Stator and Stator Manufacturing Method

Abstract

This invention provides a stator and a method for manufacturing the stator that can reduce the difference in the engagement amount of two coils inserted into a hollow tube. The stator includes a plurality of stator coils, consisting of a first coil and a second coil made of flat wire connected by a hollow tube. The first coil and the second coil are connected together by engaging the first coil inserted from one end of the hollow tube and engaging the second coil inserted from the other end of the hollow tube. A reduced diameter portion or a partition portion is provided at a position corresponding to the ends of the first coil and the second coil inserted into the hollow tube.

Description

Technical Field

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

[0002] Patent Document 1 discloses a stator coil in which one end of a first coil made of flat wire is inserted from one end of a hollow tube, and one end of a second coil made of flat wire is inserted from the other end of the hollow tube, thereby fitting and fixing the first coil and the second coil in the hollow tube.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2022-003859 Summary of the Invention

[0004] When the first coil and the second coil are inserted into the hollow tube, if there is a difference between the load applied to the contact surface between the hollow tube and the first coil due to the insertion of the first coil and the load applied to the contact surface between the hollow tube and the second coil due to the insertion of the second coil, a difference will occur between the depth of the first coil inserted into the hollow tube (hereinafter referred to as "fitting amount") and the depth of the second coil inserted into the hollow tube (hereinafter referred to as "fitting amount").

[0005] This invention was made to solve this problem, and its purpose is to provide a stator and a method for manufacturing the stator that can reduce the difference in the engagement amount of two coils inserted into a hollow tube.

[0006] The stator of the present invention comprises a plurality of stator coils, consisting of a first coil and a second coil made of flat wire connected by a hollow tube. The first coil and the second coil are connected together by fitting the first coil inserted from one end of the hollow tube and fitting the second coil inserted from the other end of the hollow tube. A reduced diameter portion or a partition portion is provided at a position corresponding to the ends of the first coil and the second coil inserted into the hollow tube.

[0007] The stator manufacturing method of the present invention is as follows: the stator has a plurality of stator coils formed by connecting a first coil and a second coil made of flat wire via a hollow tube. The stator manufacturing method includes the following steps: inserting and fitting the first coil into one end of the hollow tube; riveting the hollow tube at a position corresponding to the end of the first coil inserted into the hollow tube, thereby forming a reduced diameter portion on the hollow tube; and inserting and fitting the second coil into the reduced diameter portion from the other end of the hollow tube, thereby connecting the first coil and the second coil together through the hollow tube.

[0008] Invention Effects

[0009] According to the first aspect of the present invention, the stator has a reduced diameter portion or a partition portion formed on the hollow tube, which allows the positions of the ends of the first coil and the second coil inserted into the hollow tube to be determined. Specifically, the first coil and the second coil are not inserted deeper into the hollow tube than the reduced diameter portion or the partition portion. Therefore, a stator capable of reducing the difference in the engagement amount of the two coils inserted into the hollow tube can be provided.

[0010] According to the stator manufacturing method of the second aspect of the present invention, since a reduced diameter portion is formed on the hollow tube after the first coil is inserted, the position of the end of the second coil inserted into the hollow tube can be determined by this reduced diameter portion. Specifically, the second coil is not inserted deeper into the hollow tube than into the reduced diameter portion. Therefore, a stator manufacturing method that can reduce the difference in the engagement amount of the two coils inserted into the hollow tube can be provided. Attached Figure Description

[0011] Figure 1 This is a perspective view showing an example of the stator involved in the present invention.

[0012] Figure 2 This is a perspective view showing the connection portion of the stator coils of the stator involved in the present invention.

[0013] Figure 3 This is a cross-sectional view showing an example of a hollow tube according to the present invention.

[0014] Figure 4 This is a cross-sectional view showing the connection between the first coil and the second coil, which are connected via a hollow tube with a reduced diameter portion according to the present invention.

[0015] Figure 5 This is a cross-sectional view illustrating an example of a method for manufacturing a stator according to the present invention. Detailed Implementation

[0016] Hereinafter, one embodiment of the present invention will be described with reference to the accompanying drawings. However, the present invention is not limited to the following embodiment. Furthermore, for clarity, the following description and drawings are appropriately simplified.

[0017] Hereinafter, with reference to the accompanying drawings, the stator and stator manufacturing method involved in the present invention will be described. Figure 1 This is a perspective view showing an example of the stator 1 according to the present invention. The stator 1 is the stator of a rotary electric motor. The stator 1 includes a plurality of stator coils 10. Figure 1 As shown, the front end of the stator coil 10 is arranged along the rotation axis Ax of the stator 1. The stator coil 10 can have an upper and lower surface of any shape, such as U-shaped or mountain-shaped.

[0018] Figure 2 This is a three-dimensional view showing the connection portion of stator coil 10. For example... Figure 2 As shown, the stator coil 10 is formed by connecting a first coil 11 and a second coil 12, both made of flat wire, via a hollow tube 13. Similar to the front end of the stator coil 10, the hollow tube 13 is arranged along the rotation axis Ax of the stator 1. Furthermore, in Figure 2 In the example shown, a partition wall portion 13A, described later, is formed on the hollow tube 13 (see reference). Figure 3 ).

[0019] Figure 3 This is a cross-sectional view showing an example of the hollow tube 13 according to the present invention. Figure 3 As shown, the hollow tube 13 includes a partition wall portion 13A or a reduced diameter portion 13B. Specifically, the partition wall portion 13A and the reduced diameter portion 13B are formed at positions corresponding to the ends of the first coil 11 and the second coil 12 inserted into the hollow tube 13. More specifically, the partition wall portion 13A and the reduced diameter portion 13B are formed at positions in the hollow tube 13 where the length of the first coil 11 inserted into the hollow tube 13 is substantially the same as the length of the second coil 12 inserted into the hollow tube 13.

[0020] More specifically, the partition wall 13A is formed between the end of the first coil 11 inserted into the hollow tube 13 and the end of the second coil 12 inserted into the hollow tube 13. For example, the hollow tube 13 having the partition wall 13A can be formed by extruding punches from both ends of the base material sandwiched between the upper and lower dies.

[0021] Furthermore, the reduced diameter portion 13B is formed between the end of the first coil 11 inserted into the hollow tube 13 and the end of the second coil 12 inserted into the hollow tube 13. The hollow tube 13 with the reduced diameter portion 13B can be formed by riveting a hollow tube without the reduced diameter portion 13B to a desired location. Various joining methods can be used in the riveting process, such as mechanical riveting, thermal riveting, electric riveting, ultrasonic riveting, and laser welding.

[0022] Furthermore, the shape and size of the hole 13C in the hollow tube 13 are such that the first coil 11 and the second coil 12 can be inserted and fitted. Specifically, as described later, the shape and size of the hole 13C in the hollow tube 13 have an insertion portion 11A that can be pressed into the first coil 11 (see reference). Figure 4 ) and the insertion part 12A of the second coil 12 (reference) Figure 4 The shape and size of the first coil 11 are fitted into the hollow tube 13 by pressing the insertion part 11A of the first coil 11 and the insertion part 12A of the second coil 12 into the hole 13C of the hollow tube 13.

[0023] Figure 4This is a cross-sectional view showing the connection between the first coil 11 and the second coil 12, which are connected via a hollow tube 13 having a reduced diameter portion 13B. (See attached image.) Figure 4 As shown, the hollow tube 13 connects the first coil 11 and the second coil 12 by fitting the insertion portion 11A of the first coil 11 inserted from one end of the hollow tube 13 and the insertion portion 12A of the second coil 12 inserted from the other end of the hollow tube 13. Specifically, in Figure 4 In the example shown, the insertion portion 11A of the first coil 11 and the insertion portion 12A of the second coil 12 are pressed into the hollow tube until the position of the reduced diameter portion 13B is reached. As a result, the end face of the insertion portion 11A of the first coil 11 comes into contact with the end face of the insertion portion 12A of the second coil 12.

[0024] Furthermore, when the hollow tube 13 with partition 13A connects the first coil 11 and the second coil 12, the insertion portion 11A is pressed into the hollow tube 13 until the end face of the insertion portion 11A of the first coil 11 contacts the partition 13A, and the insertion portion 12A is pressed into the hollow tube 13 until the end face of the insertion portion 12A of the second coil 12 contacts the partition 13A. Thus, the end face of the insertion portion 11A of the first coil 11 and the end face of the insertion portion 12A of the second coil 12 are in electrical contact via the partition 13A.

[0025] In the above description, an example in which a partition portion 13A or a reduced diameter portion 13B is pre-formed in the hollow tube 13 was described, but the reduced diameter portion 13B may also be formed during the manufacturing process of the stator 1. Figure 5 This is a cross-sectional view illustrating the manufacturing method of stator 1 in which a reduced diameter portion 13B is formed on hollow tube 13 during the manufacturing process of stator 1.

[0026] exist Figure 5 In the manufacturing method of the stator 1 shown, firstly, one end of a hollow tube 13 without a reduced diameter portion 13B, from which the insertion portion 11A of the first coil 11 is inserted (pressed in), is inserted into (pressed in) to the desired position and fitted. Next, the hollow tube 13 is riveted at a position corresponding to the end of the first coil 11 into which it is inserted, thereby forming a reduced diameter portion 13B on the hollow tube 13. The riveting is the same as described above. Next, the insertion portion 12A of the second coil 12 is inserted (pressed in) from the other end of the hollow tube 13 into the reduced diameter portion 13B and fitted. Thus, the hollow tube 13 connects the first coil 11 and the second coil 12 together. Specifically, the end face of the insertion portion 11A of the first coil 11 contacts the end face of the insertion portion 12A of the second coil 12.

[0027] In the stator 1 of the present invention described above, since a reduced diameter portion 13B or a partition portion 13A is formed on the hollow tube 13, the positions of the ends of the first coil 11 and the second coil 12 inserted into the hollow tube 13 can be determined by the reduced diameter portion 13B or the partition portion 13A. Specifically, in the hollow tube 13, the first coil 11 and the second coil 12 will not be inserted deeper than the reduced diameter portion 13B or the partition portion 13A. Therefore, a stator 1 can be provided that can reduce the difference in the engagement amount of the two coils 11 and 12 inserted into the hollow tube 13.

[0028] Furthermore, according to the stator 1 manufacturing method of the present invention, after the first coil 11 is inserted into the hollow tube 13, a reduced diameter portion 13B is formed on the hollow tube 13. Therefore, the position of the end of the second coil 12 inserted into the hollow tube 13 can be determined by this reduced diameter portion 13B. Specifically, the second coil 12 will not be inserted deeper into the hollow tube 13 than the reduced diameter portion 13B. Therefore, a stator 1 manufacturing method can be provided that reduces the difference in the engagement amount of the two coils 11 and 12 inserted into the hollow tube 13.

[0029] Furthermore, sometimes, after pressing the insertion portion 11A of the first coil 11 into the hollow tube 13 from one end, when pressing the insertion portion 12A of the second coil 12 into the hollow tube 13 from the other end, the position of the hollow tube 13 deviates towards the first coil 11, causing deformation of the hollow tube 13. To solve this problem, it is also possible to consider that the load applied to the contact surface between the hollow tube 13 and the insertion portion 11A when pressing the insertion portion 11A of the first coil 11 into the hollow tube 13 is greater than the load applied to the contact surface between the hollow tube 13 and the insertion portion 12A when pressing the insertion portion 12A of the second coil 12 into the hollow tube 13. However, if there is a difference between the load applied to the contact surface between the hollow tube 13 and the insertion part 11A due to the insertion of the insertion part 11A and the load applied to the contact surface between the hollow tube 13 and the insertion part 12A due to the insertion of the insertion part 12A, the engagement amount of the first coil 11 and the engagement amount of the second coil 12 will be different.

[0030] Furthermore, in reality, there is a deviation in the load generated by the insertion part 11A and the insertion part 12A pressing into the hollow tube 13 among multiple stator coils 10. It is difficult to strictly control the load difference set between the load generated by the insertion part 11A pressing into the hollow tube 13 and the load generated by the insertion part 12A pressing into the hollow tube 13.

[0031] Furthermore, from the viewpoint of preventing the stator coil 10 from bending, there is an upper limit to the load generated when the insertion portion 11A of the first coil 11 and the insertion portion 12A of the second coil 12 are pressed into the hollow tube 13. Therefore, if a difference is set between the load generated when the insertion portion 11A is pressed into the hollow tube 13 and the load generated when the insertion portion 12A is pressed into the hollow tube 13 within the range of this upper limit, the pressing load of the insertion portion 12A of the second coil 12 becomes too small, which may result in insufficient fitting strength between the hollow tube 13 and the insertion portion 12A.

[0032] In contrast, in the stator 1 and its manufacturing method according to the present invention, there can be no difference between the load generated when the insertion part 11A is pressed into the hollow tube 13 and the load generated when the insertion part 12A is pressed into the hollow tube 13. Therefore, the fitting strength between the hollow tube 13 and the insertion parts 11A and 12A can be made sufficiently strong. This prevents the hollow tube 13 from shifting towards the first coil 11 and deforming when the insertion part 12A is pressed into the hollow tube 13 from the other end after the insertion part 11A has been pressed into the hollow tube 13 from one end.

[0033] Furthermore, as described above, in the hollow tube 13, the insertion portion 11A of the first coil 11 and the insertion portion 12A of the second coil 12 will not be inserted deeper than the reduced diameter portion 13B or the partition portion 13A. Therefore, the difference in the engagement amount of the two coils 11 and 12 inserted into the hollow tube 13 can be reduced.

[0034] 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.

[0035] Symbol Explanation

[0036] 1-Stator, 10-Stator coil, 11-First coil, 12-Second coil, 13-Hollow tube, 13A-Divider section, 13B-Reduced diameter section, 13C-Hole.

Claims

1. A stator, characterized in that, It has multiple stator coils, consisting of a first coil and a second coil made of flat wire connected by a hollow tube. The hollow tube connects the first coil and the second coil by fitting a first coil inserted from one end of the hollow tube and a second coil inserted from the other end of the hollow tube. A reduced diameter portion or a partition portion is provided at a position corresponding to the ends of the first coil and the second coil inserted into the hollow tube.

2. A method for manufacturing a stator, the stator comprising a plurality of stator coils formed by connecting a first coil and a second coil made of flat wire via a hollow tube, the method comprising the following steps: The first coil is inserted and fitted from one end of the hollow tube; The hollow tube is riveted at a position corresponding to the end of the first coil inserted into the hollow tube, thereby forming a reduced diameter portion on the hollow tube; and The second coil is inserted from the other end of the hollow tube and fitted into the reduced diameter section, thereby connecting the first coil and the second coil together through the hollow tube.

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