Manufacturing device of stator

Abstract

To provide a manufacturing device of a stator which can increase design freedom regarding a position of an extension line segment coil.SOLUTION: A manufacturing device of a stator comprises: a contact member constituted to form a bending starting point in an extension line segment coil among a plurality of segment coils inserted into a slot of a stator core and constituted to contact a side face of a projection projected from the slot of the extension line segment coil from the outside in a radial direction of the stator core to form the bending starting point; and an extension line holding part which holds the projection of the extension line segment coil and constituted to be movable along the radial direction and an axial direction of the stator core to the contact member.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The technology disclosed in this specification relates to a manufacturing apparatus for manufacturing a stator, which is a component part of a rotating electric machine. [Background technology]

[0002] The stator is formed by bending the protruding portions of the multiple segment coils inserted into the slots of the stator core that protrude from the slots. The multiple segment coils include general line segment coils that serve as general wires and lead wire segment coils that serve as lead wires. The protruding portions of the general line segment coils are bent in the circumferential direction of the stator and then joined to the protruding portions of the other general line segment coils. As a result, the general line segment coils form coils on the inner surface of the stator core. The protruding portions of the lead wire segment coils are bent in the radial and axial directions of the stator core and then connected to power lines extending from the connection terminals.

[0003] Patent Document 1 discloses an example of a technique for bending a protruding portion of a lead wire segment coil. In this technique, a punch is used to bend the protruding portion of the lead wire segment coil in the radial direction of the stator core, and then a roller is used to bend the portion of the protruding portion that extends outward from the stator core in the axial direction of the stator core. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-131425 A Summary of the Invention [Problem to be solved by the invention]

[0005] The stator core is provided with ribs protruding radially from the outer circumferential surface. Such ribs are formed with bolt holes for receiving bolts for fixing the stator core to a housing. Bending using a punch and rollers cannot be applied to the vicinity of the position where the ribs are present because the ribs of the stator core interfere with the rollers. In this way, bending using a punch and rollers reduces the design freedom regarding the position of the lead wire segment coil. This specification provides a stator manufacturing device that can increase the design freedom regarding the position of the lead wire segment coil. [Means for solving the problem]

[0006] The stator manufacturing apparatus disclosed in this specification may include a contact member configured to form a bending start point in a lead wire segment coil among a plurality of segment coils inserted into the slots of a stator core, the contact member being configured to contact a side surface of a protruding portion of the lead wire segment coil protruding from the slot from the radial outside of the stator core to form the bending start point, and a lead wire holding part that holds the protruding portion of the lead wire segment coil, the lead wire holding part being configured to be movable along the radial and axial directions of the stator core relative to the contact member. According to this stator manufacturing apparatus, the protruding portion of the lead wire segment coil can be bent by moving the lead wire holding part relative to the contact member. Therefore, the lead wire segment coil formed using this stator manufacturing apparatus can have a high degree of design freedom in terms of position.

[0007] The lead wire holding portion may be configured to be movable along the radial and axial directions of the stator core relative to the abutting member within a range of the stator core when viewed from the axial direction of the stator core. The protruding portion of the lead wire segment coil formed using this stator manufacturing apparatus is positioned inside the outer peripheral surface of the stator core in the radial direction of the stator core. Therefore, the stator formed using this stator manufacturing apparatus can have a small size.

[0008] The lead wire holding portion may have a lead wire cap including a recess that covers the tip of the protruding portion of the lead wire segment coil. The lead wire cap may have a tapered surface configured to widen the opening width of the recess at a portion of the opening edge of the recess that is located radially inward of the stator core. When covering the protruding portion of the lead wire segment coil, such a lead wire cap can hold the protruding portion of the lead wire segment coil while separating the lead wire segment coil from the multiple segment coils.

[0009] The contact member may be configured to form a bending start point on the general wire segment coil among the plurality of segment coils, and may be configured to form the bending start point by contacting a side surface of a protruding portion of the general wire segment coil protruding from the slot from the circumferential direction of the stator core. In this stator manufacturing device, the contact member can have the function of forming the bending start point on both the lead wire segment coil and the general wire segment coil.

[0010] The stator manufacturing apparatus disclosed in this specification may further include a general wire holding part that holds the protruding portion of the general wire segment coil and is configured to be movable along the circumferential direction of the stator core relative to the abutting member. In this case, the lead wire holding part may have a lead wire cap including a recess that covers the protruding portion of the lead wire segment coil. The general wire holding part may have a general wire cap including a recess that covers the protruding portion of the general wire segment coil. The lead wire cap and the general wire cap may have a common shape. According to this stator manufacturing apparatus, the lead wire cap and the general wire cap can be used together, so that the manufacturing cost of the stator can be reduced. [Brief description of the drawings]

[0011] [Figure 1] FIG. 2 is a schematic perspective view of a stator; [Diagram 2] 1A to 1C are schematic perspective views of intermediate products in a process of manufacturing a stator; [Diagram 3] 1A to 1C are schematic perspective views of intermediate products in a process of manufacturing a stator; [Figure 4] 13 is a diagram illustrating a process for bending a protruding portion of a lead wire segment coil, and is a schematic cross-sectional view of a slot of a stator core cut along the radial direction of the stator core. FIG. [Diagram 5] 13 is a diagram illustrating a process for bending a protruding portion of a lead wire segment coil, and is a schematic cross-sectional view of a slot of a stator core cut along the radial direction of the stator core. FIG. [Figure 6] FIG. 2 is a schematic perspective view of a portion of a lead cap; [Figure 7] 13 is a diagram illustrating a process for bending a protruding portion of a lead wire segment coil, and is a schematic cross-sectional view of a slot of a stator core cut along the radial direction of the stator core. FIG. [Figure 8] 13 is a diagram showing a schematic view of a contact member contacting a protruding portion of a lead wire segment coil. FIG. [Figure 9] FIG. 4 is a schematic perspective view of a contact member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, a stator, which is a component of a rotating electric machine, will be described with reference to the drawings. For the purpose of clarity of illustration, the shapes of common components may be changed between different drawings, but components with the same reference numerals indicate the same components.

[0013] 1 shows a finished stator 1, and FIGS. 2 and 3 show intermediate products in the process of manufacturing the stator 1. The stator 1 includes a stator core 10 and a plurality of segment coils 20.

[0014] The stator core 10 is formed by stacking a plurality of laminated steel plates made of, for example, a magnetic material in the axial direction. The stator core 10 has an annular yoke portion 12, a plurality of teeth 14 extending radially inward from the inner peripheral surface of the yoke portion 12, and a rib 16 protruding radially outward from the outer peripheral surface of the yoke portion 12. A rotor (not shown) is inserted into the central hole of the yoke portion 12. Each of the plurality of teeth 14 extends from one opening edge of the yoke portion 12 to the other opening edge along the axial direction of the stator core 10, and is arranged at intervals from one another along the circumferential direction of the stator core 10. The spaces between adjacent teeth 14 are called slots 18. The ribs 16 are formed with bolt holes 19 configured to receive bolts for fixing the stator core 10 to a housing (not shown).

[0015] Each of the plurality of segment coils 20 is inserted into a corresponding one of the plurality of slots 18 of the stator core 10. Each of the plurality of segment coils 20 is a rectangular wire formed by coating the surface of a conductor with an insulator. As shown in FIG. 2, each of the plurality of segment coils 20 is formed into an approximately U-shape, and then inserted into the slot 18 of the stator core 10 along the axial direction of the stator core 10. As shown in FIG. 2 and FIG. 3, the portion of the two arm portions 22 of the segment coil 20 that protrudes from the slot 18 of the stator core 10 is called a protruding portion 24. The stator 1 is formed by inserting the approximately U-shaped segment coil 20 into the slot 18 of the stator core 10 and then bending the protruding portion 24 of the segment coil 20. The tip of the protruding portion 24 has a peeled portion where the insulator is removed and the conductor is exposed.

[0016] Here, as shown in FIG. 1, the multiple segment coils 20 include multiple general line segment coils 20A and three lead line segment coils 20B.

[0017] The general line segment coil 20A is a segment coil for forming a coil on the inner circumferential surface of the stator core 10. The protruding portion 24 of the general line segment coil 20A is bent in the circumferential direction of the stator core 10. The bent general line segment coils 20A are joined by welding at the peeled portions formed at the tip between the corresponding general line segment coils 20A. As a result, the protruding portions 24 of the general line segment coils 20A form a coil on the inner circumferential surface of the stator core 10. In this example, the U-phase coil group, the V-phase coil group, and the W-phase coil group are formed by distributed winding on the inner circumferential surface of the stator core 10. The general line segment coils 20A also include a connection line segment coil that connects coils of the same phase.

[0018] The lead wire segment coil 20B is a segment coil for providing lead wires corresponding to the U-phase coil group, the V-phase coil group, and the W-phase coil group. One arm portion 22 of the protruding portion 24 of the lead wire segment coil 20B is bent in the radial direction and the axial direction of the stator core 10. In this example, three lead wires 22U, 22V, and 22W are provided by the three lead wire segment coils 20B. The three lead wires 22U, 22V, and 22W are electrically connected to corresponding power lines among three power lines (U-phase power line, V-phase power line, and W-phase power line) extending from three connection terminals. For example, a power conversion device is connected to the three connection terminals.

[0019] Next, a method for bending the protruding portion 24 of the lead wire segment coil 20B will be described. Fig. 4 shows a state in which the U-shaped segment coil 20 is inserted into the slot 18 of the stator core 10. Within the slot 18 of the stator core 10, the lead wire segment coil 20B is inserted at the outermost position in the radial direction of the stator core 10, and the general wire segment coil 20A is inserted elsewhere.

[0020] 5, the lead wire cap 32 of the lead wire holding part 30 descends toward the lead wire segment coil 20B along the axial direction of the stator core 10, and holds the lead wire cap 32 of the lead wire holding part 30 so as to cover the tip of the protruding part 24 of the lead wire segment coil 20B. Here, the structure of the lead wire cap 32 of the lead wire holding part 30 will be described with reference to FIG.

[0021] The lead wire cap 32 has a fixed portion 33 and four walls 34, 35, 36, 37 standing from the fixed portion 33. The fixed portion 33 is a portion that is fixed to a moving device (not shown) via, for example, a fastener. This allows the lead wire cap 32 to move in accordance with the movement of the moving device. The four walls 34, 35, 36, 37 include a pair of thin walls 34, 35 that are arranged opposite to each other, and a pair of thick walls 36, 37 that are arranged opposite to each other. The thickness of the thin walls 34, 35 is smaller than the thickness of the thick walls 36, 37. The height of the pair of thick walls 36, 37 is greater than the height of the pair of thin walls 34, 35. The recess 38 defined by the four walls 34, 35, 36, 37 has a shape that corresponds to the tip of the protruding portion 24 of the lead wire segment coil 20B. The depth of the recess 38 defined by the four walls 34, 35, 36, and 37 is greater than the length of the peeled portion of the protruding portion 24 of the lead wire segment coil 20B where the conductor is exposed.

[0022] The pair of thin-walled portions 34, 35 are portions that face each other along the radial direction of the stator core 10 when covering the tip end of the protruding portion 24 of the lead wire segment coil 20B. Each of the pair of thin-walled portions 34, 35 has tapered surfaces 34T, 35T that are configured to widen the opening width at the opening edge of the recess 38. The tapered surfaces 34T, 35T are not particularly limited, but may be curved surfaces with a curvature radius of about 1 mm, for example. The tapered surface may be formed only on the thin-walled portion 34 of the pair of thin-walled portions 34, 35 that is located on the radial inner side of the stator core 10. The thickness of the thin-walled portions 34, 35 is not particularly limited, but may be, for example, about 1.2 mm to about 2.4 mm. When the pair of thin-wall portions 34, 35 have this type of shape, when the lead wire cap 32 covers the tip portion of the protrusion 24 of the lead wire segment coil 20B, it can cover the tip portion of the protrusion 24 of the lead wire segment coil 20B while expanding the space between it and the adjacent general wire segment coil 20A.

[0023] The pair of thick wall portions 36, 37 are portions that face each other in the circumferential direction of the stator core 10 when covering the tip end of the protrusion 24 of the lead wire segment coil 20B. Each of the pair of thick wall portions 36, 37 has tapered surfaces 36T, 37T configured to widen the opening width at the opening edge of the recess 38. The tapered surfaces 36T, 37T are not particularly limited, and may be configured as curved surfaces with a curvature radius of about 3 mm, for example.

[0024] Next, as shown in Fig. 7 and Fig. 8, the contact member 40 configured to form a bending starting point in the lead wire segment coil 20B is positioned to contact the side surface of the protruding portion 24 of the lead wire segment coil 20B. Note that, for the purpose of clarity, Fig. 8 illustrates only one lead wire segment coil 20B among the multiple segment coils 20. Here, the structure of the contact member 40 will be described with reference to Fig. 9.

[0025] The abutting member 40 has a base 42 and a pair of branches 44, 46 protruding from the base 42. When the abutting member 40 abuts against the lead wire segment coil 20B, the base 42 is a portion located on the yoke portion 12 of the stator core 10, and the pair of branches 44, 46 are portions located on the teeth 14 of the stator core 10. The base 42 of the abutting member 40 abuts against the side surface of the protruding portion 24 of the lead wire segment coil 20B from the radial outside of the stator core 10. In addition, the pair of branches 44, 46 of the abutting member 40 abut against the side surfaces of the protruding portions 24 of the general wire segment coil 20A and the lead wire segment coil 20B from the circumferential direction of the stator core 10.

[0026] As shown in FIG. 7, after the contact member 40 contacts the side of the protruding portion 24 of the lead wire segment coil 20B, the lead wire cap 32 moves relative to the contact member 40 while holding the lead wire segment coil 20B. The lead wire cap 32 moves radially outward of the stator core 10. Since the base 42 of the contact member 40 contacts the side of the protruding portion 24 of the lead wire segment coil 20B, the contact portion becomes the bending starting point, and the protruding portion 24 of the lead wire segment coil 20B is bent in the radial direction of the stator core 10. The lead wire cap 32 also moves in a direction approaching the stator core 10 along the axial direction of the stator core 10. The tip of the lead wire segment coil 20B covered by the lead wire cap 32 is bent in the axial direction of the stator core 10 while maintaining a state parallel to the axial direction of the stator core 10. In this manner, the protruding portion 24 of the lead wire segment coil 20B can be bent by moving the lead wire cap 32 relative to the contact member 40. This bending process can be applied, for example, to the vicinity of the position where the rib 16 (see FIG. 1, etc.) of the stator core 10 is present. Therefore, the lead wire segment coil 20B formed by this bending process can be disposed at a desired position without being affected by the position of the rib 16, and therefore has a high degree of design freedom with respect to the position.

[0027] In addition, the lead wire cap 32 is configured to be movable along the radial and axial directions of the stator core 10 relative to the abutting member 40 within the range of the stator core 10 when viewed from the axial direction of the stator core 10. As a result, the protruding portion 24 of the lead wire segment coil 20B formed by this bending process is bent so as to be positioned inside the outer circumferential surface of the stator core 10 in the radial direction of the stator core 10. Since the length of the lead wire segment coil 20B can be optimized within the range in which connection with the power line is permitted, the amount of coil used can be reduced. In addition, the protruding portion 24 of the bent lead wire segment coil 20B is coated with a thermosetting resin to ensure insulation. Since the protruding portion 24 of the lead wire segment coil 20B is positioned inside the outer circumferential surface of the stator core 10, the amount of resin used can be reduced.

[0028] In the above example, the protruding portion 24 of the lead wire segment coil 20B is bent in the radial and axial directions of the stator core 10. In addition, a support portion (not shown) that fixedly supports the stator core 10 may rotate the stator core 10 about its axis, so that the protruding portion 24 of the lead wire segment coil 20B may also be bent in the circumferential direction of the stator core 10. This allows the lead wire segment coil 20B to be disposed at any position within the stator 1, thereby providing high design freedom in terms of the position.

[0029] In the above example, a method for bending the protruding portion 24 of the lead wire segment coil 20B has been described. In order to manufacture the stator 1, it is necessary to bend the protruding portion 24 of the general wire segment coil 20A in the circumferential direction of the stator core 10 to form a coil. In order to bend the general wire segment coil 20A, a general wire cap having a common shape with the lead wire cap 32 described above can be used. In this example, a plurality of general wire caps are arranged in the radial and circumferential directions of the stator core 10, and similar to the lead wire cap 32, each of the plurality of general wire caps holds the general wire segment coil 20A by covering the tip of the protruding portion 24 of the corresponding general wire segment coil 20A. After holding the general wire segment coil 20A, the general wire cap moves in the circumferential direction of the stator core 10 to bend the protruding portion 24 of the general wire segment coil 20A in the circumferential direction of the stator core. By making the lead wire cap 32 and the general wire cap have a common shape, the lead wire cap 32 can be used as a general wire cap. Therefore, the bending process of the general wire segment coil 20A and the lead wire segment coil 20B can be performed using common manufacturing equipment, and the manufacturing cost of the stator 1 can be reduced. [Explanation of symbols]

[0030] 1: stator, 10: stator core, 12: yoke portion, 14: teeth, 16: ribs, 18: slots, 19: bolt holes, 20: segment coils, 20A: general line segment coils, 20B: lead line segment coils, 24: protrusions, 30: lead line retaining portions, 32: lead line caps, 40: contact members

Claims

1. A stator manufacturing apparatus comprising: A contact member configured to form a bending starting point in a lead wire segment coil among a plurality of segment coils inserted into the slots of a stator core, the contact member being configured to contact a side surface of a protruding portion of the lead wire segment coil protruding from the slot from the radial outside of the stator core to form the bending starting point; A stator manufacturing apparatus comprising: a lead wire holding portion that holds the protruding portion of the lead wire segment coil, the lead wire holding portion being configured to be movable along the radial and axial directions of the stator core relative to the abutment member.

2. 2. A stator manufacturing apparatus as described in claim 1, wherein the lead wire holding portion is configured to be movable along the radial and axial directions of the stator core relative to the abutment member within a range in which the stator core is present, when viewed from the axial direction of the stator core.

3. the lead wire holding portion has a lead wire cap including a recess that covers a tip end of the protruding portion of the lead wire segment coil, 2. A stator manufacturing apparatus as described in claim 1, wherein the lead wire cap has a tapered surface configured to widen the opening width of the recess at a portion of the opening edge of the recess that is located radially inward of the stator core.

4. 2. A stator manufacturing apparatus as described in claim 1, wherein the abutment member is configured to form a bending starting point on a general wire segment coil among the plurality of segment coils, and is configured to abut against a side surface of a protruding portion of the general wire segment coil protruding from the slot from the circumferential direction of the stator core to form the bending starting point.

5. A general wire holding portion that holds the protruding portion of the general wire segment coil and is configured to be movable along the circumferential direction of the stator core relative to the abutment member. the lead wire holding portion has a lead wire cap including a recess that covers a tip end of the protruding portion of the lead wire segment coil, The general wire holding portion has a general wire cap including a recess that covers a tip end of the protruding portion of the general wire segment coil, The stator manufacturing apparatus according to claim 4 , wherein the lead wire cap and the general wire cap have a common shape.

Images