Manufacturing device for stator

Abstract

To provide a manufacturing device for a stator capable of effectively heating protrusions of a plurality of segment coils with induction heating.SOLUTION: A manufacturing device for a stator comprises: an induction heating coil including at least any one of an inner coil disposed in a hollow of a stator core and an outer coil disposed around the stator core; and a magnetic flux induction member. A plurality of segment coils include protrusions protruding from a slot of the stator core in an axial direction of the stator. At least a portion of the induction heating coil can be disposed at a position away from the stator core with respect to the protrusions of the plurality of segment coils in the axial direction of the stator core. The magnetic flux induction member can be disposed at a position where a magnetic flux generated around the induction heating coil is induced to the protrusions of the segment coils.SELECTED DRAWING: Figure 2

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 includes a hollow cylindrical stator core and a plurality of segment coils inserted into slots formed on the inner peripheral surface of the stator core. Thermosetting slot paper is used in the slots of the stator core to fix the stator core and the plurality of segment coils. Thermosetting resin is used to ensure insulation of the welded joints between the segment coils at the protruding parts of the plurality of segment coils protruding from the slots. An example of a technique for heating these thermosetting materials is disclosed in Patent Document 1. In the technique of Patent Document 1, the thermosetting material is heated by induction heating the stator core and electrically heating the plurality of segment coils. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2008-72825 A Summary of the Invention [Problem to be solved by the invention]

[0004] The technology of Patent Document 1 can heat the stator core by induction heating, but cannot effectively heat the protruding parts of the multiple segment coils. This specification provides a stator manufacturing device that can effectively heat the protruding parts of the multiple segment coils by induction heating. [Means for solving the problem]

[0005] The stator manufacturing apparatus disclosed in this specification is an apparatus for manufacturing a stator including a hollow cylindrical stator core and a plurality of segment coils inserted into slots formed on the inner peripheral surface of the stator core. The stator manufacturing apparatus may include an induction heating coil having at least one of an inner coil arranged in the hollow of the stator core and an outer coil arranged around the stator core, and a magnetic flux induction member. The plurality of segment coils have protruding portions protruding from the slots of the stator core in the axial direction of the stator. At least a part of the induction heating coil may be configured to be arranged at a position farther from the stator core in the axial direction of the stator core than the protruding portions of the plurality of segment coils. The magnetic flux induction member may be configured to be arranged at a position where the magnetic flux generated around the induction heating coil is guided to the protruding portions of the segment coils.

[0006] According to the above-mentioned manufacturing device for a stator, at least a part of the induction heating coil is disposed near the protruding portion of the plurality of segment coils. Furthermore, according to the above-mentioned manufacturing device for a stator, since the magnetic flux can be induced to the protruding portion of the plurality of segment coils by the magnetic flux induction member, the protruding portion of the plurality of segment coils is effectively induction heated. [Brief description of the drawings]

[0007] [Figure 1] FIG. 2 is a schematic perspective view of a stator; [Diagram 2] 1 is a schematic cross-sectional view of a stator in a state in which an induction heating coil and a magnetic flux guide member are disposed relative to the stator when the stator is induction heated; FIG. [Diagram 3] 3 is a diagram for explaining the flow of magnetic flux induced by a magnetic flux guide member in the cross-sectional view of FIG. 2. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, a stator, which is a component of a rotating electric machine, and a manufacturing apparatus for the stator will be described with reference to the drawings. For the purpose of clarity, the shapes of common components may be changed between different drawings, but components with common reference numerals indicate the same components.

[0009] As shown in FIG. 1, the stator 1 includes a stator core 10 and a plurality of segment coils 20.

[0010] 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 a yoke portion 12 that is a hollow cylindrical body, and a plurality of teeth 14 that extend radially inward from the inner 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 portion of the yoke portion 12 to the other opening edge portion along the axial direction of the stator core 10, and is arranged at intervals from each other along the circumferential direction of the stator core 10. The spaces between adjacent teeth 14 are called slots 16. The axial direction of the stator core 10 is indicated by the z-axis. One direction perpendicular to the z-axis is indicated by the x-axis, and a direction perpendicular to both the z-axis and the x-axis is indicated by the y-axis.

[0011] Each of the multiple segment coils 20 is inserted into a corresponding one of the multiple slots 16 of the stator core 10. Each of the multiple segment coils 20 is a rectangular wire formed by coating an insulator on the surface of a conductor (e.g., copper). Each of the multiple segment coils 20 has a first protruding portion 22 and a second protruding portion 24 protruding from the slot 16 of the stator core 10. The first protruding portion 22 is a portion of the segment coil 20 protruding from the slot 16 of the stator core 10 on one side in the axial direction of the stator core 10 (the upper surface side in this example). The second protruding portion 24 is a portion of the segment coil 20 protruding from the slot 16 of the stator core 10 on the other side in the axial direction of the stator core 10 (the lower surface side in this example). Each of the multiple segment coils 20 is formed into a substantially U-shape, and then inserted into the slots 16 of the stator core 10 along the axial direction of the stator core 10, and then formed by bending the first protrusions 22 of the segment coils 20. The tip of the first protrusion 22 of the bent segment coil 20 is welded to the tip of the first protrusion 22 of another bent segment coil 20. In this way, multiple coils are formed that are distributed around the inner circumferential surface of the stator core 10.

[0012] The stator core 10 and the multiple segment coils 20 are fixed with a thermosetting material (not shown). Specifically, the stator core 10 and the multiple segment coils 20 are fixed by interposing a thermosetting sheet paper between the stator core 10 and the multiple segment coils 20, and then heating the stator core 10 by induction heating to foam the sheet paper. In addition, in order to insulate the welded portion of the first protrusion 22 of the multiple segment coils 20 and to fix the protrusions 22, 24 of the multiple segment coils 20, the protrusions 22, 24 are hardened with a thermosetting material (not shown). Specifically, the protrusions 22, 24 of the multiple segment coils 20 are hardened by being heated by induction heating and solidifying the thermosetting resin.

[0013] 2 shows the state when the stator core 10 and the multiple segment coils 20 are induction heated. An inner coil 30 is disposed within the hollow space of the stator core 10. Furthermore, an outer coil 40 is disposed around the stator core 10. Both the inner coil 30 and the outer coil 40 are connected to a high-frequency power supply circuit (not shown). The inner coil 30 and the outer coil 40 are examples of induction heating coils.

[0014] A portion of the inner coil 30 (in this example, both ends indicated by "32" and "34") is configured so that it can be positioned in the axial direction of the stator core 10 farther from the stator core 10 than the protruding parts 22, 24 of the multiple segment coils 20, i.e., outside the protruding parts 22, 24 of the multiple segment coils 20. As a result, both ends 32, 34 of the inner coil 30 are positioned near the protruding parts 22, 24 of the multiple segment coils 20, and are positioned so that the magnetic flux generated around them affects the protruding parts 22, 24.

[0015] A portion of the outer coil 40 (in this example, both ends indicated by "42" and "44") is configured so that it can be positioned in the axial direction of the stator core 10 farther from the stator core 10 than the protruding parts 22, 24 of the multiple segment coils 20, i.e., outside the protruding parts 22, 24 of the multiple segment coils 20. As a result, both ends 42, 44 of the outer coil 40 are positioned near the protruding parts 22, 24 of the multiple segment coils 20, and are positioned so that the magnetic flux generated around them affects the protruding parts 22, 24.

[0016] A first magnetic flux induction member 50 is provided corresponding to the first protruding portion 22 of the plurality of segment coils 20, and a second magnetic flux induction member 60 is provided corresponding to the second protruding portion 24 of the plurality of segment coils 20. These magnetic flux induction members 50, 60 are made of a material capable of controlling the flow of magnetic flux, and may be, but are not limited to, a magnetic material such as ferrite, copper, or iron. Each of the magnetic flux induction members 50, 60 has a hollow cylindrical shape and is arranged side by side on the stator core 10 so that its axial center coincides with the axial center of the stator core 10.

[0017] The first magnetic flux induction member 50 is disposed between the end 32 of the inner coil 30 and the end 42 of the outer coil 40 in the radial direction of the stator core 10. The first magnetic flux induction member 50 extends in a loop along the first protruding portion 22 of the plurality of segment coils 20 between the end 32 of the inner coil 30 and the end 42 of the outer coil 40 when viewed from the axial direction of the stator core 10. At least a part of the first magnetic flux induction member 50 is disposed at a position overlapping with the first protruding portion 22 of the plurality of segment coils 20 when viewed from the axial direction of the stator core 10. In this example, the first magnetic flux induction member 50 is disposed at a position overlapping with the first protruding portion 22 of the plurality of segment coils 20 in its entirety when viewed from the axial direction of the stator core 10, that is, within the range of the first protruding portion 22 of the plurality of segment coils 20. Similarly, the second magnetic flux induction member 60 is disposed between the end 34 of the inner coil 30 and the end 44 of the outer coil 40 in the radial direction of the stator core 10. In addition, the second magnetic flux induction member 60 extends in a loop along the second protrusions 24 of the plurality of segment coils 20 between the end 34 of the inner coil 30 and the end 44 of the outer coil 40 when viewed in the axial direction of the stator core 10. At least a portion of the second magnetic flux induction member 60 is arranged at a position overlapping with the second protrusions 24 of the plurality of segment coils 20 when viewed in the axial direction of the stator core 10. In this example, when viewed in the axial direction of the stator core 10, the entire second magnetic flux induction member 60 is arranged at a position overlapping with the second protrusions 24 of the plurality of segment coils 20, that is, within the range of the second protrusions 24 of the plurality of segment coils 20.

[0018] As shown in FIG. 3, the magnetic flux generated around the inner coil 30 is shown around both ends 32, 34. Similarly, the magnetic flux generated around the outer coil 40 is shown around both ends 42, 44. The magnetic flux generated around both ends 32, 34 of the inner coil 30 passes along the inner circumferential surface of the magnetic flux induction members 50, 60 and is induced to penetrate the protruding parts 22, 24 of the multiple segment coils 20. The magnetic flux generated around both ends 42, 44 of the outer coil 40 passes along the outer circumferential surface of the magnetic flux induction members 50, 60 and is induced to penetrate the protruding parts 22, 24 of the multiple segment coils 20. As a result, many magnetic fluxes pass through the protruding parts 22, 24 of the multiple segment coils 20. As a result, the protruding parts 22, 24 of the multiple segment coils 20 are effectively heated by induction heating.

[0019] By using such a stator manufacturing device, both the thermosetting sheet paper between the stator core 10 and the multiple segment coils 20, and the thermosetting resin covering the protruding parts 22, 24 of the multiple segment coils 20 can be hardened by induction heating alone. Since only one heating source is required, the manufacturing cost of the stator can be reduced.

[0020] In the above example, both ends 32, 34 of the inner coil 30 and both ends 42, 44 of the outer coil 40 are configured to be positioned near the protruding parts 22, 24 of the multiple segment coils 20. Alternatively, only both ends of either the inner coil 30 or the outer coil 40 may be configured to be positioned near the protruding parts 22, 24 of the multiple segment coils 20. Even in this case, the magnetic flux passing through the protruding parts 22, 24 of the multiple segment coils 20 is increased, so that the protruding parts 22, 24 of the multiple segment coils 20 are effectively heated by induction heating. [Explanation of symbols]

[0021] 1: stator, 10: stator core, 12: yoke portion, 14: teeth, 16: slots, 20: segment coil, 22, 24: protrusions, 30: inner coil, 40: outer coil, 50, 60: magnetic flux induction member

Claims

[Claim 1] A manufacturing apparatus for a stator including a hollow cylindrical stator core and a plurality of segment coils inserted into slots formed on an inner peripheral surface of the stator core, an induction heating coil having at least one of an inner coil arranged in the hollow of the stator core and an outer coil arranged around the stator core; A magnetic flux guide member, The plurality of segment coils have protrusions protruding from the slots of the stator core in an axial direction of the stator, At least a portion of the induction heating coil is configured to be disposed at a position farther from the stator core in an axial direction of the stator core than the protruding portions of the plurality of segment coils, A stator manufacturing apparatus, wherein the magnetic flux induction member is configured to be positionable in a position so as to induce magnetic flux generated around the induction heating coil to the protrusion portion of the segment coil.

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