Stator and method for manufacturing the same

Abstract

To solve a problem of a defective portion of an adhesive that is easily generated between conductor segments on one side and the other side in a conventional stator, which is desired to be improved.SOLUTION: A stator S includes: a stator core 1 having slots 1A at predetermined intervals in a circumferential direction; and first and second rectangular wires S1 and S2 bent in a U-shape, and having a structure in which the first and second rectangular wires S1 and S2 are inserted into respective selected slots 1A from both sides in an axial direction of the stator core 1. With the stator, the first and second rectangular wires S1 and S2 have an insulating coating material 2 extending over an outer periphery of each end portion and a solder joint portion 3 interposed between end surfaces, and the end portions are joined to each other in the slot 1A. High quality is achieved in the joint portion of the rectangular wires S1 and S2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a stator used in a rotating electrical machine such as a motor or a generator, and a method for manufacturing the same. [Background technology]

[0002] An example of a conventional stator is described in Patent Document 1. Patent Document 1 describes a stator including a stator core having a plurality of slots, one-side conductor segments having first and second legs inserted into the first and second slots from one axial end side of the stator core, and another-side conductor segments having the first and second legs inserted into the first and second slots from the other axial end side of the stator core.

[0003] In the above-mentioned stator, the conductor segments on one side and the other side form recesses and protrusions that engage with each other between the ends of the first leg and the second leg, and adhesive is interposed between them.The conductor segments on one side and the other side are pressed against each other and heated, causing the adhesive to protrude outward and joining the two sides. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5962607 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the conventional stators described above, the adhesive is allowed to protrude outward to seal the gap between the coatings of the conductor segments on one side and the other side and join them together, which makes it easy for the adhesive to become missing, posing the risk of reduced insulation and the occurrence of voids, and so improvements were desired.

[0006] The present invention has been made in consideration of the above-mentioned conventional situation, and aims to provide a stator and a manufacturing method thereof that can achieve high quality in the joint between the flat wires in a stator in which the first and second flat wires for forming the coil are joined within the slot. [Means for solving the problem]

[0007] The stator according to the present invention comprises a stator core having slots at predetermined intervals in the circumferential direction, and first and second U-shaped bent rectangular wires, which are inserted into selected slots from both axial sides of the stator core. The stator is characterized in that the first and second rectangular wires have an insulating coating material that spans the outer peripheries of their ends and a solder joint between their end faces, and the ends are joined together within the slots.

[0008] The manufacturing method of the stator according to the present invention is a method for manufacturing a stator having a structure in which a stator core has slots at predetermined intervals in the circumferential direction, and first and second U-shaped bent flat wires are inserted into selected slots from both sides of the axial direction of the stator core.The manufacturing method is characterized by the following: at least one of the first and second flat wires is provided with an insulating coating material that protrudes toward the other flat wire and has self-adhesive properties on the outer periphery of the end of the first and second flat wires, then a recess is formed on the end face of at least one of the first and second flat wires, solder material is placed in the recess, and the first and second flat wires are inserted into the slots, and their ends are butted together, so that the insulating coating material is formed across the outer periphery of their ends, and then the first and second flat wires are heated to melt the solder material to form a solder joint between their end faces, and the ends of the first and second flat wires are joined together. [Effects of the Invention]

[0009] The stator of the present invention adopts the above-mentioned configuration, so that the insulating coating material ensures good insulation between the ends of the first and second flat wires, while the solder joints allow the flat wires to be reliably joined together, thereby achieving high-quality joints between the flat wires.

[0010] The stator manufacturing method of the present invention adopts the above-mentioned configuration, so that the insulating coating material can prevent leakage of the heated and melted solder material, and the solder joint can reliably join the flat wires together while ensuring good insulation between the ends of the first and second flat wires, thereby providing a stator with a high-quality joint between the flat wires. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a cross-sectional view of a main part showing a first embodiment of a stator according to the present invention. [Figure 2] FIG. [Figure 3] FIG. [Figure 4] FIG. 10 is an explanatory diagram showing an example of a process for joining rectangular wires together. [Figure 5] 10A and 10B are explanatory diagrams showing another example of a process for joining rectangular wires together. [Figure 6] 10A and 10B are explanatory diagrams showing the joining process of rectangular wires in a stator core, respectively. [Figure 7] FIG. 10 is a plan view showing a second embodiment of the stator. [Figure 8] This is a perspective view of a bus bar (left figure) and a perspective view of a bus bar and a rectangular wire (right figure). [Figure 9] 10 is a diagram showing a third embodiment of the stator, and is a perspective view of a neutral bus bar (left figure) and a perspective view of the neutral bus bar and a rectangular wire (right figure). FIG. [Figure 10] 10A and 10B are diagrams showing a fourth embodiment of the stator, and are cross-sectional views showing two examples of the arrangement of rectangular wires in slots on the left and right. DETAILED DESCRIPTION OF THE INVENTION

[0012] First Embodiment 1 to 6 are diagrams illustrating a first embodiment of a stator and a manufacturing method thereof according to the present invention, and in particular, FIGS. 4 to 6 show the manufacturing process of the stator.

[0013] 1 to 3 includes a stator core 1 having slots 1A at predetermined intervals in the circumferential direction, and a first rectangular wire S1 and a second rectangular wire S2 bent into a U-shape. This stator S has a structure in which the first and second rectangular wires S1 and S2 are inserted into selected slots 1A from both axial sides of the stator core 1.

[0014] The stator core 1 is a laminate of electromagnetic steel sheets and has an overall cylindrical shape, with rectangular slots 1A, the long sides of which extend in the radial direction of the stator core 1, arranged at predetermined intervals in the circumferential direction. The first and second rectangular wires S1, S2 have rectangular cross-sectional shapes, and in the example shown in Fig. 2, five wires are housed in each slot 1A in a series arrangement.

[0015] As shown in Figure 1, the stator S has first and second rectangular wires S1, S2, each of which has an insulating coating material 2 spanning the outer periphery of the ends thereof and a solder joint 3 interposed between the end faces thereof, and the ends of the first and second rectangular wires S1, S2 are joined together within the slot 1A. The first and second rectangular wires S1, S2 are joined together by the insulating coating material 2 and the solder joint 3 to form a coil. In this case, as a more preferred embodiment, the stator S can be configured such that at least one of the first and second rectangular wires S1, S2 has a recess 4 for soldering on its end face.

[0016] The stator S, together with a rotor (not shown), constitutes a rotating electric machine such as a motor or a generator. In this embodiment, a stator S constituting a three-phase motor is exemplified. In this case, the stator S forms three-phase coils by inserting rectangular wires S1 and S2 into selected slots 1A and joining them together. In this case, as a more preferred embodiment, a configuration can be adopted in which rectangular wires S1 and S2 forming coils of the same phase are housed in each slot 1A.

[0017] 4 to 6, a method for manufacturing the stator S will be described. This manufacturing method manufactures a stator S having a structure in which the stator core 1 has slots 1A at predetermined intervals in the circumferential direction, and first and second rectangular wires S1, S2 bent into a U-shape, and the first and second rectangular wires S1, S2 are inserted into selected slots 1A from both axial sides of the stator core 1.

[0018] That is, in the manufacturing method of the stator S, as shown in Fig. 4 as an example of the process, the insulating coating material 2, which protrudes toward the other flat wire S1 and has self-adhesive properties, is provided on the outer periphery of the end of at least one of the first and second flat wires S1 and S2 (the lower one in Fig. 6). In this case, the insulating coating material 2 is formed by applying it to the end of the flat wire S2, including the outer periphery and the entire edge of the end face, as shown in the left diagram of Fig. 4.

[0019] Then, as shown in the center 2 of Figure 4, a laser beam L is irradiated onto the end surface of at least one of the first and second rectangular wires S1 and S2 to remove a portion of the insulating coating material 2, forming a recess 4. This recess 4 only needs to have a volume at least equivalent to the volume of the solder material 3M of the solder joint 3. The recess 4 can also be formed by machining.

[0020] In addition, as shown in another example of the process in Figure 5, the manufacturing method of the above-mentioned stator S includes providing an insulating coating material 22 that protrudes toward the other flat wire S1 and has self-fusing properties on the outer periphery of the end of at least one of the first and second flat wires S1, S2 (lower in Figure 6), and forming a recess 4 in the central part of the insulating coating material 22.

[0021] The manufacturing method of the stator S involves placing a soft solder material 3M in the recess 4 as shown in the left diagrams of Figures 4 and 5, then inserting the first and second rectangular wires S1 and S2 into the slot 1A as shown in the left diagram of Figure 6, and then butting their ends together and applying pressure as shown in the right diagram of Figure 6. This forms an insulating coating material 2 around the outer peripheries of the ends of the first and second rectangular wires S1 and S2. The manufacturing method of the stator S then involves heating the first and second rectangular wires S1 and S2, melting the solder material 3M and forming a solder joint 3 between their end faces as shown in Figure 1. This joins the ends of the first and second rectangular wires S1 and S2 within the slot 1A.

[0022] 4 to 6 show a configuration in which the insulating coating material 2, recessed portion 4, and solder material 3M are arranged on the lower rectangular wire S2, but it is also possible to provide the insulating coating material 2 and recessed portion 4 on both the first and second rectangular wires S1, S2. In this case, both insulating materials 2 are integrated by butting the first and second rectangular wires S1, S2 together.

[0023] As yet another example, the sheet-shaped insulating coating material 2 can be wrapped around the outer periphery of the end of one of the flat wires S2, so that it extends toward the other flat wire S1, and the end of the other flat wire S1 can be inserted inside the extended portion, so that the insulating coating material 2 straddles the outer periphery of both ends.

[0024] The stator S having the above configuration ensures good insulation between the ends of the first and second flat wires S1, S2 by the insulating coating material 2, while the flat wires S1, S2 can be reliably joined together by the solder joint 3, thereby realizing high-quality joints between the flat wires S1, S2.

[0025] Furthermore, the above-mentioned stator S can also prevent damage to the rectangular wires S1 and S2 by using the insulating coating material 2, and it is also useful to apply varnish to the coils to further improve insulation. Furthermore, in the above-mentioned stator, all of the joints between the rectangular wires are located within the slots 1A, so as shown in Figure 3, only the corners of the U-shaped rectangular wires S1 and S2 are exposed on both axial sides of the stator core 1, resulting in a compact and neat appearance.

[0026] Furthermore, in the above-mentioned manufacturing method of the stator S, the insulating coating material 2 acts as a breakwater to prevent leakage of the heated and melted solder material 3M, and the insulating coating material 2 ensures good insulation between the ends of the first and second flat wires S1, S2, while the solder joint 3 reliably joins the flat wires S1, S2 to each other, thereby making it possible to provide a stator S having a high-quality joint between the flat wires S1, S2.

[0027] Furthermore, the above-mentioned stator S has a recess 4 for soldering on at least one end surface of the first and second rectangular wires S1, S2, which allows the solder material 3M to be stably positioned and enables a good solder joint 3 to be formed using the minimum necessary amount of solder material 3M.

[0028] Furthermore, the above-mentioned stator S constitutes a three-phase motor, and by accommodating flat wires S1 and S2 forming coils of the same phase in each slot 1A, insulation between the coils is not required, and simple coil arrangement can be achieved.

[0029] 7 to 10 are diagrams showing second and third embodiments of a stator according to the present invention. In the following embodiments, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0030] Second Embodiment 7 is a stator having bus bars Bu, Bv, and Bw, which are external terminals for each phase, at one axial end of a stator core 1. In this case, the stator S constitutes a three-phase motor.

[0031] As shown in the left diagram of Fig. 8, each of the bus bars Bu, Bv, and Bw has a pair of connectors C1 and C2 that are inserted into the stator core 1, and is molded with resin R to maintain strength and ensure insulation. As shown in the right diagram of Fig. 8, each of the bus bars Bu, Bv, and Bw is attached to rectangular wires S1 and S2 before being inserted into the slot 1A, and is ultimately connected to a control circuit of an inverter (not shown).

[0032] The stator having the above configuration can achieve the same effects as the previous embodiment, and in addition, by employing the bus bars Bu, Bv, and Bw, it is possible to simplify the assembly process and reduce manufacturing costs.

[0033] Third Embodiment The embodiment shown in Fig. 9 includes a neutral busbar Bn at one axial end of the stator core, connecting each phase. The neutral busbar Bn shown in the left diagram of Fig. 9 includes a pair of connectors C1 and C2, each connecting to each phase, for a total of six connectors. The neutral busbar Bn is molded with resin R to maintain strength and ensure insulation. As shown in the right diagram of Fig. 9, this neutral busbar Bn is attached to rectangular wires S1 and S2, and ultimately forms a control circuit for an inverter (not shown).

[0034] The stator having the above configuration can achieve the same effects as the previous embodiment, and in addition, by employing the neutral bus bar Bn, it is possible to simplify the assembly process and reduce manufacturing costs.

[0035] <Fourth embodiment> Fig. 10 shows cross-sectional views of a fourth embodiment of the stator, showing two examples of the arrangement of rectangular wires S1 and S2 in slots 1A. The slots 1A shown on the left in Fig. 10 are formed at predetermined intervals in the radial direction of the stator core 1 (the vertical direction in the drawing), and each accommodates rectangular wires S1 and S2, each of which has three cross-sectional sides covered with insulating paper.

[0036] 10 shows a rectangular slot 1A with its long sides extending in the radial direction of the stator core 1, and accommodates a plurality of rectangular wires S1, S2 covered with insulating paper, arranged at predetermined intervals. In this way, the rectangular wires to be accommodated in the slot 1A can be appropriately selected taking into consideration the coil occupancy rate in the slot, insulation properties, heat dissipation properties, etc.

[0037] The configuration of the stator and the manufacturing method thereof according to the present invention is not limited to the above-described embodiments, and can be modified as appropriate within the scope of the gist of the present invention, and the configurations of the above-described embodiments can also be combined. [Explanation of symbols]

[0038] 1 stator core 1A slot 2. Insulating coating material 3 Solder joints 3M solder material 4 recess S stator S1 1st flat wire S2 2nd flat wire Bu, Bv, Bw busbars Bn Neutral busbar

Claims

1. A stator having a structure comprising a stator core having slots at predetermined intervals in the circumferential direction, and first and second rectangular wires bent into a U-shape, the first and second rectangular wires being inserted into selected slots from both sides of the axial direction of the stator core, A stator characterized in that the first and second flat wires have an insulating coating material spanning the outer periphery of each end and a solder joint interposed between each end face, and the ends are joined together within the slot.

2. 2. The stator according to claim 1, wherein at least one of the first and second rectangular wires has a recess for soldering on an end surface thereof.

3. A stator for a rotating electric machine having coils for multiple phases, 2. The stator according to claim 1, wherein the rectangular wires forming coils of the same phase are housed in the respective slots.

4. 4. The stator according to claim 3, wherein a bus bar serving as an external terminal for each phase is provided at one axial end of the stator core.

5. 4. The stator according to claim 3, wherein a neutral bus bar connecting each phase is provided at one end of the stator core in the axial direction.

6. A method for manufacturing a stator having a structure comprising a stator core having slots at predetermined intervals in the circumferential direction, and first and second rectangular wires bent into a U-shape, the first and second rectangular wires being inserted into selected slots from both sides of the stator core in the axial direction, After providing an insulating coating material having self-adhesive properties on the outer periphery of the end of at least one of the first and second rectangular wires, the insulating coating material protrudes toward the other rectangular wire, A recess is formed on an end surface of at least one of the first and second rectangular wires, After disposing the solder material in the recess, The first and second rectangular wires are inserted into the slots, and their ends are butted together to form the insulating coating material over the outer peripheries of the ends; A method for manufacturing a stator, characterized in that the first and second flat wires are then heated to melt the solder material and form a solder joint between the end faces of each other, and the ends of the first and second flat wires are joined together.

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