when viewed from the axial direction and a rectangular resin portion 321 that is generally rectangular when viewed from the axial direction. Figure 6A The trapezoidal resin section 322 and the rectangular resin section 321 are alternately arranged in the circumferential direction with a predetermined gap CL1. Figure 6A Therefore, after the end face resin portion 32 below the top 213 of the conductor segment 210 is formed, the upper mold 50 can be pulled out radially outward along the reference line L1 passing through the center of the rectangular resin portion 321. Figure 7 Therefore, the resin portion 32 at the end face is easy to mold.

[0069] (3) The conductor segment 210 has a straight portion 214 that protrudes a specified length (specified height H2, H4) from the end faces 200a, 200b of the stator core 20 along the axial direction, a bent portion 212 that bends from the end of the straight portion 214, and an inclined portion 215. Figure 5 The circumferentially oriented resin portions 32 and 33 have axially oriented heights H1 and H3 below specified heights H2 and H4, respectively. Figure 5 Because the bending portion (bending portion 212, etc.) of coil 21 has a large shape deviation, resin is prone to leak from the mold during resin molding when it reaches the bending portion. In this regard, resin leakage can be prevented by providing end face resin portions 32 and 33 within the range of the straight portion 214.

[0070] (4) The straight portion 214 has a recess 210a on its outer peripheral surface facing the groove resin portion 31. Figure 5 As a result, the contact area between the coil 21 and the resin is increased, which can suppress the axial displacement of the coil 21 and reduce the stress during thermal shrinkage.

[0071] (5) The conductor segment 210 has a pair of legs 211, 211 inserted into a pair of different slots 22 in the circumferential direction and a top 213 connecting the pair of legs 211, 211. Figure 3 The manufacturing method of the stator 2 for the rotary motor described above includes: a step of setting a stator core 20 in a lower mold 55 having a recess 58 facing the lower end face of the slot 22; a step of inserting the leg 211 of the conductor segment 210 from above the stator core 20 into the interior of the slot 22; a step of inserting a plurality of upper molds 50 having a recess 53 facing the upper end face of the slot 22 in the circumferential direction from the radially outer side along the upper end face 200a of the stator core 20, forming a space SP0 through the slot 22 from the recess 58 of the lower mold 55 to the recess 53 of the upper mold; and a step of supplying resin material 70 to the space SP0 to form resin portions 31 to 33. Figure 10With this structure, the resin parts 31 to 33 can be molded while the stator core 20 is set in the lower mold 55, making it easy to manufacture the stator 2.

[0072] (6) The manufacturing method of the stator 2 for the rotary motor also includes the process of inserting the guide plate 60 (guide) into the interior of the groove 22 from below the lower mold 55. Figure 10 In the process of inserting conductor segment 210, leg 211 of conductor segment 210 is inserted along guide plate 60, and guide plate 60 is pulled out from below after leg 211 is inserted. Figure 12 , Figure 13 Therefore, damage to the conductor segment 210 can be prevented when it comes into contact with the circumferential surface of the groove 22 during insertion.

[0073] (7) The manufacturing apparatus for the stator 2 of the rotary electric motor includes: a lower mold 55, which is disposed facing the lower end face 200b of the stator core 20; an upper mold 50, which is disposed facing the upper end face 200a of the stator core 20; and a guide plate 60, which is inserted from below through the lower mold 55 into a plurality of circumferential slots 22. Figures 11-15 The guide plate 60 has a pair of sidewalls 62, 62 forming a space SP3 for inserting the conductor segment 210 and a connecting wall 63. Figure 12 Therefore, it is possible to prevent the conductor segment 210 from contacting the peripheral surface of the groove 22 when the conductor segment 210 is inserted, and to protect the surface of the conductor segment 210.

[0074] (8) The upper mold 50 is a plurality of upper molds that are inserted radially outward along the upper end face 200a of the stator core 20 and have a recess 53 facing the slot 22. Figure 7 , Figure 15 Therefore, since there is a top 213 above the stator core 200, even if the upper mold cannot be removed if it is moved above the stator core 20, the upper mold 50 can be easily removed, and the groove resin part 31 and the upper and lower end face resin parts 32 and 33 can be molded simultaneously.

[0075] (9) The lower mold 55 is configured to have a recess 58 facing the groove 22, and a space SP0 is formed from the recess 58 to the recess 53 of the upper mold 50 via the groove 22. Figure 16A The lower mold 55 has a recess 59 for providing resin material 70 as a substrate for resin supplied to the space SP0, and a flow channel 591 connecting the recess 58 of the lower mold 55 and the recess 59. Figure 17 This shortens the flow channel section 591 and improves resin utilization.

[0076] This embodiment can be modified in various ways. Several modifications will be described below. In the above embodiment (… Figure 6A , Figure 6B In the above embodiment, trapezoidal resin portions 322, 332 (first end face resin portions) and rectangular resin portions 321, 331 (second end face resin portions) are alternately provided on the axial end faces 200a, 200b of the stator core 20 in a circumferential manner. However, the structure of the multiple end face resin portions in the circumferential direction is not limited to the above description. End face resin portions of the same shape can also be provided in the circumferential direction. Figure 5 In the coil 21, a recess 210a is provided on the outer peripheral surface of the straight portion 214 facing the groove resin portion 31. However, multiple recesses 210a may be provided on the outer peripheral surface of the straight portion 214. The shape and number of recesses 210a are not limited to those described above.

[0077] In the above implementation method ( Figure 3 In the above embodiment, the conductor segment 210 is generally U-shaped, having a pair of legs 211 (legs) and a top 213 (connecting portion) connecting the pair of legs 211, but the structure of the segmented coil is not limited to the above description. Figure 12 The guide plate 60 (guide) is inserted into the interior of the groove 22 from below the lower mold 55, and the conductor segment 210 is inserted into the space SP3 formed by a pair of side walls 62, 62 and connecting wall 63, but the structure of the coil housing portion forming the space SP3 is not limited to the above description.

[0078] In the above implementation method ( Figure 16A In this embodiment, resin material 70 is provided in the recess 59 on the lower surface of the lower mold 55 as a base material for resin supplied to the space SP0 from the recess 58 of the lower mold 55 to the recess 53 of the upper mold 50. However, a resin placement portion may also be provided on the upper surface of the lower mold. A resin placement portion may also be provided on the upper mold. In the above embodiment ( Figure 17 The lower mold 55 is provided with a flow channel 591 that extends through the lower mold 55 in the vertical direction and connects the recesses 58 and 59 of the lower mold 55 that form the end face resin portion 33. However, the structure of the connecting portion that connects the recesses of the lower mold and the resin setting portion is not limited to the above description.

[0079] In the above embodiment, the stator 2 for a rotary motor is applied to a vehicle, but the stator for a rotary motor of the present invention can also be applied to devices other than vehicles.

[0080] It is possible to combine one or more of the above-described embodiments and variations, and to combine the variations with each other.

[0081] By using this invention, the occupancy rate of the coil in the slot can be increased without damaging the insulation.

[0082] The present invention has been described above in conjunction with preferred embodiments, but those skilled in the art should understand that various modifications and changes can be made without departing from the scope of the claims.

Claims

1. A stator for a rotary electric motor, characterized in that, have: The stator core (20) is provided with a plurality of circumferential slots (22) extending substantially parallel to the axis (CL0). Segmented coil (210), which is disposed in the slot (22); and The resin part fixes the segmented coil (210) to the stator core (20) with the axial end of the segmented coil (210) protruding from the axial end face of the stator core (20). The resin section has a groove resin section (31) disposed in the groove and an end face resin section (32, 33) connected to the groove resin section (31) and disposed on the axial end face (200a, 200b) of the stator core (20). The end face resin portions (32, 33) are multiple end face resin portions in the circumferential direction that are separated from each other corresponding to the multiple grooves (22) in the circumferential direction.

2. The stator for a rotary electric motor according to claim 1, characterized in that, The plurality of end-face resin portions (32, 33) in the circumferential direction have a first end-face resin portion (322, 332) that is generally trapezoidal when viewed from the axial direction and a second end-face resin portion (321, 331) that is generally rectangular when viewed from the axial direction. The first end face resin portion (322, 332) and the second end face resin portion (321, 331) are alternately arranged in the circumferential direction with a predetermined gap (CL1).

3. The stator for a rotary electric motor according to claim 2, characterized in that, The first end face resin portion (322, 332) is configured in a generally trapezoidal shape with a first reference line (L2) extending radially from the axis (CL0) as the center, and the second end face resin portion (321, 331) is configured in a generally rectangular shape with a second reference line (L1) extending radially from the axis (CL0) as the center.

4. The stator for a rotary electric motor according to claim 1, characterized in that, The segmented coil (210) has a straight portion (214) that protrudes a predetermined length (H2, H4) from the axial end faces (200a, 200b) of the stator core (20) and a curved portion (212, 215) that bends from the end of the straight portion (214). The height (H1, H3) of the plurality of end face resin portions (32, 33) in the circumferential direction is less than or equal to the specified length (H2, H4) in the axial direction.

5. The stator for a rotary electric motor according to claim 4, characterized in that, The straight portion (214) has a recess (210a) on its outer peripheral surface facing the resin tank portion (31).

6. A method for manufacturing a stator for a rotary electric machine, comprising a method for manufacturing a stator for a rotary electric machine according to any one of claims 1 to 5, characterized in that, The segmented coil (210) has a pair of legs (211, 211) that are different from each other and are inserted into a pair of slots (22) in the circumferential direction, and a connecting portion (213) that connects the pair of legs (211, 211). The manufacturing method includes: The process of setting the stator core (20) in a lower mold (55) having a recess (58) facing the lower end face of the slot (22); The process of inserting the legs (211, 211) of the segmented coil (210) from above the stator core (20) into the interior of the slot (22); A process in which multiple upper molds (50) having recesses (53) facing the upper end face of the slot (22) are inserted radially outward along the upper end face (200a) of the stator core (20), forming a space (SP0) via the slot (22) from the recess (58) of the lower mold (55) to the recess (53) of the upper mold (50); and The process of supplying resin (70) to the space (SP0) to form the resin part.

7. The method for manufacturing a stator for a rotary electric machine according to claim 6, characterized in that, It also includes the process of inserting the guide (60) from below the lower mold (55) into the interior of the groove (22). In the process of inserting the segmented coil (210), the leg (211) of the segmented coil (210) is inserted along the guide (60), and the guide (60) is pulled out from below after the leg (211) is inserted.

8. A manufacturing apparatus for a stator of a rotating electric machine, comprising an apparatus for manufacturing a stator of a rotating electric machine according to any one of claims 1 to 5, characterized in that, have: The lower mold (55) is arranged facing the lower end face (200b) of the stator core (20); The upper mold (50) is disposed facing the upper end face (200a) of the stator core (20); and A guide (60) is inserted from below through the lower mold (55) into a plurality of slots (22) in the circumferential direction. The guide (60) has a coil receiving portion that forms a space (SP3) for inserting the segmented coil (210).

9. The apparatus for manufacturing a stator for a rotary electric machine according to claim 8, characterized in that, The upper mold (50) is a plurality of upper molds that are inserted radially outward along the upper end face (200a) of the stator core (20) and have a recess (53) facing the groove (22).

10. The apparatus for manufacturing a stator for a rotary electric machine according to claim 9, characterized in that, The lower mold (55) is configured to have a recess (58) facing the groove (22), and a space (SP0) is formed from the recess (58) to the recess (53) of the upper mold (50) via the groove (22). The lower mold (55) has a resin setting portion (59) for setting a substrate of resin supplied to the space (SP0) and a connecting portion (591) connecting the recess (58) of the lower mold (55) and the resin setting portion (59).

Images