Method for manufacturing a stator

Abstract

Provided is a stator manufacturing method capable of preventing interference between an insulating paper and a coil winding when the coil winding is inserted into a slot. The stator manufacturing method includes: a stator core preparation step of preparing a stator core having a slot; an insulating paper insertion step of inserting an insulating paper into the slot; a suction step of causing the insulating paper to be sucked to a wall surface of the slot by generating a negative pressure between the insulating paper inserted into the slot and the wall surface of the slot; and a coil winding insertion step of inserting a coil winding into the slot in a state in which the insulating paper is sucked to the wall surface of the slot.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a stator, and more particularly to a method for manufacturing a stator for a rotating electric machine such as a generator or motor. Background Technology

[0002] The stator of a rotating electrical machine such as a generator or motor has a stator core with slots and coil windings inserted into the slots via insulating paper. When manufacturing a stator with this structure, for example, as described in Patent Document 1 below, firstly, a rod-shaped scraper with multiple suction sections capable of generating negative pressure formed between it and the insulating paper is used to suction the insulating paper by winding it around. Next, while the insulating paper is being suctioned, the scraper is inserted into the slots, and the suction is stopped, thereby placing the insulating paper in the slots. Then, the coil windings are inserted into the slots of the stator core.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2021-90326 Summary of the Invention

[0004] However, in the above manufacturing method, the insulating paper inserted into the slot may deviate from its designated position within the slot, and there may also be deviations in the position of the inserted coil winding. Therefore, interference between the insulating paper and the coil winding may sometimes occur when the coil winding is inserted into the slot. If interference occurs between the insulating paper and the coil winding, the insulating paper may be damaged.

[0005] This invention was made to solve this technical problem, and its purpose is to provide a method for manufacturing a stator that can prevent interference between the insulating paper and the coil winding when the coil winding is inserted into the slot.

[0006] The stator manufacturing method of the present invention is used for a stator having a stator core with slots and a coil winding inserted into the slots via insulating paper. The stator manufacturing method includes: an insulating paper insertion step, which inserts the insulating paper into the slots; an adsorption step, which adsorbs the insulating paper onto the wall surface of the slot by generating a negative pressure between the insulating paper inserted into the slots; and a coil winding insertion step, which inserts the coil winding into the slots while the insulating paper is adsorbed onto the wall surface.

[0007] According to the stator manufacturing method of the present invention, in the adsorption process, a negative pressure is generated between the insulating paper inserted into the slot of the stator core and the wall of the slot, causing the insulating paper to adhere to the wall of the slot, thus ensuring a tight seal between the insulating paper and the wall of the slot. In the coil winding insertion process, the coil winding is inserted into the slot while the insulating paper is adhered to the wall of the slot. That is, in the coil winding insertion process, the coil winding is inserted while the insulating paper is in tight seal with the wall of the slot. This prevents interference between the insulating paper and the coil winding when the coil winding is inserted into the slot. Therefore, it is possible to suppress the occurrence of scratches or damage to the insulating paper caused by interference with the coil winding.

[0008] In a preferred embodiment of the stator manufacturing method according to the present invention, the stator core is formed from laminated steel plates. During the adsorption process, a negative pressure is generated between the insulating paper and the wall of the slot by evacuating air from the outer peripheral wall of the stator core. Thus, when the stator core is formed from laminated steel plates, a negative pressure is generated in the gaps between the laminated steel plates by evacuating air from the outer peripheral wall of the stator core. Consequently, the insulating paper inserted into the slot is adsorbed onto the wall of the slot, thereby ensuring a preferably tight seal between the insulating paper and the wall of the slot.

[0009] Invention Effects

[0010] According to the present invention, interference between the insulating paper and the coil winding can be prevented when the coil winding is inserted into the slot. Attached Figure Description

[0011] Figure 1 It is a schematic three-dimensional diagram representing the stator.

[0012] Figure 2 It is a partial three-dimensional view of the stator core.

[0013] Figure 3 This is a flowchart illustrating the stator manufacturing method involved in the implementation method.

[0014] Figure 4 It is a three-dimensional diagram showing the bent state of the insulating paper and the insertion of the insulating paper.

[0015] Figure 5 This is a schematic diagram used to illustrate the adsorption process. Detailed Implementation

[0016] Hereinafter, embodiments of the stator manufacturing method according to the present invention will be described with reference to the accompanying drawings. In the following description, unless otherwise specified, "axial" refers to the direction along the central axis of the annular central hole of the stator core, in other words, along the direction of rotation of the generator or motor inserted into the annular central hole of the stator core. "Radial" refers to a radial direction passing through the central axis in a plane perpendicular to the aforementioned axial direction, and "circumferential" refers to a direction along the circumference with the central axis as the center. Furthermore, in the following description, "inner circumferential side" and "outer circumferential side" are based on the center of the annular central hole of the stator core.

[0017] Before explaining the stator manufacturing method, based on Figure 1 and Figure 2 The structure of the stator is explained.

[0018] [Structure of the stator]

[0019] Figure 1 It is a schematic three-dimensional diagram representing the stator. Figure 2 This is a partial three-dimensional view of the stator core. For example... Figure 1 As shown, the stator 1 constituting a rotating electrical machine such as a motor or generator includes a stator core 10. The stator core 10 includes an annular yoke 11 and a plurality of teeth 12, 12... protruding from the inner circumferential surface of the yoke 11 toward the center of the yoke 11. Furthermore, the space between adjacent teeth 12 forms slots 13, 13... The number of teeth 12 and slots 13 is the same. Figure 1 In Chinese, omission indicates a part of something.

[0020] More specifically, the yoke 11 is formed in a circumferential ring shape. Multiple teeth 12, 12... of the stator core 10 extend radially from the yoke 11 toward the center of the yoke 11. The inner circumferential surfaces of the multiple teeth 12, 12... are formed by curved surfaces, and the inner circumferential space surrounded by the curved surfaces forms the annular central hole of the stator core 10, which is the space where the rotor (not shown) of the rotary electric motor is disposed.

[0021] like Figure 2 As shown, each slot 13 has a pair of sidewalls 13a, 13a extending radially and facing each other circumferentially, and a rear wall surface 13b connecting the pair of sidewalls 13a, 13a. The pair of sidewalls 13a, 13a are parallel in such a way that the spacing on the inner circumferential side is the same as the spacing on the outer circumferential side. In contrast, the outer circumferential wall thickness of each tooth 12 is large, and the inner circumferential wall thickness is small, forming a tapered shape towards the inner circumferential side. Moreover, at the inner circumferential end of each tooth 12, opposing and protruding protrusions 12a, 12a are formed circumferentially to reduce the slot width of each slot 13. The protrusions 12a, 12a form an opening 14 on the inner circumferential side of the stator core 10. In addition, the rear wall surface 13b constitutes the inner wall surface of the yoke portion 11.

[0022] The stator core 10 is formed of laminated steel plates. More specifically, the stator core 10 is formed, for example, by laminating a predetermined number of annular magnetic body plates along the axial direction of the rotating motor. Furthermore, both sides of the magnetic body plates are electrically insulated. As the material for the magnetic body plates, electromagnet steel plates, which are a type of silicon steel plate, can be used.

[0023] The stator 1 is, for example, a segment conductor (SC) wound stator. In addition to the stator core 10 mentioned above, it also includes coil windings 15, 15... wound on each tooth 12 and inserted into each slot 13, and insulating paper 20, 20... disposed in each slot 13 and between the stator core 10 and each coil winding 15.

[0024] Coil windings 15, 15… are wound on multiple teeth 12, 12… and inserted into multiple slots 13, 13… More specifically, each coil winding 15 is a segmented conductor, called a segmented conductor, formed by bending a flat-angle conductor into a roughly U-shape, and includes a pair of parallel insertion portions and a rotating portion connecting one end of the pair of insertion portions. With its insertion portion axially inserted into the slot 13, the side opposite to the rotating portion of the coil winding 15 is connected by welding or the like to form an SC wound coil. Furthermore, when the coil windings 15 form a three-phase distributed winding, one phase winding is formed by winding across multiple slots 13 on the teeth 12. The coil windings 15 are formed by winding a flat conductor on each tooth 12, skipping teeth 12 adjacent to the coil winding 15, for example, connecting them in a distributed winding manner on the first two teeth 12, for example, forming a three-phase coil with u-phase, v-phase, and w-phase layers.

[0025] Insulating paper 20, 20… is disposed inside a plurality of slots 13, 13… and is located between the stator core 10 and the coil windings 15, 15… inserted into the slots 13, thereby electrically insulating the stator core 10 from the coil windings 15.

[0026] The insulating paper 20, for example, has a five-layer structure, comprising a sheet-like insulating substrate, and foamed adhesive layers and a cover layer disposed on both sides of the insulating substrate in a manner that clamps the insulating substrate. The insulating substrate is, for example, an electrically insulating substrate with a thickness of approximately several tens of micrometers. Examples of materials used for the insulating substrate include polyethylene naphthalate (PEN), polystyrene (PS), polyethylene terephthalate (PET), polyimide (PI), and heat-resistant imide.

[0027] The cover layer is the outermost layer disposed on the insulating paper 20, and is formed, for example, from non-woven fabric. This cover layer is bonded to the insulating substrate via a foamed adhesive layer. The foamed adhesive layer is formed, for example, from a thermosetting resin such as epoxy resin or phenolic resin containing a foaming agent. As described later, the insulating papers 20, 20… having the above structure are inserted into the groove 13 in a U-shaped cross-section.

[0028] [Stator manufacturing method]

[0029] like Figure 3 As shown, the stator manufacturing method involved in this embodiment includes a stator core preparation process S1, an insulating paper insertion process S2, an adsorption process S3, and a coil winding insertion process S4.

[0030] In the stator core preparation step S1, a stator core 10 having slots 13 is prepared. Specifically, for example, the stator core 10 is manufactured by stacking multiple annular magnetic material sheets (e.g., silicon steel sheets) punched in the same shape along the axial direction of the rotating motor. Electrical insulation treatment is performed on both sides of the magnetic material sheets. The stator core 10 manufactured in the stator core preparation step S1 is, for example, Figure 2 The stator core shown.

[0031] In the insulating paper insertion process S2, insulating paper 20 is inserted into the slot 13 of the stator core 10. Specifically, firstly, the rolled insulating paper is released and cut into a specified length. Then, the cut insulating paper is bent into a U-shaped cross-section.

[0032] Figure 4 This is a three-dimensional diagram showing the bent state of the insulating paper and its insertion. For example... Figure 4 As shown, in its bent state, the insulating paper 20 has a pair of opposing side portions 21 and a connecting portion 22 connecting the pair of side portions 21. Furthermore, the height H2 of the insulating paper 20 is greater than the axial height H1 of the stator core 10 (reference). Figure 2 and Figure 4 Slightly larger, the length L2 of the insulating paper 20 is greater than the radial length L1 of the stator core 10 (reference). Figure 2 and Figure 4 Slightly larger.

[0033] Next, the bent insulating paper 20 is inserted into the slot 13 from the end face side of the stator core 10, which is orthogonal to the axis of the rotating motor, such that a pair of side faces 21 face the pair of side walls 13a of the slot 13, and the connecting portion 22 faces the rear wall 13b of the slot 13. Here, the insulating paper 20 is inserted into the slot 13 from the upper side of the stator core 10. Then, in the inserted state in the slot 13, the connecting portion 22 of the insulating paper 20 contacts the rear wall 13b of the slot 13, and the pair of side faces 21 contacts the side walls 13a of the slot 13.

[0034] like Figure 4 As shown, the height H2 of the insulating paper 20 is slightly larger than the axial height H1 of the stator core 10, so that in the inserted state, the insulating paper 20 protrudes slightly beyond the upper end of the slot 13. Furthermore, the length L2 of the insulating paper 20 is slightly larger than the radial length L1 of the stator core 10, so that the front ends of the pair of side portions 21 of the insulating paper 20 approach each other in such a way that they close the opening 14 between the protrusions 12a, 12a of adjacent teeth 12.

[0035] In the adsorption process S3, the insulating paper 20 inserted into the groove 13 is adsorbed onto the wall of the groove 13 by generating a negative pressure between the insulating paper 20 and the wall of the groove 13. At this time, as... Figure 5 As shown, a negative pressure generating device 30 connected to the stator core 10 is used for adsorption. The negative pressure generating device 30, for example, has a shape that surrounds the outer peripheral wall of the stator core 10, and includes an annular suction section 31 detachably mounted to the outer peripheral wall of the stator core 10, a vacuum pump 33, and a communication path 32 connecting the suction section 31 and the vacuum pump 33. The suction section 31, for example, has a plurality of suction ports (not shown) arranged at equal intervals along the circumference of the stator core 10.

[0036] Then, after installing the suction unit 31 onto the outer peripheral wall of the stator core 10 with the suction port in contact with the outer peripheral wall of the stator core 10, the vacuum pump 33 is turned on to directly suction air from the outer peripheral wall of the stator core 10, thereby generating a negative pressure between the insulating paper 20 and the wall of the slot 13. Due to the negative pressure, a pair of side portions 21 of the insulating paper 20 adhere to a pair of side wall surfaces 13a of the slot 13, and the connecting portion 22 of the insulating paper 20 adheres to the rear wall surface 13b of the slot 13. As a result, the side portions 21 are tightly sealed to the side wall surfaces 13a, and the connecting portion 22 is tightly sealed to the rear wall surface 13b.

[0037] In the coil winding insertion process S4, the coil winding 15 is inserted into the slot 13 while the insulating paper 20 is adsorbed onto the walls of the slot 13 (more specifically, the side walls 13a and the rear walls 13b). Specifically, firstly, for example, an insulating paper pressing clamp (not shown) is used to expand the upper end of the insulating paper 20 protruding from the upper end of the slot 13. Next, the coil winding 15, which has been prepared from the expanded upper end side, is inserted into the slot 13. Additionally, at this time, to facilitate smoother insertion of the coil winding 15, a guide pin (not shown) can be inserted into the slot 13 from the lower side of the stator core 10, and the coil winding 15 is inserted using the inserted guide pin.

[0038] After inserting the coil winding 15, turn off the vacuum pump 33 to stop air suction. Next, remove the suction part 31 of the negative pressure generating device 30 from the outer peripheral wall of the stator core 10. Through the series of procedures described above, the manufacturing of the stator 1 is completed.

[0039] According to the stator manufacturing method of this embodiment, in the adsorption step S3, a negative pressure is generated between the insulating paper 20 inserted into the slot 13 of the stator core 10 and the wall surface of the slot 13 (more specifically, the side wall surface 13a and the rear wall surface 13b), causing the insulating paper 20 to be adsorbed onto the wall surface of the slot 13, thus enabling the insulating paper 20 to be tightly sealed to the wall surface of the slot 13. In the coil winding insertion step S4, the coil winding 15 is inserted into the slot 13 while the insulating paper 20 is adsorbed onto the wall surface of the slot 13. That is, in the coil winding insertion step S4, the coil winding 15 is inserted while the insulating paper 20 is tightly sealed to the wall surface of the slot 13. As a result, interference between the insulating paper 20 and the coil winding 15 when the coil winding 15 is inserted into the slot 13 can be prevented. Therefore, scratches and damage to the insulating paper 20 caused by interference with the coil winding 15 can be suppressed.

[0040] Furthermore, since it is possible to suppress scratches and damage to the insulating paper 20 caused by interference with the coil winding 15, damage to the insulating paper 20 can be reduced, and a stator 1 with high insulation can be provided. Moreover, since interference between the insulating paper 20 and the coil winding 15 can be prevented, the machining tolerance of the stator core 10 can be reduced, and the space used for non-interference can be decreased. As a result, the conductor occupancy rate can be increased, and a high-performance rotary electric motor can be manufactured.

[0041] Furthermore, in the adsorption process S3, air is drawn from the outer peripheral wall of the stator core 10, which is composed of laminated steel plates, creating a negative pressure in the gaps between the laminated steel plates. As a result, the insulating paper 20 inserted into the slot 13 is adsorbed onto the wall of the slot 13, thus ensuring a tight seal between the insulating paper 20 and the wall of the slot 13. Therefore, interference between the insulating paper 20 and the coil winding 15 when the coil winding 15 is inserted into the slot 13 can be further prevented.

[0042] The embodiments of the present invention have been described in detail above, but the present invention is not limited to the above embodiments. Various design changes can be made without departing from the spirit of the present invention as set forth in the claims. For example, in the above-described coil winding insertion step S4, the coil winding 15 may be directly inserted into the slot 13 without using the insulating paper pressing clamp.

[0043] Symbol Explanation

[0044] 1-Stator, 10-Stator core, 11-Magnetic yoke, 12-Tooth, 12a-Protrusion, 13-Slot, 13a-Side wall, 13b-Rear wall, 14-Opening, 15-Coil winding, 20-Insulating paper, 21-Side side, 22-Connecting part, 30-Negative pressure generating device, 31-Suction part, 32-Connecting path, 33-Vacuum pump.

Claims

1. A method for manufacturing a stator, comprising a stator having a stator core having slots and coil windings inserted into the slots via insulating paper, the method comprising: The insulating paper insertion process involves inserting the insulating paper into the groove; The adsorption process involves creating a negative pressure between the insulating paper inserted into the groove and the wall of the groove, causing the insulating paper to adhere to the wall. and The coil winding insertion process involves inserting the coil winding into the slot while the insulating paper is adsorbed onto the wall surface.

2. The method for manufacturing a stator according to claim 1, characterized in that, The stator core is formed of laminated steel plates. In the adsorption process, a negative pressure is generated between the insulating paper and the wall of the slot by evacuating air from the outer peripheral wall of the stator core.

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