Stator manufacturing method

Abstract

The stator manufacturing method provided by the invention is high in production efficiency in mixed flow production. In this stator manufacturing method, either a first electrode, which is fixed and a second electrode, which is provided so as to be movable in the axial direction, are electrically connected to a coil, and when the first electrode is connected to a stator main body, the second electrode is moved to a position farther from the coil end than the first electrode, and the coil end is connected to the stator main body. When connecting the second electrode to the stator main body, the second electrode is moved to a position closer to the coil end than the first electrode, and the stator main body is moved to contact the second electrode with the coil end, and the first electrode and the coil end are welded to each other, and when connecting the second electrode to the stator main body, the second electrode is moved to a position closer to the coil end than the first electrode, and the stator main body is moved to contact the second electrode with the coil end. The second electrode is welded to the coil end.

Description

Technical Field

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

[0002] Technology has been developed for connecting electrodes to stator coils. For example, Patent Document 1 discloses a main core, i.e., an alignment fixture, for aligning the stator, the electrodes connected to the stator coils, and the welding torch used to weld the coils to the electrodes.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2021-079392 Summary of the Invention

[0004] Regarding the coils connecting electrodes to the stator, the inventors discovered the following problems. Depending on the stator specifications, the type of coil and the type of electrodes connected to the coil vary. Therefore, in mixed-flow production where different types of stators are produced on the same production line, if the type of electrodes connected to the coil changes, it is necessary to remove the alignment fixture from the manufacturing equipment and replace it with a different alignment fixture. In this method, the time required for changing the alignment fixture can potentially reduce production efficiency.

[0005] This invention was made to solve this problem by providing a stator manufacturing method with high production efficiency in mixed-flow production.

[0006] In the stator manufacturing method of the present invention, a first electrode and a second electrode are arranged opposite the coil end of the coil in the axial direction to a stator body having a coil and being movable along the axial direction. Either the first electrode or the second electrode is electrically connected to the coil. The first electrode is fixed, and the second electrode is configured to move along the axial direction. When connecting the first electrode to the stator body, the second electrode is moved to a position further away from the coil end than the first electrode, and the stator body is moved to bring the first electrode into contact with the coil end. The first electrode is then welded to the coil end. When connecting the second electrode to the stator body, the second electrode is moved to a position closer to the coil end than the first electrode, and the stator body is moved to bring the second electrode into contact with the coil end. The second electrode is then welded to the coil end.

[0007] Therefore, the stator manufacturing method of the present invention can change the electrode connected to the stator body simply by moving the second electrode axially.

[0008] The coil is composed of multiple segmented coils, and the first electrode and the second electrode can be welded to the front ends of the multiple segmented coils that are adjacent to each other along the radial direction of the stator body.

[0009] The number of the front ends to which the first electrode is welded may be different from the number of the front ends to which the second electrode is welded.

[0010] The welding can be tungsten inert gas (TIG) welding.

[0011] The stator can be installed in a vehicle, and depending on the type of coil, an electrode connected to the coil is selected from the first electrode and the second electrode.

[0012] Invention Effects

[0013] According to the present invention, a stator manufacturing method with high production efficiency in mixed-flow production can be provided. Attached Figure Description

[0014] Figure 1 This is a side view of the stator according to Embodiment 1.

[0015] Figure 2 This is an enlarged view of the coil end in the stator according to Embodiment 1.

[0016] Figure 3 This diagram shows the initial configuration of the stator body, the first electrode, and the second electrode in the stator manufacturing method according to Embodiment 1.

[0017] Figure 4 This diagram illustrates the configuration of connecting the first electrode to the stator body in the stator manufacturing method according to Embodiment 1.

[0018] Figure 5 This diagram illustrates the configuration of connecting the second electrode to the stator body in the stator manufacturing method according to Embodiment 1.

[0019] Figure 6 This is a flowchart of the stator manufacturing method according to Embodiment 1. Detailed Implementation

[0020] Hereinafter, specific embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the following embodiments. Furthermore, for the sake of clarity, the following description and drawings have been appropriately simplified.

[0021] (Implementation Method 1)

[0022] <Structure of the stator>

[0023] First, refer to Figure 1 and Figure 2 The structure of the stator manufactured by the stator manufacturing method according to Embodiment 1 will be described. Figure 1 This is a side view of the stator according to Embodiment 1. Figure 2 This is an enlarged view of the coil end in the stator according to Embodiment 1. Figure 1 As shown, the stator 100 includes a stator body 1 and electrodes 2.

[0024] The stator body 1 has a stator core 10 and a coil 20.

[0025] The stator core 10 is formed by overlapping multiple thin, annular electromagnetic steel plates. The stator core 10 includes multiple teeth (not shown) that project radially inward from the outer periphery of the annulus at circumferential intervals, and multiple core slots (not shown) formed between adjacent teeth. Alternatively, the stator core 10 can be integrally formed, for example, by press-forming and sintering strongly magnetic powder.

[0026] The coil 20 is disposed in the core slot of the stator core 10. The coil ends 22, as part of the coil 20, protrude from both end faces of the stator core 10 in the axial (z-direction) direction. The coil 20 is composed of multiple segmented coils 21 formed by flat copper wire in a U-shape. Figure 2 As shown, multiple segmented coils 21 are arranged circumferentially along the stator core 10. Furthermore, the multiple segmented coils 21 are stacked sequentially from the inside to the outside along the radial direction of the stator core 10. Additionally, the coil 20 is not limited to segmented coils 21; for example, it can be composed of multiple cassette coils.

[0027] like Figure 2 As shown, the coil end 22 has a front end portion 23 of the segmented coil 21. The connection portion 24 connected to the electrode 2 is composed of a plurality of front ends 23 adjacent to each other along the radial direction of the stator core 10. Figure 2 In the example, the connecting part 24 is composed of eight front ends 23a to 23h, but it is not limited to this.

[0028] like Figure 2 As shown, electrode 2 is a pair of metal parts. Electrode 2 is electrically connected to coil 20 by welding to connection part 24. As a welding method, tungsten inert gas (TIG) welding can be cited as an example, but it is not limited to this. For example, metal active gas (MAG) welding or plasma welding can also be used.

[0029] The stator 100 is installed, for example, in a vehicle. Depending on the type of vehicle, the specifications of the stator 100 may differ. Depending on the specifications of the manufactured stator 100, the type of coil 20 may vary, for example, the shape of the coil 20 or the number of front ends 23 in the connecting portion 24. Therefore, it is necessary to select the type of electrode 2 connected to the coil 20 according to the type of coil 20. The stator manufacturing method according to Embodiment 1 is a method of manufacturing a stator 100 by electrically connecting either a first electrode or a second electrode, which are of different types, to the coil 20. The stator manufacturing method will be described below.

[0030] <Stator Manufacturing Method>

[0031] refer to Figures 3 to 6 The stator manufacturing method described in Embodiment 1 will now be explained. Figure 3 This diagram shows the initial configuration of the stator body, the first electrode, and the second electrode in the stator manufacturing method according to Embodiment 1. Figure 4 This diagram illustrates the configuration of connecting the first electrode to the stator body in the stator manufacturing method according to Embodiment 1. Figure 5 This diagram illustrates the configuration of connecting the second electrode to the stator body in the stator manufacturing method according to Embodiment 1. Figure 6 This is a flowchart of the stator manufacturing method according to Embodiment 1. Figure 6 The flowchart shown is executed by a manufacturing system not illustrated.

[0032] First, use Figures 3 to 5 The positional relationship and movement of the stator body 1, the first electrode 2a and the second electrode 2b are explained.

[0033] The stator body 1 is mounted on the base B of the lifter L. The stator body 1 can move axially (z-direction) by the lifting action of the lifter L. Furthermore, the stator body 1 can rotate about the axis by the rotation action of the lifter L. The lifter L can identify the type of coil 20, and according to the type of coil 20, it can change the amount of axial (z-direction) movement and the rotation angle about the axis of the lifter L.

[0034] The first electrode 2a and the second electrode 2b are arranged opposite the coil end 22 in the axial (z-direction) direction. Furthermore, the first electrode 2a and the second electrode 2b are arranged with a height difference in the axial (z-direction). The first electrode 2a is fixed. That is, in Figure 6 In the flowchart shown, the first electrode 2a does not move. On the other hand, the second electrode 2b can be moved axially (in the z-direction) by means of, for example, a lifter not shown.

[0035] When connecting the first electrode 2a to the stator body 1, the manufacturing system moves the second electrode 2b to a position further away from the coil end 22 than the first electrode 2a. The second electrode 2b is moved, and as... Figure 4 As shown, the manufacturing system moves the stator body 1 so that the first electrode 2a contacts the coil end 22. Then, the manufacturing system welds the first electrode 2a to the coil end 22.

[0036] When connecting the second electrode 2b to the stator body 1, the manufacturing system moves the second electrode 2b to a position closer to the coil end 22 than the first electrode 2a. The second electrode 2b is moved, and as... Figure 5 As shown, the manufacturing system moves the stator body 1 so that the second electrode 2b contacts the coil end 22. Then, the manufacturing system welds the second electrode 2b to the coil end 22.

[0037] As described above, the stator manufacturing method according to Embodiment 1 can change the electrode connected to the stator body 1 simply by moving the second electrode 2b along the axial direction (z direction). That is, the stator manufacturing method according to Embodiment 1 can manufacture a stator connected to the first electrode 2a and a stator connected to the second electrode 2b on the same production line without removing the alignment fixture from the manufacturing equipment and replacing it with another alignment fixture.

[0038] Next, regarding Figure 6 The flowchart shown is used for illustration. Figure 6 The order of steps in the flowchart shown is not limited to this and can be replaced as appropriate.

[0039] First, the manufacturing system places the stator body 1 on the base B (step S101). Alternatively, the stator body 1 can be placed on the base B by an operator.

[0040] Next, the manufacturing system determines the type of coil 20 disposed on the stator body 1 of the base (step S102). Based on the type of coil 20, the manufacturing system selects the electrode 2 connected to the coil 20 from the first electrode 2a and the second electrode 2b. The manufacturing system can determine the type of coil 20 and, through the calculation function of the lifter L, calculate the axial (z-direction) movement of the lifter L and the rotation angle centered on the axis.

[0041] If the electrode connected to the coil 20 is selected as the first electrode 2a (step S103: "Yes"), the manufacturing system moves the second electrode 2b to a position further away from the coil end 22 than the first electrode 2a (step S104).

[0042] Next, as Figure 4As shown, the manufacturing system moves the stator body 1 so that the first electrode 2a contacts the coil end 22 (step S105). The manufacturing system can move and rotate the lifter L along the axial direction (z direction) according to the value calculated by the calculation function of the lifter L.

[0043] Next, the manufacturing system welds the first electrode 2a to the coil end 22 (step S106).

[0044] If the electrode connected to the coil 20 is selected as the second electrode 2b (step S103: "No"), the manufacturing system moves the second electrode 2b to a position closer to the coil end 22 than the first electrode 2a (step S107).

[0045] Next, as Figure 5 As shown, the manufacturing system moves the stator body 1 so that the second electrode 2b contacts the coil end 22 (step S108). The manufacturing system can move and rotate the lifter L along the axial direction (z direction) according to the value calculated by the calculation function of the lifter L.

[0046] Next, the manufacturing system welds the second electrode 2b to the coil end 22 (step S109).

[0047] Furthermore, the present invention can realize part or all of the processing of the manufacturing system by having the central processing unit (CPU) execute computer programs.

[0048] When the above-described program is read into a computer, it includes a set of commands (or software code) for causing the computer to perform one or more functions described in the embodiments. The program may be stored in a non-transitory computer-readable medium or a tangible storage medium. By way of example, and not limitation, computer-readable media or tangible storage media include random-access memory (RAM), read-only memory (ROM), flash memory, solid-state drive (SSD) or other memory technologies, CD-ROM, digital versatile disc (DVD), Blu-ray disc (registered trademark) or other optical disc storage, magnetic tape cassettes, magnetic tape, disk storage, or other magnetic storage devices. The program may be transmitted on a temporary computer-readable medium or a communication medium. By way of example, and not limitation, temporary computer-readable media or communication media include electrical, optical, acoustic, or other forms of propagation signals.

[0049] As explained above, according to the stator manufacturing method of Embodiment 1, the electrode 2 connected to the stator body 1 can be changed simply by moving the second electrode 2b along the axial direction (z direction). That is, the stator manufacturing method of Embodiment 1 allows for the manufacture of stators connected to the first electrode 2a and stators connected to the second electrode 2b on the same production line without removing the alignment fixture from the manufacturing equipment and replacing it with another alignment fixture. Therefore, the stator manufacturing method of Embodiment 1 can improve production efficiency in mixed-flow stator production.

[0050] Furthermore, the present invention is not limited to the above-described embodiments, and appropriate modifications can be made without departing from the spirit of the invention.

[0051] Symbol Explanation

[0052] 1-Stator body, 2-Electrode, 2a-First electrode, 2b-Second electrode, 10-Stator core, 20-Coil, 21-Segmented coil, 22-Coil end, 23-Front end, 24-Connecting part, 100-Stator, B-Base, L-Lifter.

Claims

1. A stator manufacturing method, comprising, relative to a stator body having coils and being movably disposed along an axial direction, arranging a first electrode and a second electrode at positions opposite to the coil ends of the coils along the axial direction, and electrically connecting either the first electrode or the second electrode to the coils, characterized in that... The first electrode is fixed, and the second electrode is configured to move along the axial direction. When connecting the first electrode to the stator body, the second electrode is moved to a position further away from the coil end than the first electrode, and the stator body is moved so that the first electrode contacts the coil end, and the first electrode is welded to the coil end. When connecting the second electrode to the stator body, the second electrode is moved to a position closer to the end of the coil than the first electrode, and the stator body is moved so that the second electrode contacts the end of the coil, and the second electrode is welded to the end of the coil.

2. The stator manufacturing method according to claim 1, characterized in that, The coil is composed of multiple segmented coils. The first and second electrodes are welded to the front ends of the plurality of segmented coils that are adjacent to each other along the radial direction of the stator body.

3. The stator manufacturing method according to claim 2, characterized in that, The number of the front ends to which the first electrode is welded is different from the number of the front ends to which the second electrode is welded.

4. The stator manufacturing method according to claim 1 or 2, characterized in that, The welding is tungsten inert gas welding.

5. The stator manufacturing method according to claim 1 or 2, characterized in that, The stator is installed in the vehicle. Depending on the type of coil, an electrode is selected from the first electrode and the second electrode to be connected to the coil.

Images