Manufacturing method of rotary electric machine, and rotary electric machine

Abstract

To provide a manufacturing method of a rotary electric machine, that is capable of suppressing a position displacement of an insulation paper sheet from being generated, and to provide the rotary electric machine thereof.SOLUTION: A manufacturing method of a rotary electric machine according to the present exposure comprises: a stator core 1 provided with a slot 1b passing therethrough along a rotation axis direction; and an insulation paper sheet 3 arranged on an inner-peripheral face of the slot 1b, and a first coil 21 and a second coil 22 that are inserted in the insulation paper sheet 3. The insulation paper sheet 3 is provided with a protrusion 3a protruding to a central axis Z1 of the slot 1b. A first conductor wire 21a is exposed from a first coating film 21b, and is inserted in a copper tube 4 at a tip of the first coil 21. A second conductor wire 22a is exposed from a second coating film 22b at a tip of the second coil 22. The manufacturing method comprises: a first step ST1 of inserting the first coil 21 and the copper tube 4 in the insulation paper sheet 3, from one side in the rotation axis direction; and a second step ST2 of inserting the second coil 22 in the insulation paper sheet 3, from the other side in the rotation axis direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a rotating electrical machine and a rotating electrical machine.

Background Art

[0002] The rotating electrical machine disclosed in Patent Document 1 has a stator core. The stator core has an annular outer peripheral side core and an inner peripheral side core provided on the radially inner side of the outer peripheral side core. The inner peripheral side core has a plurality of teeth arranged radially. Slots are provided between the teeth adjacent to each other in the circumferential direction of the stator. By pushing the radial insulating portion of the slot insulating paper in the inner circumferential direction with a plate-shaped insertion jig, the slot insulating paper is inserted into the slot. In the slot insulating paper, a protrusion protruding in the thickness direction of the radial insulating portion is provided on the radial insulating portion. Therefore, even if there is a difference in the frictional force received by the left and right circumferential insulating portions when the slot insulating paper is inserted into the slot, the slot insulating paper is less likely to be displaced, the insertion position of the slot insulating paper into the slot is stabilized, and the insulation quality can be improved.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The inventors of the present application have discovered the following technical problems. There is a rotating electrical machine in which, after inserting insulating paper into a slot, a coil is moved along the rotation axis direction of the stator and inserted into the slot. In such a rotating electrical machine, when the coil is inserted, the coil and the insulating paper may come into contact with each other, and there is a risk that the insulating paper may be displaced in the rotation axis direction.

[0005] The present disclosure has been made in view of the above-described problems, and provides a method for manufacturing a rotating electrical machine that suppresses the risk of displacement of insulating paper, and a rotating electrical machine.

Means for Solving the Problems

[0006] A method for manufacturing a rotating electrical machine according to the present disclosure is a stator core having slots penetrating along the rotation axis direction, insulating paper disposed on the inner peripheral surface of the slot, and first and second coils inserted into the insulating paper, and is a method for manufacturing a rotating electrical machine comprising: the insulating paper includes a convex portion protruding toward the central axis of the slot, the first coil includes a first conductor and a first coating covering the first conductor, at the tip of the first coil, the first conductor is exposed from the first coating and inserted into a copper tube, the second coil includes a second conductor and a second coating covering the second conductor, at the tip of the second coil, the second conductor is exposed from the second coating, a first step of inserting the first coil and the copper tube into the insulating paper from one side in the rotation axis direction, and a second step of inserting the second coil into the insulating paper from the other side in the rotation axis direction after performing the first step.

[0007] Further, in the method for manufacturing a rotating electrical machine described above, in the first step, the first coil and the copper tube may be inserted into the insulating paper, and the copper tube may be brought into contact with the convex portion.

[0008] Further, in the method for manufacturing a rotating electrical machine described above, in the second step, after performing the first step, by inserting the second coil into the insulating paper from the other side in the rotation axis direction, the second coating may be brought into contact with the convex portion.

[0009] Also, in the method for manufacturing the rotating electrical machine described above, in the second step, the second conductor may be inserted into the copper tube by inserting the second coil into the insulating paper from the other side in the rotating shaft direction, and the first and second conductors may be electrically connected via the copper tube.

[0010] The rotating electrical machine according to the present disclosure is a stator core having slots penetrating along the rotating shaft direction, insulating paper disposed on the inner peripheral surface of the slot, and a rotating electrical machine including first and second coils inserted into the insulating paper, wherein the insulating paper includes a convex portion protruding toward the central axis of the slot, the first coil includes a first conductor and a first coating covering the first conductor, at the tip of the first coil, the first conductor is exposed from the first coating and inserted into a copper tube, the second coil includes a second conductor and a second coating covering the second conductor, at the tip of the second coil, the second conductor is exposed from the second coating and inserted into the copper tube, the convex portion contacts the copper tube, the convex portion contacts the second coating, the first and second conductors are electrically connected via the copper tube.

Advantages of the Invention

[0011] According to the present disclosure, the risk of displacement of the insulating paper can be suppressed.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Mode for Carrying Out the Invention

[0013] Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings are simplified as appropriate.

[0014] <Embodiment 1> Embodiment 1 will be described with reference to FIGS. 1 to 3 and FIG. 6. FIG. 1 is a perspective view showing an example of a configuration of a stator according to Embodiment 1. FIG. 2 is a cross-sectional view taken along the cutting line II-II of an example of a configuration of the stator shown in FIG. 1. FIG. 3 is a schematic diagram showing a method for manufacturing a rotating electrical machine according to Embodiment 1. FIG. 6 is a schematic diagram showing another example of a configuration of the stator shown in FIG. 1.

[0015] Of course, the right-handed XYZ coordinates shown in FIG. 1 and other drawings are for convenience in explaining the positional relationship of the components. Usually, the positive Z-axis direction is vertically upward, the XY plane is a horizontal plane, and is common among the drawings.

[0016] (One configuration example) As shown in FIG. 1, the stator 10 includes a stator core 1, a coil 2, and an insulating paper 3.

[0017] The stator core 1 includes a core body 1a and a slot 1b. The core body 1a may be formed using, for example, electromagnetic steel sheets. The slot 1b penetrates the core body 1a along the rotation axis direction (here, the Z-axis direction). The slot 1b extends along the central axis Z1. The core body 1a according to the present embodiment has an opening 1c that opens on the front side of the paper surface (here, the negative Y-axis side). Further, the core body 1a according to the present embodiment extends in a substantially U shape when viewed from above (here, the Z-axis direction).

[0018] The insulating paper 3 is disposed on the inner peripheral surface of the slot 1b. The insulating paper 3 includes a convex portion 3a that protrudes toward the central axis Z1 of the slot 1b. The insulating paper 3 is, for example, a laminated sheet body including two non-woven fabrics sandwiching a resin film. The convex portion 3a may extend linearly on the main surface of the insulating paper 3 on the central axis Z1 side of the slot 1b.

[0019] The coil 2 is inserted into the insulating paper 3. As shown in FIG. 2, the coil 2 includes a first coil 21 and a second coil 22.

[0020] The first coil 21 includes a first conductor 21a and a first coating 21b. The first coating 21b covers the first conductor 21a. The first conductor 21a may be made of a material having electrical conductivity, for example, copper or a copper alloy. The first coating 21b may be made of a material having electrical insulation, for example, an enamel resin. At the tip of the first coil 21, the first conductor 21a is exposed from the first coating 21b. At the tip of the first coil 21, the first conductor 21a is inserted into the copper tube 4. The copper tube 4 is a hollow tube made of copper or a copper alloy. Both ends of the hollow tube are open.

[0021] The second coil 22 includes a second conductor 22a and a second coating 22b. The second coating 22b covers the second conductor 22a. The second coil 22 may have the same configuration as the first coil 21. Specifically, at the tip of the second coil 22, the second conductor 22a is exposed from the second coating 22b. At the tip of the second coil 22, the second conductor 22a is inserted into the copper tube 4.

[0022] When the insulating paper 3 is pushed upward, the convex portion 3a mechanically interferes with the copper tube 4. Therefore, the copper tube 4 stops the insulating paper 3. When the convex portion 3a contacts the copper tube 4, the copper tube 4 may further suppress the upward movement of the insulating paper 3. On the other hand, when the insulating paper 3 is pushed downward, the convex portion 3a mechanically interferes with the second coating 22b. Therefore, the second coil 22 stops the insulating paper 3. When the convex portion 3a contacts the second coating 22b, the second coil 22 may further suppress the downward movement of the insulating paper 3. That is, since the copper tube 4 and the second coil 22 sandwich the convex portion 3a, the position of the insulating paper 3 can be determined. The first lead wire 21a and the second lead wire 22a are electrically connected via the copper tube 4.

[0023] Note that the stator 10 according to the present embodiment is a split stator. As shown in FIG. 6, a plurality of stators 10 may be combined to form an annular stator 11. In FIG. 6, the illustration of the coil 2 and the insulating paper 3 is omitted. For example, the annular stator 11 may be manufactured by arranging a plurality of stators 10 annularly with the opening 1c inside in a cylindrical ring member 14. Further, a rotating electrical machine can be formed by combining the stator and the rotor.

[0024] (Manufacturing method) Next, with reference to FIG. 3, a method for manufacturing a rotating electrical machine according to Embodiment 1 will be described. FIG. 3 is a schematic diagram showing a method for manufacturing a rotating electrical machine according to Embodiment 1.

[0025] Prior to the first step ST1, at the tip of the first coil 21, the first lead wire 21a is inserted into the copper tube 4. The first lead wire 21a may be inserted into the copper tube 4 so that the tip of the first lead wire 21a reaches the middle of the copper tube 4.

[0026] Insert the first coil 21 and the copper tube 4 into the insulating paper 3 from one side in the direction of the rotation axis (first step ST1). When inserting the first coil 21 and the copper tube 4 into the insulating paper 3, it is advisable to bring the copper tube 4 into contact with the convex portion 3a. The copper tube 4 may push the convex portion 3a downward to move the insulating paper 3 to a predetermined position. When the first coil 21 and the copper tube 4 are inserted into the insulating paper 3, even if the insulating paper 3 is pushed upward, the convex portion 3a mechanically interferes with the copper tube 4.

[0027] Finally, insert the second coil 22 into the insulating paper 3 from the other side in the direction of the rotation axis (second step ST2). By inserting the second coil 22 into the insulating paper 3 from the other side in the direction of the rotation axis, it is advisable that the second lead wire 22a passes through the convex portion 3a and is inserted into the copper tube 4. Further, it is advisable to bring the second coating 22b into contact with the convex portion 3a. The second coil 22 may push the convex portion 3a upward to move the insulating paper 3 to a predetermined position. When the second coil 22 is inserted into the insulating paper 3, even if the insulating paper 3 is pushed downward, the convex portion 3a mechanically interferes with the second coating 22b. Also, insert the second lead wire 22a into the copper tube 4, and electrically connect the first lead wire 21a and the second lead wire 22a via the copper tube 4. Thereby, the first coil 21 and the second coil 22 are electrically connected, and the coil 2 has the function of a coil. The tip of the first lead wire 21a and the tip of the second lead wire 22a may be separated in the vertical direction.

[0028] As described above, a rotating electrical machine can be manufactured by attaching a rotor (not shown) to the stator 10.

[0029] According to the manufacturing method described above, even if the insulating paper 3 is pushed upward, the convex portion 3a mechanically interferes with the copper tube 4. Therefore, the copper tube 4 can stop the insulating paper 3 and hold the insulating paper 3 in a predetermined position. Thus, it is possible to suppress the possibility that the position of the insulating paper 3 is displaced due to the contact between the first coil 21 of the coil 2 and the insulating paper 3.

[0030] Further, according to the above manufacturing method, even if the insulating paper 3 is pushed downward, the convex portion 3a mechanically interferes with the second coating 22b. Therefore, the second coil 22 of the coil 2 can stop the insulating paper 3 and hold the insulating paper 3 at a predetermined position. Thus, it is possible to suppress the possibility that the insulating paper 3 is displaced due to the contact between the second coil 22 of the coil 2 and the insulating paper 3.

[0031] Next, with reference to FIG. 4, an example of a method for manufacturing the insulating paper 3 will be described. FIG. 4 is a schematic diagram showing an example of a process for manufacturing the rotating electrical machine shown in FIG. 3.

[0032] The insulating paper 30 is bent to form the convex portion 3a (step ST21). The insulating paper 30 is, for example, a single sheet body that has no creases and extends on a plane (here, the YZ plane). The convex portion 3a protrudes from the main surface of the insulating paper 30 (here, the YZ plane). The convex portion 3a extends linearly on the main surface of the insulating paper 30. The convex portion 3a extends along a substantially rectangular shape in its cross section (here, the ZX plane). The fold line of the insulating paper 30 in this step ST21 extends in the Y-axis direction.

[0033] Further, the insulating paper 30 is bent so that both ends of the convex portion 3a face each other (step ST22). The fold line of the insulating paper 30 in this step ST22 extends in the Z-axis direction. From the above, the insulating paper 3 can be manufactured.

[0034] Next, with reference to FIG. 5, an example of a method for manufacturing the insulating paper 13, which is a modified example of the insulating paper 3, will be described. FIG. 5 is a schematic diagram showing another example of a process for manufacturing the rotating electrical machine shown in FIG. 3.

[0035] Resin is partially applied to the insulating paper 30 to form the convex portion 3b (step ST31). The convex portion 3b protrudes from the main surface of the insulating paper 30. The convex portion 3a extends linearly on the main surface of the insulating paper 30. The cross-sectional shape of the convex portion 3b is, for example, a substantially rectangular shape. The fold line of the insulating paper 30 in this step ST31 extends in the Y-axis direction.

[0036] Further, the insulating paper 30 is bent so that both ends of the convex portion 3b face each other (step ST32). The fold line of the insulating paper 30 in this step ST32 extends in the Z-axis direction. Thus, the insulating paper 13 can be manufactured.

[0037] Note that the present invention is not limited to the above-described embodiments, and can be appropriately modified without departing from the gist thereof. Further, the present invention may be implemented by appropriately combining the above-described embodiments and examples thereof.

Explanation of Reference Numerals

[0038] 1 Stator core 1a Core body 1b Slot 1c Opening 2 Coil 21 First coil 21a First conductor 21b First coating 22 Second coil 22a Second conductor 22b Second coating 3, 13, 30 Insulating paper 3a, 3b Convex portion 4 Copper tube 10 Stator 11 Annular stator 14 Ring member Z1 Central axis

Claims

1. A method for manufacturing a rotating electrical machine, comprising: a stator core having a slot penetrating along a rotation axis direction; insulating paper disposed on an inner circumferential surface of the slot; and first and second coils inserted into the insulating paper, wherein the insulating paper includes a convex portion protruding toward a central axis of the slot, the first coil includes a first conductor and a first coating covering the first conductor, at a tip of the first coil, the first conductor is exposed from the first coating and inserted into a copper tube, the second coil includes a second conductor and a second coating covering the second conductor, at a tip of the second coil, the second conductor is exposed from the second coating, a first step of inserting the first coil and the copper tube into the insulating paper from one side in the rotation axis direction, and a second step of inserting the second coil into the insulating paper from the other side in the rotation axis direction after performing the first step. A method for manufacturing a rotating electrical machine.

2. In the first step, the first coil and the copper tube are inserted into the insulating paper, and the copper tube is brought into contact with the convex portion. The method for manufacturing a rotating electrical machine according to Claim 1.

3. In the second step, after performing the first step, the second coil is inserted into the insulating paper from the other side in the rotation axis direction, so that the second coating is brought into contact with the convex portion. The method for manufacturing a rotating electrical machine according to Claim 1 or 2.

4. In the second step, the second coil is inserted into the insulating paper from the other side in the rotation axis direction, so that the second conductor is inserted into the copper tube, and the first and second conductors are electrically connected via the copper tube. The method for manufacturing a rotating electrical machine according to Claim 1 or 2.

5. A rotating electrical machine, comprising: a stator core having a slot penetrating along a rotation axis direction; insulating paper disposed on an inner circumferential surface of the slot; and first and second coils inserted into the insulating paper, wherein the insulating paper includes a convex portion protruding toward a central axis of the slot, the first coil includes a first conductor and a first coating covering the first conductor, at a tip of the first coil, the first conductor is exposed from the first coating and inserted into a copper tube, the second coil includes a second conductor and a second coating covering the second conductor, at a tip of the second coil, the second conductor is exposed from the second coating and inserted into the copper tube. ​ ​ ​ ​ The convex portion contacts the copper tube, The convex portion contacts the second coating, The first and second conductors are electrically connected via the copper tube, Rotating electrical machine.

Images