Manufacturing method of rotary electric machine and rotary electric machine

Abstract

To provide a manufacturing method of a rotary electric machine, which can protect a coil end, can simplify work and can improve environmental resistance of the coil after manufacture, and to provide the rotary electric machine.SOLUTION: A manufacturing method of a rotary electric machine 1 includes a step for forming a coating 19 of a self-repairing paint with self-repairing ability at a coil end 5 provided in a stator 3.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present embodiment relates to a method for manufacturing a rotating electric machine and a rotating electric machine. [Background technology]

[0002] For example, as disclosed in Patent Document 1, a rotating electric machine is manufactured by combining a plurality of parts, such as a stator, a rotor, a fan, and a bracket. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2022-109626 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in conventional manufacturing processes, protective equipment such as protective covers were attached to the coil ends until just before the assembly process to prevent them from being damaged during storage and transportation, requiring work to attach and remove the protective equipment.

[0005] Therefore, the present invention provides a manufacturing method for a rotating electric machine, which can protect the coil ends, simplify the work, and further improve the environmental resistance of the coils after manufacture, and a rotating electric machine. [Means for solving the problem]

[0006] A method for manufacturing a rotating electric machine according to an embodiment includes a step of forming a coating of a self-repairing paint having self-repairing ability on a coil end provided on a stator. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram showing a schematic configuration of a rotating electric machine according to a first embodiment; [Diagram 2] A schematic diagram showing the configuration of a stator [Diagram 3] Diagram explaining the manufacturing method [Figure 4] FIG. 13 is a schematic diagram showing the inside of a slot in a second embodiment; [Diagram 5] Diagram explaining the manufacturing method [Figure 6] Illustrative of another manufacturing method [Figure 7] FIG. 11 is a diagram for explaining a manufacturing method according to the third embodiment. [Figure 8] Illustrative of another manufacturing method [Figure 9] 1 is a diagram illustrating a manufacturing method according to another embodiment. [Figure 10] Illustrative of another manufacturing method DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] A number of embodiments will be described below, with parts that are substantially common to the embodiments being denoted by the same reference numerals.

[0009] (First embodiment) Hereinafter, an embodiment will be described with reference to the drawings. A rotating electric machine 1 shown as an example in Fig. 1 houses a stator 3 and a rotor 4 inside a case 2 formed in a hollow shape with both ends open. The stator 3 is fixed to the inner surface of the case 2, and coil ends 5 are formed at its ends in the left-right direction in the figure. In the following, the direction to the left and right in the figure along the central axis of rotation (J1) is referred to as the axial direction, the direction perpendicular to the axial direction is referred to as the radial direction, the right side in the figure is referred to as the load side, and the left side in the figure is referred to as the anti-load side.

[0010] The rotor 4 is disposed on the inner peripheral side of the stator 3 with a predetermined gap therebetween, and a shaft member 6 is attached to its center. The rotor 4 also has fins 7 formed by, for example, aluminum die casting so as to protrude in the axial direction at both axial ends. The shaft member 6 is rotatably supported at both ends by bearings 8, thereby allowing the rotor 4 to rotate relatively to the stator 3.

[0011] These bearings 8 are fixed to a load side bracket 9A and a counter-load side bracket 9B that close the openings on both ends of the case 2. For this reason, each bracket 9 is provided with a fixing portion 10 for fixing the bearings 8, which protrudes inward, that is, toward the rotor 4. In the case of this embodiment, the load side bracket 9A is formed with an accommodation space portion 11 for accommodating the coil end 5. For this reason, the end portion on the left side in the figure of the fixing portion 10 and the connection portion with the case 2 located radially outward from the coil end 5 are located to the left of the end portion of the coil end 5 in the figure after assembly. In addition, in the case of this embodiment, a cooling fan 12 and a fan cover 13 are provided on the outside of the counter-load side bracket 9.

[0012] As shown in Fig. 2, the stator 3 is composed of a stator core 14 made of laminated magnetic steel plates, and coils 16 inserted into a plurality of slots 15 provided on the inner periphery of the stator core 14. The coils 16 are formed by winding wires 17 (see Fig. 5) made of a thin conductor with an insulating coating such as enamel, and the coil ends 5 are formed by shaping the portions protruding from both ends of the stator core 14. Insulating paper 18 (see Fig. 5) is provided in the slots 15 to insulate the stator core 14 from the coils 16, and inter-phase insulating paper (not shown) is provided in the coil ends 5 to insulate the coils 16 of each phase. The coils 16 can also be formed from so-called rectangular wires or conductor bars.

[0013] A coating 19 of a self-repairing paint having self-repairing ability is formed on the coil end 5. In this embodiment, this coating 19 is formed in a manner that covers at least the surface of the coil end 5. This self-repairing paint is a paint that has the function of repairing scratches that occur on the surface of the coating 19 by itself over time, and generally recovering to the initial state when the coating 19 was formed.

[0014] In this embodiment, the self-repairing paint used is, for example, a type that has insulating properties and is mainly composed of urethane resin, and that hardens when irradiated with ultraviolet light after application. The method for applying the self-repairing paint can be appropriately selected according to the type of self-repairing paint, such as applying it with a brush or spray, or immersing the coil end 5 in stored self-repairing paint. The self-repairing paint is not limited to the above types, and any paint that has the required heat resistance and strength, such as a two-part paint that hardens by mixing or drying, may be appropriately used.

[0015] Next, the operation and effects of the above-mentioned configuration will be described. As described above, in the conventional manufacturing process, in order to prevent the coil ends 5 from being damaged during storage or transportation, protective equipment (not shown), such as a protective cover, is attached until just before the assembly process, which requires work to attach and remove the protective equipment. Therefore, in this embodiment, the rotating electric machine 1 is manufactured as follows.

[0016] 3 shows some of the steps involved in manufacturing the stator 3 in the manufacturing process of the rotating electric machine 1. First, the coils 16 are fitted into the slots 15 of the stator core 14 (S1), and then the coil ends 5 are formed (S2). Next, a coating 19 of self-repairing paint is formed on the coil ends 5 (S3). In this step S3, the work goes as far as hardening the self-repairing paint. Note that in actual manufacturing, it is considered that the coating 19 will be formed not only on the surfaces of the coil ends 5, but also partially inside the coil ends 5.

[0017] Then, when the self-repairing paint has hardened, the stator 3 is sent to the post-processing, which includes a number of assembly steps, such as attaching the stator 3 to the case 2, placing the rotor 4 together with the shaft member 6 on the inner periphery of the stator 3, and attaching the bracket 9 to the case 2.

[0018] That is, in the post-process, the coil ends 5 may be damaged when the coil ends 5 come into contact with the case 2 during attachment to the case 2, when the rotor 4 is positioned, the rotor 4 or the shaft member 6 comes into contact with the coil ends, or the fixing parts 10 and connection parts of the bracket 9 come into contact with the coil ends 5. Also, when the stator 3 is transported for transfer to the post-process or when the stator 3 is temporarily stored before the post-process, the coil ends 5 may be damaged due to carelessness or contact with a workbench, etc.

[0019] For this reason, in this embodiment, the coating 19 of the self-repairing paint is formed on the coil end 5 as described above. As a result, even if the coil end 5 is damaged, the self-repairing property of the coating 19 will repair the damage to approximately the same state as when it was formed. This makes it possible to protect the coil end 5 from damage caused by contact during storage, transportation, and assembly, and since the coating 19 is restored, it is possible to provide repeated protection, which is suitable for the rotating electric machine 1 that is manufactured through multiple processes after the formation of the coating 19. Furthermore, since the coating 19 is restored, no protective equipment is required for storage or transportation, and the installation and removal of the protective equipment is also unnecessary, making it possible to simplify the process, and the protection provided by the coating 19 makes it possible to improve insulation and environmental resistance.

[0020] According to the embodiment described above, the following effects can be obtained. The manufacturing method of the rotating electric machine 1 includes a process of forming a coating 19 of a self-repairing paint having self-repairing ability on the coil ends 5 provided on the stator 3. This makes it possible to protect the coil ends 5 from scratches caused by contact during storage, transportation, and the assembly process, while simplifying the work and further improving the environmental resistance and insulation of the coils 16 after manufacture.

[0021] The rotating electric machine 1 also includes a stator 3 having a coating 19 of self-repairing paint having self-repairing ability formed on the coil ends 5. With such a rotating electric machine 1, it is possible to obtain the same effects as those obtained by the manufacturing method described above.

[0022] Second embodiment The second embodiment will be described below. In the second embodiment, a method for protecting a portion mounted in the slot 15 will be described. Note that since the configuration of the rotating electric machine 1 and some of the manufacturing processes are common to the first embodiment, the description will also refer to Figs. 1 to 3.

[0023] As shown in Fig. 4, a coil 16 is disposed inside the slot 15. In this embodiment, the coil 16 is composed of a plurality of strands 17, and a plurality of spaces (S) exist between the strands 17 and on the opening side of the slot 15. If such spaces (S) exist, the coil 16 or strands 17 may move within the slot 15. The same applies when the coil 16 is formed from a rectangular wire or a conductor bar.

[0024] 5, for example, after mounting coil 16 (S1), forming coil end 5 (S2), and forming coating 19 of self-repairing paint on coil end 5 (S3), a step (S10) of filling slot 15 with the self-repairing paint can be further performed. In this case, coating 19 can be formed in step S3, and then step S10 can be performed, but steps S3 and S10 can also be combined to simultaneously form coating 19 of the self-repairing paint and fill slot 15.

[0025] In this way, both the manufacturing method including the step of filling the slots 15 with the self-repairing paint and the rotating electric machine 1 including the stator 3 in which the slots 15 are filled with the self-repairing paint can prevent the coils 16 and the wires 17 from moving inside the slots 15. Furthermore, since the coatings 19 of the self-repairing paint are formed between the wires 17 and on the opening sides of the slots 15, it is possible to prevent the wires 17 and the coils 16 from being damaged and also improve the environmental resistance after manufacturing.

[0026] 6, after mounting the coil 16 (S1), forming the coil end 5 (S2), and forming the coating 19 of self-repairing paint on the coil end 5 (S3), a step (S11) of filling the inside of the slot 15 with varnish can be further performed. Note that in step S11, the varnish is dried and hardened after filling.

[0027] In this way, both the manufacturing method including the step of filling the inside of the slots 15 with varnish and the rotating electric machine 1 including the stator 3 in which the inside of the slots 15 is filled with varnish can prevent the coils 16 and the wires 17 from moving inside the slots 15. In addition, since the varnish is filled between the wires 17 and on the opening sides of the slots 15, the wires 17 and the coils 16 can be prevented from being damaged.

[0028] Third embodiment Hereinafter, the third embodiment will be described. In the second embodiment, a method for protecting the coil end 5 will be described. Note that since the configuration of the rotating electric machine 1 and some of the manufacturing processes are common to the first embodiment, the description will be made with reference to Figs. 1 to 3.

[0029] The coil ends 5 need to be small in order to miniaturize the rotating electric machine 1, and at the same time, they need to be strong enough not to lose their shape or change position due to vibration in order to ensure insulation. Therefore, for example, as shown in Fig. 7, a process can be carried out in which the coil 16 is attached (S1), the coil ends 5 are formed (S2), a coating 19 of self-repairing paint is formed on the coil ends 5 (S3), and then the coil ends 5 are solidified with the self-repairing paint (S20).

[0030] This step S20 is a process of, so to speak, impregnating the coil ends 5 with the self-repair paint and hardening it. In other words, the coating 19 is formed at least on the surface of the coil ends 5, whereas solidification refers to the state in which the self-repair paint is filled and hardened up to the inside of the coil ends 5, where gaps exist between the wires 17 as shown in Fig. 4. Note that, since solidifying the coil ends 5 with the self-repair paint essentially forms a coating 19 of the self-repair paint on the coil ends 5, steps S3 and S20 can be performed simultaneously, or step 20 can be performed separately after performing step S3.

[0031] In this way, the manufacturing method including the step of solidifying the coil ends 5 with self-repairing paint, and the rotating electric machine 1 including the stator 3 with the coil ends 5 solidified with self-repairing paint, can prevent the coil ends 5 from losing their shape or changing their position. Of course, since the coil ends are essentially protected by the self-repairing paint, they can be prevented from being damaged and their environmental resistance after manufacturing can also be improved.

[0032] Alternatively, as shown in Fig. 8, after mounting coil 16 (S1), forming coil ends 5 (S2), and forming coating 19 of self-repairing paint on coil ends 5 (S3), a step of solidifying coil ends 5 with varnish (S21) can be performed. In this step S21, a step of impregnating coil ends 5 with varnish can be performed as in the conventional method. In this way, both the manufacturing method including the step of solidifying coil ends 5 with varnish and the rotating electric machine 1 including stator 3 with coil ends 5 solidified with varnish can prevent deformation or change in position of coil ends 5.

[0033] (Other embodiments) The process of forming a coating 19 of self-repair paint on the coil end 5, the process of filling the slot 15 with self-repair paint or varnish, and the process of solidifying the coil end 5 with self-repair paint or varnish described in each embodiment can be combined or their order changed as appropriate, provided that there is no contradiction.

[0034] 9, for example, the coil 16 is attached (S1), the coil end 5 is formed (S2), a coating 19 of self-repairing paint is formed on the coil end 5 (S3), the slot 15 is filled with the self-repairing paint (S10), and the coil end 5 is solidified with the self-repairing paint (S20). Note that steps S3, S10, and S20 can be performed simultaneously, or can be performed separately.

[0035] This manufacturing method, and also the rotating electric machine 1 having a stator 3 in which a coating 19 of self-repairing paint is formed on the coil ends 5, the inside of the slots 15 is filled with self-repairing paint, and the coil ends 5 are solidified with the self-repairing paint, can prevent the coil ends 5 from being damaged during assembly, simplify the assembly work, and further improve the environmental resistance and insulation of the coils 16 after manufacture.

[0036] 10, coils 16 can be attached (S1), coil ends 5 can be formed (S2), the coil ends 5 can be solidified with varnish (S21), and then coatings 19 of self-repairing paint can be formed on the coil ends 5 (S3). This manufacturing method, as well as a rotating electric machine 1 including a stator 3 in which the coil ends 5 are solidified with varnish and coatings 19 of self-repairing paint are formed on the coil ends 5, can prevent the coil ends 5 from being damaged during assembly, can simplify the work, and can improve the environmental resistance and insulation of the manufactured coils 16.

[0037] In addition, although the embodiment has been described as an example of forming a coating 19 of self-repairing paint on the coil end 5, the coating 19 of self-repairing paint can also be formed on the surface of the stator core 14 or on parts or structures provided inside the rotating electric machine 1, such as the fins 7. Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope and spirit of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0038] In the drawings, 1 denotes a rotating electric machine, 3 denotes a stator, 5 denotes a coil end, 15 denotes a slot, 16 denotes a coil, and 19 denotes a coating.

Claims

1. A manufacturing method for a rotating electric machine, comprising a step of forming a coating of a self-repairing paint having self-repairing ability on a coil end provided on a stator.

2. 2. The method for manufacturing a rotating electric machine according to claim 1, further comprising the step of filling the interior of the slot in which the coil is mounted with a self-repairing paint.

3. 2. The method for manufacturing a rotating electric machine according to claim 1, further comprising the step of filling the interiors of the slots in which the coils are mounted with varnish.

4. The method for manufacturing a rotating electric machine according to claim 1 , further comprising the step of solidifying the coil ends with varnish.

5. The method for manufacturing a rotating electric machine according to claim 1 , further comprising the step of solidifying the coil ends with a self-repairing paint.

6. A rotating electric machine having a stator with a self-repairing paint coating formed on the coil ends.

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