Manufacturing method of coil

Abstract

To provide a manufacturing method of a coil, which can suppress a damage of a coat of the coil.SOLUTION: A manufacturing method of a coil comprises: a first process of coupling first coils with one end of a coupling member; and a second process of inserting a plurality of first coils with which the coupling member is coupled, and a plurality of second coils into a slot of a stator core and coupling the second coils with the other end of the coupling member coupled with the first coils, and when insertion directions of two first coils adjacent to each other to be inserted into the slot are different from each other, the total of insertion amounts of the two first coils adjacent to each other to be inserted into the slot is shorter than the entire length of the slot in the second process.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a coil. [Background technology]

[0002] Patent Document 1 discloses a technique for ensuring insulation between coils by arranging radially adjacent connecting members that connect coils in slots of a stator core with each other so as to be shifted in the axial direction. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 7003674 Summary of the Invention [Problem to be solved by the invention]

[0004] In the technique disclosed in Patent Document 1, there is a risk that the coil may come into contact with adjacent connecting members during coil manufacturing, causing damage (peeling off) to the coating of the coil.

[0005] The present disclosure has been made in consideration of the above, and aims to provide a coil manufacturing method that can suppress damage to the coil coating. [Means for solving the problem]

[0006] The coil manufacturing method of the present disclosure includes a first step of connecting a first coil to one end of a connecting member, and a second step of inserting a plurality of the first coils connected to the connecting member and a plurality of second coils into slots of a stator core, and connecting the second coils to the other end of the connecting member connected to the first coils, wherein in the second step, when the insertion directions of two adjacent first coils inserted into the slots are different, the total insertion amount of the two adjacent first coils inserted into the slot is shorter than the total length of the slot. Effect of the Invention

[0007] According to the present disclosure, damage to the coil coating can be suppressed. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram for explaining a first connection step of the manufacturing method of the coil according to the embodiment. [Diagram 2] FIG. 2 is a diagram for explaining a coil forming step of the coil manufacturing method according to the embodiment. [Diagram 3] FIG. 3 is a view for explaining a second connecting step in the manufacturing method of the coil according to the embodiment. [Figure 4] FIG. 4 is a diagram showing an example of a coil manufactured by the coil manufacturing method according to the embodiment. [Diagram 5] FIG. 5 is a diagram for explaining the relationship between the total insertion amount of two coils and the total length of the slot in the second connecting step of the coil manufacturing method according to the embodiment. [Figure 6] FIG. 6 is a diagram for explaining the relationship between the total insertion amount of two coils and the total length of the slot in the second connecting step of the coil manufacturing method according to the embodiment. [Figure 7] FIG. 7 is a diagram for explaining the relationship between the total insertion amount of two coils and the total length of the slot in the second connecting step of the coil manufacturing method according to the embodiment. [Figure 8] FIG. 8 is a diagram for explaining the relationship between the total insertion amount of two coils and the total length of the slot in the second connecting step of the coil manufacturing method according to the embodiment. [Figure 9] FIG. 9 is a diagram showing another example of a coil manufactured by the coil manufacturing method according to the embodiment. [Figure 10] FIG. 10 is a diagram showing another example of a coil manufactured by the coil manufacturing method according to the embodiment. [Figure 11] FIG. 11 is a diagram showing another example of a coil manufactured by the coil manufacturing method according to the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] A method for manufacturing a coil according to an embodiment of the present disclosure will be described with reference to the drawings. Note that the components in the following embodiments include those that are easily replaceable by a person skilled in the art, or those that are substantially the same.

[0010] A method for manufacturing a coil according to an embodiment will be described with reference to Figs. 1 to 4. The method for manufacturing a coil according to an embodiment is a method for manufacturing a coil (stator coil) used in, for example, an assembled stator. The method for manufacturing a coil according to an embodiment includes a first connecting step (first step), a coil forming step, and a second connecting step (second step). Each step of the method for manufacturing a coil according to an embodiment will be described in detail below.

[0011] (First connection process) In the first connecting step, as shown in Fig. 1, a coil 2 is connected to one end of a connecting member 1. The connecting member 1 is, for example, a hollow copper tube. The coil 2 is made of plate-like aluminum or the like, and has a coating (insulating coating) formed on its surface. Note that no coating is formed on the portion of the coil 2 connected to one end of the connecting member 1, and the conductor is exposed (see exposed conductor portion 31 in Fig. 3 described later).

[0012] (Coil forming process) In the coil forming process, the coil 2 is formed into a segment coil shape as shown in (a) and (b) of Figure 2. In this coil forming process, the coil 2 is formed so that the connecting member 1 is located on the side where the leg of the coil 2 is shorter.

[0013] (Second connection process) 3, in the second connecting step, a plurality of coils (first coils) 2 connected with connecting members 1 and a plurality of coils (second coils) 3 are inserted into slots of a stator core, and coil 3 is connected to the other end of connecting member 1 connected to coil 2. Coil 3 is a coil to which connecting member 1 is not connected, and includes exposed conductor portion 31 on which no coating is formed.

[0014] In Fig. 3, the up-down direction of the paper is the axial direction of the stator core, the left-right direction of the paper is the radial direction of the stator core, and the depth direction of the paper is the circumferential direction of the stator core. Also, the stator core and the slots of the stator core are not shown in the figure.

[0015] In the second connecting step, specifically, as shown in Fig. 3, a coil group (first coil group) 4 in which a plurality of coils 2 and a plurality of coils 3 are combined is inserted into the slot from a first direction. Also, a coil group (second coil group) 5 in which a plurality of coils 2 and a plurality of coils 3 are combined is inserted into the slot from a second direction opposite to the first direction. As a result, the conductor exposed portions 31 of the coils 3 are each connected to the other end of the connecting member 1 connected to the plurality of coils 2, as shown in Fig. 4.

[0016] In the second connecting step, the coil groups 4 and 5 are inserted into the same slot (one slot) of the stator core. That is, in the example of Fig. 3, the coil group 4 in which the coils 2 and 3 are alternately combined in groups of three in the radial direction of the stator core and the coil group 5 in which the coils 2 and 3 are alternately combined in groups of three in the radial direction of the stator core are inserted into the same slot from different directions.

[0017] Furthermore, in the second connecting step, when the insertion directions of two adjacent coils 2 inserted into a slot are different, the sum A+B of the insertion amounts of the two adjacent coils 2 inserted into the slot is made shorter than the overall length C of the slot, as shown in FIG. 4. Note that "two adjacent coils 2" refers to two coils 2 arranged adjacent to each other in the radial direction of the stator core in the same slot. The insertion amounts A and B of the coils 2 may also be lengths including the connecting member 1. Below, the relationship between the sum of the insertion amounts of the two coils 2 and the overall length of the slot will be described in detail with reference to FIGS. 5 to 8.

[0018] 5 to 8 show some of the coils 2, 3 to be inserted into one slot 61 of the stator core 6 in the second connecting step. Unlike the above-mentioned Figs. 1 to 4, these figures do not show actual steps of the manufacturing method of the coil according to the embodiment.

[0019] For example, as shown in Fig. 5, a coil 2 connected to a connecting member 1 is inserted into a slot 61 of a stator core 6 from a first direction. In this case, as shown in Fig. 6, a coil 3 not connected to a connecting member 1 is inserted into the slot 61 from a second direction, so that the coils 2 and 3 are connected within the slot 61.

[0020] On the other hand, as shown in Fig. 7, it is assumed that the coil 2 connected with the connecting member 1 is inserted from the second direction next to (at a position adjacent in the radial direction of the stator core) the coils 2, 3 inserted into the slot 61 in Fig. 5 and Fig. 6. In this case, as shown in Fig. 8, the coil 3 not connected with the connecting member 1 is inserted into the slot 61 from the first direction, so that the coils 2 and 3 are connected within the slot 61.

[0021] In this way, when the insertion directions of two adjacent coils 2 in the slot 61 are different, the sum A+B of the insertion amount A of the first coil 2 and the insertion amount B of the second coil 2 is made shorter than the overall length C of the slot 61. In other words, the relationship "insertion amount A+B of the coil 2<overall length C of the slot 61" is satisfied.

[0022] Here, "insertion amount A+B of coil 2<total length C of slot 61" means, in other words, that in the second connecting step, the connecting members 1 of two radially adjacent coils 2 do not pass each other and the positions of the two connecting members 1 are separated in the axial direction. Note that insertion amounts A and B of coil 2 may be lengths including the connecting members 1.

[0023] For example, when "insertion amount A+B of coil 2 = total length C of slot 61," the positions of two radially adjacent connecting members 1 coincide in the axial direction, i.e., the two connecting members 1 are lined up side by side in the radial direction. In this case, in the second connecting step, the adjacent connecting members 1 and the coils 2, 3 may come into contact with each other, damaging the coatings of the coils 2, 3. Furthermore, since the conductor exposed portions 31 of the coil 3 are lined up side by side in the radial direction (the axial positions of the conductor exposed portions 31 coincide), there is a risk that insulation between the coils 2, 3 cannot be ensured.

[0024] Furthermore, when "the insertion amount A+B of the coil 2 is greater than the total length C of the slot 61," two radially adjacent connecting members 1 pass each other in the second connecting step. Therefore, the adjacent connecting members 1 and the coils 2, 3 may come into contact with each other, which may damage the coatings of the coils 2, 3.

[0025] Meanwhile, in the second connecting step of the coil manufacturing method according to the embodiment, by setting "insertion amount A+B of coil 2<total length C of slot 61", two radially adjacent connecting members 1 do not pass each other in the second connecting step. Therefore, adjacent connecting members 1 and coils 2, 3 do not come into contact with each other, and damage to the coatings of coils 2, 3 can be suppressed. Furthermore, since the conductor exposed portions 31 of coil 3 are not aligned horizontally in the radial direction (the axial positions of the conductor exposed portions 31 do not match), insulation between coils 2, 3 can be ensured.

[0026] Here, Fig. 4 mentioned above is an example of a coil manufactured by the coil manufacturing method according to the embodiment, but the present invention is not limited to this example as long as the condition "insertion amount A+B of coil 2<total length C of slot 61" is satisfied. For example, by changing the insertion amount of coil 2 into slot 61 from that shown in Fig. 4, coils as shown in Figs. 9 to 11 may be manufactured. All of the coils shown in the figures satisfy the condition "insertion amount A+B of coil 2<total length C of slot 61".

[0027] According to the coil manufacturing method of the embodiment described above, damage to the coatings of the coils 2 and 3 can be suppressed by making "insertion amount A+B of the coil 2<total length C of the slot 61".

[0028] That is, in an assembled stator, since an exposed conductor portion of the coil (e.g., exposed conductor portion 31) exists in slot 61, ensuring insulation of the exposed conductor portion becomes an issue. Therefore, as shown in Fig. 4, the position of connecting member 1 covering the exposed conductor portion is shifted in the axial direction to ensure insulation.

[0029] On the other hand, if the position of the connecting member 1 is simply shifted in the axial direction, the connecting members 1 may pass each other in the second connecting step, which may damage the coating of the adjacent coils 2, 3. Therefore, in the coil manufacturing method according to the embodiment, as shown in Fig. 2, the connecting member 1 is provided on the side of the coil 2 with a shorter leg. This prevents the connecting members 1 from passing each other in the second connecting step, thereby suppressing damage to the coating of the coils 2, 3.

[0030] Further advantages and modifications may readily occur to those skilled in the art. Thus, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described above. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and equivalents thereof. [Explanation of symbols]

[0031] 1 Connecting member 2 Coil (First Coil) 3 Coil (Second Coil) 31 Exposed conductor 4 Coil group (first coil group) 5 Coil group (second coil group) 6 Stator core 61 Slots

Claims

[Claim 1] a first step of connecting a first coil to one end of a connecting member; a second step of inserting the first coils and the second coils connected by the connecting member into slots of a stator core, and connecting the second coils to the other end of the connecting member connected to the first coils; Including, In the second step, when the insertion directions of the two adjacent first coils inserted into the slot are different, a total insertion amount of the two adjacent first coils inserted into the slot is shorter than a total length of the slot. How coils are manufactured.

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