Manufacturing method of stator, and stator jig

Abstract

To provide a manufacturing method of a stator capable of accurately inserting a segment coil while suppressing positional displacement of insulation paper, and a stator jig.SOLUTION: A manufacturing method of a stator includes: an insulation paper insertion step of inserting insulation paper into a slot in such a manner that a front end of the insulation paper protrudes from the slot; a guide part arrangement step of arranging, on teeth, guide parts which are movable in a radial direction of a stator core, while forming a cap by opposing them to each other in a circumferential direction of the stator core; an insulation paper expansion step of expanding an opening of the insulation paper by inserting a convex-shaped insertion tool, which is movable in a radial direction in the gap, into the opening of the front end of the insulation paper; and a segment coil insertion step of moving the insertion tool to the outside in the radial direction of the stator core toward an outer peripheral edge of the slot and inserting the segment coil into the slot while guiding the segment coil by the guide parts and the insertion tool.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a stator and a stator jig. [Background technology]

[0002] In recent years, a technique has been developed in which the opening at the tip of the insulating paper inserted into the slot of the stator core is enlarged to insert the segment coil into the slot while suppressing misalignment of the insulating paper.

[0003] For example, Patent Document 1 discloses a method for manufacturing a stator in which a pair of guide parts are moved circumferentially around the stator core while being abutted against the inside of the opening at the tip of the insulating paper, thereby expanding the opening at the tip of the insulating paper and inserting a segment coil into a slot. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2022-014828 Summary of the Invention [Problem to be solved by the invention]

[0005] In the stator manufacturing method disclosed in the above-mentioned Patent Document 1, the segment coil is guided between the guide surfaces of a pair of guide portions in the circumferential direction of the stator core, but there is a risk that the insertion of the segment coil may be misaligned in the radial direction and come into contact with the stator core.

[0006] The present disclosure has been made in consideration of the above circumstances, and provides a stator manufacturing method and a stator jig that enable segment coils to be inserted accurately while suppressing misalignment of the insulating paper. [Means for solving the problem]

[0007] A method for manufacturing a stator according to the present disclosure includes: A stator core; A segment coil is inserted into a slot formed between the teeth of the stator core; an insulating paper provided between the slot and the segment coil; A method for manufacturing a stator having the following features: an insulating paper inserting step of inserting the insulating paper into the slot so that a tip end of the insulating paper protrudes from the slot; a guide portion arranging step of arranging guide portions movable in a radial direction of the stator core so as to face each other in a circumferential direction of the stator core and to arrange the guide portions on the teeth while forming a gap; an insulating paper expanding step of expanding the opening of the insulating paper by inserting a convex-shaped insertion tool movable radially through the gap into the opening at the tip of the insulating paper; A segment coil insertion step of moving the insertion tool radially outward of the stator core toward an outer peripheral edge of the slot, and inserting the segment coil into the slot while guiding the segment coil with the guide portion and the insertion tool; Equipped with.

[0008] The method of manufacturing a stator according to the present disclosure expands the opening at the tip of the insulating paper, and the segment coil can be guided into the slot by the guide and the insertion tool. This makes it possible to manufacture a stator in which the segment coil is precisely inserted into the slot while preventing the insulating paper from shifting out of position.

[0009] The insertion tool may be inserted into the opening at the tip of the insulating paper so that the depth to which the insertion tool is inserted into the tip of the insulating paper is equal to or less than the length by which the tip of the insulating paper protrudes from the slot, and the length of the opening of the insulating paper in the circumferential direction of the stator core after expansion is equal to or greater than the length of the gap in the circumferential direction of the stator core. With this configuration, the opening at the tip of the insulating paper is appropriately expanded so that the segment coil can be inserted while suppressing misalignment of the insulating paper. Therefore, a stator can be manufactured in which the segment coil is precisely inserted into the slot.

[0010] The stator jig according to the present disclosure includes: A guide portion that is movable in a radial direction of the stator core; a protruding insertion tool provided between a slot formed between the teeth of the stator core and a segment coil to be inserted into the slot, the protruding insertion tool being inserted into an insulating paper having a tip protruding from the slot; A stator jig comprising: The guide portions are disposed on the teeth while forming a gap therebetween by arranging the guide portions opposite each other in a circumferential direction of the stator core, a protruding insertion tool that is movable radially through the gap is inserted into the opening at the tip of the insulating paper to expand the opening; The insertion tool is moved radially outward of the stator core toward the outer peripheral edge of the slot, and the segment coil is inserted into the slot while being guided by the guide portion and the insertion tool.

[0011] The stator jig according to the present disclosure expands the opening at the tip of the insulating paper and can guide the segment coil into the slot using the guide portion and the insertion tool, thereby enabling the segment coil to be inserted accurately into the slot while preventing the insulating paper from shifting out of position.

[0012] The insertion tool may have a convex shape such that the length of the opening in the insulating paper in the circumferential direction of the stator core after expansion is equal to or greater than the length of the gap in the circumferential direction of the stator core, and the depth to which the insertion tool is inserted into the tip of the insulating paper may be equal to or less than the length by which the tip of the insulating paper protrudes from the slot. With this configuration, the opening at the tip of the insulating paper is appropriately expanded so that the segment coil can be inserted while suppressing misalignment of the insulating paper. Therefore, the segment coil can be accurately inserted into the slot. Effect of the Invention

[0013] The present disclosure makes it possible to provide a stator manufacturing method and a stator jig that enable segment coils to be inserted accurately while suppressing misalignment of the insulating paper. [Brief description of the drawings]

[0014] [Figure 1] 1 is a perspective view of a stator manufactured by the stator jig and the stator manufacturing method according to embodiment 1. FIG. [Diagram 2] 1 is a diagram showing a configuration of a stator jig according to a first embodiment. [Diagram 3] 1 is a diagram showing a configuration of a stator jig according to a first embodiment. [Figure 4] 1 is a diagram showing a configuration of a stator jig according to a first embodiment. [Diagram 5] 13 is a diagram showing a state in which an insertion tool is inserted into an opening at a tip end of the insulating paper. FIG. [Figure 6] 4 is a flowchart illustrating a method for manufacturing the stator according to the first embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, the present disclosure will be described through the embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. In addition, all of the configurations described in the embodiments are not necessarily essential as means for solving the problems. For clarity of explanation, the following description and drawings are omitted and simplified as appropriate. In each drawing, the same elements are given the same reference numerals, and repeated explanations are omitted as necessary. Naturally, the right-handed xyz Cartesian coordinate system shown in the drawings is for the convenience of explaining the positional relationship of the components. Usually, the positive direction of the z axis is vertically upward, and the xy plane is a horizontal plane.

[0016] (Embodiment 1) <Stator> First, the stator will be described with reference to Fig. 1. Fig. 1 is a perspective view of a stator manufactured by the stator jig and the stator manufacturing method according to embodiment 1. The stator 10 shown in Fig. 1 is a stator after inserting a segment coil 12 and twisting and forming a coil end portion 15 by the stator jig and the stator manufacturing method according to embodiment 1.

[0017] As shown in Fig. 1, a stator 10, which is a stator of a rotating electric machine, has a stator core 11 and a plurality of segment coils 12. The stator core 11 is made of substantially cylindrical electromagnetic steel sheets laminated in the axial direction of the stator 10 (z-axis direction in Fig. 1), and is provided with teeth 16 protruding on the inner circumferential side and slots 13.

[0018] Slots 13 are formed between adjacent teeth 16. Slots 13 are recesses that extend from the inner peripheral surface of stator 10 toward the outer peripheral surface by a predetermined thickness. Stator core 11 has teeth 16 and slots 13 formed alternately in the circumferential direction of stator core 11. In the following, the circumferential direction refers to the circumferential direction of stator core 11, and is the direction indicated by the arrows in FIG. 1. Moreover, the radial direction refers to the direction from the outer periphery of stator core 11 toward the center of stator core 11, and is the direction indicated by the arrows in FIG. 1.

[0019] In the example shown in Fig. 1, two different segment coils 12 are joined at coil joints 14 at the ends of the conductor wires. A plurality of coil joints 14 are arranged in the circumferential direction at the coil end portions 15 of the segment coil 12.

[0020] 1, the coil end portions 15 are arranged in four rows in the radial direction, but it is preferable to arrange the segment coils 12 in accordance with the radial length of the slots 13. In order to join the segment coils 12 to each other, the coil joint portions 14 have their insulating coating removed, exposing the metal base.

[0021] <Configuration of stator jig> Next, the configuration of the stator jig will be described with reference to Fig. 2 to Fig. 4. Fig. 2 to Fig. 4 are drawings showing the configuration of the stator jig according to embodiment 1. In each drawing, a plan view (xy plan view) of the stator jig and the stator core is shown in the upper part, and a cross-sectional view (xz cross-sectional view) of the stator jig and the stator core is shown in the lower part. The stator jig is a jig for expanding the opening at the tip end of the insulating paper.

[0022] First, the insulating paper will be described. As shown in Figures 2 to 4, the insulating paper P1 is provided between the slot and the segment coil. As shown in the lower part of Figures 2 to 4, the leading end of the insulating paper P1 is provided so as to protrude from the slot 13. The dimensions of the insulating paper P1 will be described in detail later.

[0023] The insulating paper P1 is, for example, a sheet-like insulating member that can come into contact with the slot 13. The insulating paper P1 is intended to ensure insulation between the segment coil 12 inserted into the slot 13 and the slot 13 (stator core 11). The insulating paper P1 preferably contains an adhesive, such as a foamed adhesive resin, for fixing the segment coil 12 in its surface layer or internal layer, but may not contain an adhesive.

[0024] In the upper rows of Figures 2 to 4, the insulating paper P1 is indicated by dotted lines. Figure 2 shows the state before the opening at the tip of the insulating paper is expanded. Figure 3 shows the state after the opening at the tip of the insulating paper is expanded. Figure 4 shows the state in which the segment coil 12 is inserted into the insulating paper with the expanded opening at the tip.

[0025] Next, the configuration of the stator jig will be described. As shown in the upper part of Fig. 2, the stator jig is composed of a guide portion 21 and an insertion tool 22. The guide portion 21 is movable in the radial direction of the stator core 11. Similarly, the insertion tool 22 is also movable in the radial direction of the stator core 11. The guide portion 21 and the insertion tool 22 are independently movable in the radial direction.

[0026] Furthermore, the guide part 21 and the insertion tool 22 do not rise or fall in the z-axis direction, but move in the radial direction at a predetermined height. Figures 2 to 4 show states in which the insertion tool 22 is moved in the radial direction and is in a different position.

[0027] The insertion tool 22 will be described in detail. The insertion tool 22 is composed of a straight portion 32 and a protruding portion 42. The opening of the insulating paper is expanded by inserting the protruding portion 42 into the opening at the tip of the insulating paper. The dimensions of the insertion tool 22 will be described in detail later.

[0028] As shown in the upper parts of Figures 2 to 4, the guide parts 21 are arranged opposite each other in the circumferential direction of the stator core to form a gap SP1. The insertion tool 22 moves radially in the gap SP1 formed between the guide parts 21. The upper part of Figure 2 shows a state in which the insertion tool 22 is arranged radially outward. The upper part of Figure 3 shows a state in which the insertion tool 22 has been moved radially inward from the state in the upper part of Figure 2. The upper part of Figure 4 shows a state in which the insertion tool 22 has been moved radially outward from the state in the upper part of Figure 3 toward the outer circumferential edge of the slot 13.

[0029] As shown in the upper part of Figure 4, by moving and positioning the insertion tool 22 radially outward of the stator core toward the outer peripheral edge of the slot 13, the insertion tool 22 guides the segment coil 12 into the slot so as not to shift radially.

[0030] The guide portion 21 will be described in detail. As shown in the lower part of Fig. 3, the guide portion 21 is formed with a recess 31 so that the insulating paper P1 and the insertion tool 22 do not interfere with each other. The pair of guide portions 21 are formed so as to cover the insulating paper P1 and the insertion tool 22 with the recess 31. The guide portion 21 is not limited to the shape shown in Figs. 2 to 4, and may have any shape as long as the recess 31 is formed. In addition, the guide portions 21 may be arranged to face each other across the straight portion 32 of the insertion tool 22 without forming the recess 31 and without covering the insulating paper P1 and the insertion tool 22.

[0031] 4, the guide portion 21 is moved and positioned on the teeth 16 so that the segment coil 12 can be guided into the gap SP1 and the slot 13. That is, the guide portion 21 guides the segment coil 12 into the slot so that the circumferential direction of the segment coil 12 is not shifted.

[0032] 4, the guide portion 21 guides the segment coil so that the circumferential direction of the segment coil is not shifted, and the insertion tool 22 guides the segment coil so that the radial direction of the segment coil is not shifted. This allows the segment coil 12 to be inserted into the slot 13 accurately.

[0033] The guide part 21 and the insertion tool 22 have, for example, a cam mechanism (not shown), and can move in the radial direction by rotating a cam ring. Also, the stator core 11 can rise and fall in the axial direction (z-axis direction). Note that, naturally, the guide part 21, the insertion tool 22, and the stator core 11 can move independently of each other.

[0034] <Operation of the stator jig> 2 to 4, the operation of the stator jig will be described. First, as shown in the lower part of Fig. 2, the insulating paper P1 is inserted into the slot 13 so that the tip of the insulating paper P1 protrudes from the slot 13. For example, by inserting a blade (not shown) into the inside of the insulating paper P1 from the negative direction of the z axis, the insulating paper P1 is pushed up inside the slot 13, and the tip of the insulating paper P1 protrudes from the slot 13.

[0035] Next, as shown in the upper part of Fig. 2, the guide portions 21 are disposed facing each other in the circumferential direction of the stator core 11 to form a gap SP1, and are then disposed on the teeth 16. Also, as shown in the upper part of Fig. 2, the insertion tool 22 is disposed radially outside the stator core 11. More specifically, as shown in the upper part of Fig. 2, the insertion tool 22 is located above the stator core 11.

[0036] Next, as shown in the upper part of Fig. 3, the insertion tool 22 is moved from the state shown in the upper part of Fig. 2 to the radially inner side of the stator core 11. More specifically, as shown in the upper part of Fig. 3, the insertion tool 22 is positioned above the slot 13.

[0037] Now, as shown in the lower part of Fig. 3, the stator core 11 is raised in the positive direction of the z axis. This causes the insertion tool 22 to be inserted into the opening at the tip end of the insulating paper P1. More specifically, the protrusion 42 of the insertion tool 22 abuts against the opening at the tip end of the insulating paper P1, expanding the opening in the insulating paper. This causes the opening at the tip end of the insulating paper P1 to expand in the circumferential direction.

[0038] Next, as shown in the upper part of FIG. 4, the insertion tool 22 is moved and positioned radially outward of the stator core toward the outer peripheral edge of the slot 13. More specifically, while maintaining the expanded state of the opening of the insulating paper (lower part of FIG. 3), the insertion tool 22 is moved to the outer peripheral edge of the slot 13. This causes the opening at the tip of the insulating paper P1 to expand in the radial direction. With this configuration, the opening at the tip of the insulating paper P1 expands in the circumferential and radial directions, forming a cone shape. Then, as shown in the lower part of FIG. 4, the segment coil 12 is inserted into the slot 13.

[0039] 4, by moving the insertion tool 22 to the outer periphery of the slot 13, when inserting the segment coil 12, it is possible to prevent the insertion tool 22 from interfering with the segment coil 12. Furthermore, at the opening of the insulating paper P1, a force is generated to return to the state before expansion, but because the insertion tool 22 presses down on the opening of the insulating paper P1 with the outer periphery of the slot 13, it is possible to prevent the return to the state before expansion.

[0040] Furthermore, since the insertion tool 22 inserts the segment coil into the slot 13 while pressing down the opening of the insulating paper P1 with the outer edge of the slot 13, it is possible to prevent the insulating paper from shifting out of position or from being damaged, thereby preventing a decrease in insulation properties due to the insulating paper being damaged.

[0041] In this way, the stator jig according to the first embodiment can expand the opening at the tip of the insulating paper and guide the segment coil into the slot using the guide part and the insertion tool. Therefore, the segment coil can be accurately inserted into the slot while preventing the insulating paper from shifting out of position relative to the slot.

[0042] In addition, in the stator jig according to the first embodiment, the guide portion 21 and the insertion tool 22 can be moved independently in the radial direction, so the same stator jig can be used for a stator in which the slot position is shifted due to a change in the diameter of the stator core. In addition, since it is only necessary to prepare the guide portion 21 and the insertion tool 22, it is also possible to reduce equipment costs.

[0043] <Dimensions for stator jig> Next, the dimensions of the stator jig and the insulating paper will be described with reference to Fig. 5. Fig. 5 is a diagram showing a state in which the insertion tool is inserted into the opening at the tip end of the insulating paper.

[0044] The depth H1 to which the insertion tool is inserted into the tip of the insulating paper will be described. The depth H1 is equal to or less than the length H2 by which the tip of the insulating paper P1 protrudes from the slot. More specifically, the amount of lift of the stator core 11 is controlled so that the depth H1 becomes the length H2.

[0045] Next, the length W3 of the opening in the insulating paper in the circumferential direction of the stator core after expansion will be described. Length W3 is equal to or greater than length W4 of gap SP1 in the circumferential direction of the stator core. Since the width of the segment coil is less than length W4, the segment coil can be inserted into slot 13 when length W3 is equal to or greater than length W4.

[0046] In this way, when the insertion tool 22 is inserted into the opening in the insulating paper P1 so that the depth H1 is equal to or less than the length H2 and the length W3 is equal to or greater than the length W4, the opening at the tip of the insulating paper is appropriately expanded so that the segment coil can be inserted while suppressing misalignment of the insulating paper.

[0047] Even if the thickness or width of the segment coil 12 to be inserted into the slot 13 varies, by controlling the depth H1, i.e., the amount of lift of the stator core 11, the length W3 at the opening of the insulating paper P1 can be adjusted according to the shape of the segment coil 12. In other words, in the stator manufacturing method according to the first embodiment, even if the shape of the segment coil 12 to be inserted varies, it is possible to manufacture a stator in which the segment coil 12 is precisely inserted into the slot 13 while suppressing misalignment of the insulating paper P1.

[0048] Here, the insertion width W1 will be described. The insertion width W1 is the circumferential length of the end face of the protruding portion 42 of the insertion tool 22 on the insulating paper side. In order to insert the insertion tool 22 into the opening of the insulating paper P1, the insertion width W1 needs to be smaller than the width of the insulating paper P1 before it is expanded, i.e., the width W2. In the example shown in FIG. 5, the circumferential length of the straight portion 32 is also the same as the insertion width W1, but this is not limited thereto, and the circumferential length of the straight portion 32 may be larger or smaller than the insertion width. However, since the insertion tool 22 can move in the radial direction of the gap SP1, the circumferential length of the straight portion 32 is smaller than the length W4.

[0049] Here, the configuration has been described in which the guide portion 21 and the insertion tool 22 do not rise or fall in the z-axis direction, but the stator core 11 rises, so that the insertion tool 22 is inserted into the insulating paper. However, this is not limited to this, and the insertion tool 22 may be inserted into the insulating paper by the guide portion 21 and the insertion tool 22 rising and falling in the z-axis direction, without the stator core 11 rising or falling in the z-axis direction. In this case, the stroke of the insertion tool 22 is controlled to adjust the depth H1 and the length W3.

[0050] <Stator manufacturing method> Next, a method for manufacturing the stator according to the embodiment 1 will be described with reference to Fig. 6. Fig. 6 is a flow chart illustrating an example of the method for manufacturing the stator according to the embodiment 1. The description will be given with reference to Figs. 2 to 4 as appropriate.

[0051] First, the insulating paper is inserted into the slot (step ST1). More specifically, as shown in the lower part of Fig. 2, the insulating paper P1 is inserted into the slot 13 so that the leading end of the insulating paper P1 protrudes from the slot 13. Step ST1 is referred to as an insulating paper inserting step.

[0052] Next, the guide portions are arranged on the teeth (step ST2). More specifically, as shown in the lower part of Fig. 2, the guide portions 21, which are movable in the radial direction of the stator core 11, are arranged opposite each other in the circumferential direction of the stator core 11, so as to form a gap SP1 and are arranged on the teeth 16. Step ST2 is referred to as a guide portion arrangement step.

[0053] Next, the opening of the insulating paper is expanded (step ST3). More specifically, as shown in the lower part of Fig. 3, the insertion tool 22 is inserted into the opening at the tip of the insulating paper P1 to expand the opening of the insulating paper P1. Step ST3 is referred to as an insulating paper expanding step.

[0054] Next, the segment coil is inserted into the slot (step ST4). More specifically, as shown in the lower part of Fig. 4, the segment coil 12 is moved radially outward of the stator core 11 toward the outer periphery of the slot 13, and the segment coil 12 is inserted into the slot 13 while being guided by the guide portion 21 and the insertion tool 22. Step ST4 is referred to as a segment coil insertion step.

[0055] After the segment coil 12 is inserted in step ST4, the coil end portion 15 of the segment coil 12 is twisted to form the stator 10 shown in FIG.

[0056] In this way, the stator manufacturing method according to the first embodiment can expand the opening at the tip of the insulating paper and guide the segment coil into the slot using the guide and insertion tool. This makes it possible to manufacture a stator in which the segment coil is precisely inserted into the slot while suppressing misalignment of the insulating paper.

[0057] The present disclosure is not limited to the above-described embodiment, and may be modified as appropriate without departing from the spirit and scope of the present disclosure. [Explanation of symbols]

[0058] 10 Stator 11 Stator core 12 Segment coil 13 Slots 14 Coil joint 15 Coil end 16 Teeth 21 Guide section 22 Insertion Tool 31 Recess 32 Straight section 42 Convex H1 Depth H2, W3, W4 length P1 Insulating paper SP1 Gap W1 Insertion width W2 Width

Claims

1. A stator core; A segment coil is inserted into a slot formed between the teeth of the stator core; an insulating paper provided between the slot and the segment coil; A method for manufacturing a stator having the following features: an insulating paper inserting step of inserting the insulating paper into the slot so that a tip end of the insulating paper protrudes from the slot; a guide portion arranging step of arranging guide portions movable in a radial direction of the stator core so as to face each other in a circumferential direction of the stator core and to arrange the guide portions on the teeth while forming a gap; an insulating paper expanding step of expanding the opening of the insulating paper by inserting a convex-shaped insertion tool movable radially through the gap into the opening at the tip of the insulating paper; A segment coil insertion step of moving the insertion tool radially outward of the stator core toward the outer peripheral edge of the slot, and inserting the segment coil into the slot while guiding the segment coil with the guide portion and the insertion tool; A method for manufacturing a stator comprising the steps of:

2. In the insulating paper expanding step, a depth to which the insertion tool is inserted into the tip end of the insulating paper is equal to or less than a length by which the tip end of the insulating paper protrudes from the slot; so that the length of the opening in the insulating paper in the circumferential direction of the stator core after the expansion is equal to or greater than the length of the gap in the circumferential direction of the stator core, inserting the insertion tool into the opening at the tip end of the insulating paper; A method for manufacturing a stator according to claim 1 .

3. A guide portion that is movable in a radial direction of the stator core; a protruding insertion tool provided between a slot formed between the teeth of the stator core and a segment coil to be inserted into the slot, the protruding insertion tool being inserted into an insulating paper having a tip protruding from the slot; A stator jig comprising: The guide portions are disposed on the teeth while forming a gap therebetween by arranging the guide portions opposite each other in a circumferential direction of the stator core, a protruding insertion tool that is movable radially through the gap is inserted into the opening at the tip of the insulating paper to expand the opening; The insertion tool is moved radially outward of the stator core toward the outer peripheral edge of the slot, and the segment coil is inserted into the slot while being guided by the guide portion and the insertion tool. Stator fixture.

4. The insertion tool includes: the opening of the insulating paper after expansion has a convex shape such that the length in the circumferential direction of the stator core is equal to or greater than the length of the gap in the circumferential direction of the stator core, a depth to which the insertion tool is inserted into the tip end of the insulating paper is equal to or less than a length of the tip end of the insulating paper protruding from the slot; The stator jig according to claim 3 .

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