Manufacturing method of stator

Abstract

To provide technology for insulating a coil end by avoiding a conductive member in a stator in which the conductive member extends at an upper part of an axial direction of the coil end.SOLUTION: A stator 2 comprises: a stator core 4 which is annular to its center shaft; a stator coil 6 attached to the stator core 4; and a conductive member 12 which is arranged at an upper part of an axial direction of a coil end 8 projecting from one end surface 4a of the stator core 4 and connected with a lead-out coil 10. A manufacturing method of the stator core 2 arranges a masking member 20 which masks the conductive member 12 at the upper part of the axial direction of the coil end 8 of the stator core 2, and supplies insulation coating from the upper part of the axial direction toward the coil end 8 via the masking member 20.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The technology disclosed in this specification relates to a method for manufacturing a stator. [Background technology]

[0002] Conventionally, for example, a stator in a motor unit is equipped with a stator coil in which a rectangular wire coil is attached to a stator core. At both axial ends of the stator core, the ends of the coil extending axially outward from the stator core are welded together to form coil ends.

[0003] Conductive members such as power lines and neutral lines are connected by welding to the lead coils extending from a portion of the coil ends. In some cases, it may not be suitable to paint these conductive members or their vicinity with an insulating coating material. On the other hand, it may be preferable to insulate the coil ends adjacent to the conductive members with an insulating coating material.

[0004] A method of supplying and painting an insulating coating agent only to the coil ends has been disclosed (Patent Document 1). In this method, the coil terminals extending from the stator core are capped from below to prevent the insulating powder paint from adhering to them, and the coil ends are immersed in the powder paint to paint them. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2015-95980 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, in a stator, the conductive member may extend axially upward from the coil end, which is the direction in which the coil end protrudes. In such a configuration, the method disclosed in Patent Document 1 cannot supply the insulating coating agent to the coil end while avoiding supplying the insulating coating agent to the conductive member or to the conductive member connected to the stator coil.

[0007] The present specification provides a technique for insulating coil ends in a stator in which a conductive member extends axially above the coil ends, while avoiding the conductive member. [Means for solving the problem]

[0008] The technology disclosed in this specification is embodied in a manufacturing method of a stator. The stator includes a stator core having an annular shape with respect to its central axis, a stator coil mounted on the stator core, and a conductive member disposed axially above a coil end protruding from one end face of the stator core and connected to a lead coil. The manufacturing method includes a step of disposing a masking member axially above the coil end to mask the conductive member, and a step of supplying an insulating coating agent from the axially above toward the coil end via the masking member.

[0009] According to this manufacturing method, a masking member is arranged to mask the conductive member extending axially upward from the coil end, and an insulating coating agent is supplied to the coil end from above in the axial direction through this masking member. Therefore, even if the conductive member is arranged to extend axially upward and is connected to the coil, the insulating coating agent can be supplied and applied to the coil end while avoiding the area including the conductive member. [Brief description of the drawings]

[0010] [Figure 1] 1A and 1B are diagrams illustrating a stator as a workpiece in the method for manufacturing a stator disclosed in this specification; [Diagram 2] 2 is an enlarged view showing the structure of a coil end of a stator in the range indicated by a frame A in FIG. 1. [Diagram 3]2 is an enlarged view of the area indicated by frame B in FIG. 1, illustrating an example of a manufacturing process for a stator. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The manufacturing method of the stator disclosed in this specification will be described below with reference to the drawings as appropriate. In this specification, the term "axial direction" refers to the common central axis direction of a large number of coil ends protruding from one end face of the stator core.

[0012] Fig. 1 shows an object to be processed by the method for manufacturing a stator disclosed in this specification. Fig. 1 shows a vertical end surface passing through a central axis Z of a stator core 4 of a stator 2 before an insulating coating is to be applied. The stator 2 is, for example, an electronic part of an automobile or a component part of a motor that supplies power to the motor. The motor may be a traction motor.

[0013] The stator 2 includes a stator core 4, a stator coil 6, and a conductive member 12. The stator core 4 is a substantially circular ring shaped body about a central axis Z, and is made of, for example, laminated steel plates. A rotor (not shown) is disposed in a central hole of the stator core 4 to form a motor.

[0014] The stator coil 6 is formed of, for example, a rectangular wire coil. The stator coil 6 does not have an insulating coating such as enamel. The stator coil 6 is wound around the stator core 4 while being inserted into a plurality of insertion holes provided in the stator core 4.

[0015] As shown in FIG. 1, one end face 4a of the stator core 4 is provided with coil ends 8 protruding from the end face 4a. Note that the coil ends 8 are shown in FIG. 1 with details omitted. FIG. 2 shows an enlarged view of the range of frame A in FIG. 1. As shown in an enlarged view in FIG. 2, the coil ends 8 are formed by connecting the terminals of the stator coils 6 protruding from one of the upper and lower end faces 4a of the stator core 4 by, for example, TIC welding. The numerous coil ends 8 thus formed have their own axial direction as a whole, and protrude in a direction away from the end face 4a (axially upward in this specification) along the axial direction. The numerous coil ends 8 are also distributed in a ring shape across the end face 4a of the stator core 4.

[0016] The conductive member 12 is disposed axially above the coil end 8 protruding from one end face 4a of the stator core 4, and is connected to a predetermined drawn coil 10 (see FIG. 3(a)). The conductive member 12 and the drawn coil 10 are connected by, for example, welding. The conductive member 12 is, for example, a three-phase AC power line or a neutral line. The conductive member 12 may be integrated into a busbar module as necessary.

[0017] Next, the process of applying an insulating coating agent X to the coil ends 8 of the stator 2 as the workpiece will be described with reference to Fig. 3. Fig. 3 shows these processes in a schematic manner by enlarging the frame B in Fig. 1.

[0018] As shown in FIG. 3(a), a masking member 20 is disposed axially above the conductive member 12 of the stator 2. The masking member 20 includes a shielding portion 22 and an opening 24. The shielding portion 22 masks (shields) an area occupied by the conductive member 12 connected to the lead coil 10 on the end surface 4a of the stator core 4 when viewed from the axially upper side of the coil end 8. The opening 24 exposes (opens) an area occupied by objects that are suitable for insulation, such as the coil end 8 and the bus bar. The shielding portion 22 and the opening 24 may have any shape as long as they prevent the supply of the insulating coating agent X to the conductive member 12 and enable the supply of the insulating coating agent X to the coil end 8 and the like. A painting robot may be used as appropriate to dispose the masking member 20.

[0019] Next, as shown in Fig. 3(b), the insulating coating agent X is supplied. That is, the insulating coating agent X is supplied from the axially upper side of the masking member 20 toward the coil end 8 through the masking member 20. The insulating coating agent X is not particularly limited, and a known insulating coating agent such as a powder paint can be used. The manner in which the insulating coating agent X is supplied through the masking member 20 is not particularly limited, and can be, for example, spraying, dripping, or the like.

[0020] Since the insulating coating agent X is supplied from above in the axial direction through the masking member 20, the insulating coating agent X reaches the coil ends 8 through the openings 24, and coats and insulates the coil ends 8. Moreover, since the insulating coating agent X is blocked by the shielding portion 22, it is not supplied to the conductive member 12.

[0021] After the insulating coating agent X is supplied, drying, curing, etc. are performed as necessary to form a coating film of the insulating coating agent X supplied to the coil ends 8. Finally, a stator 2 with insulated coil ends 8 can be obtained.

[0022] As described above, the method of manufacturing a stator disclosed in this specification supplies the insulating coating agent X from above in the axial direction using the masking member 20 that shields the area occupied by the conductive member 12 when viewed from above in the axial direction and exposes the coil ends 8. This makes it possible to form the necessary insulating coating film on the coil ends 8 while avoiding the supply of the insulating coating agent X to the conductive member 12, even in the case of a stator 2 that includes the conductive member 12 above the coil ends 8 in the axial direction. [Explanation of symbols]

[0023] 2 stator, 4 stator core, 6 stator coil, 8 coil end, 10 lead coil, 12 conductive member, 20 masking member

Claims

[Claim 1] A method for manufacturing a stator, comprising the steps of: The stator includes a stator core having an annular shape with respect to a central axis thereof, a stator coil attached to the stator core, and a conductive member disposed axially above a coil end protruding from one end face of the stator core and connected to a lead coil, disposing a masking member that masks the conductive member above the coil end in the axial direction; supplying an insulating coating agent from above in the axial direction toward the coil end through the masking member; A manufacturing method comprising:

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