Method of manufacturing assembly type coil stator

Abstract

To solve the problem in which in an assembly type coil stator, a slot sheet cannot adequately cover a coil inside a slot, which may result in a risk of not improving an insulation performance of the coil.SOLUTION: An assembly type coil stator comprises a stator, an assembly type coil, and a slot sheet. A folded slot sheet has an overlapping portion. A manufacturing apparatus is provided with a cuff support having a protrusion inserted into a slot sheet opening. The protrusion is constituted of a first protrusion and a second protrusion. A method of manufacturing the assembly type coil stator includes: a setup step in which the stator is setup on the manufacturing apparatus so that the overlapping portion faces the second protrusion, and each of a pair of long sides of the slot sheet opening faces the first protrusion; and a mouth expanding step in which the first protrusion applies a force to the slot sheet so that the pair of long sides of the slot sheet opening separates from each other, and the second protrusion applies a force so that an edge of the overlapping portion separates from a central axis.SELECTED DRAWING: Figure 4

Description

[Technical Field]

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

[0002] Conventional motors, as disclosed in Patent Document 1, have slot paper inside the slots in the stator to insulate the coils from the stator. The slot paper is a sheet of insulating paper shaped to fit the shape of the slot hole. The slot paper is attached to the slot so as to cover the inner surface of the slot. The slot in Patent Document 1 has a slit portion on the inner periphery of the stator that connects the inside of the slot to the outside of the slot where the rotor is located. The slot paper in Patent Document 1 is arranged so as not to block the slit portion when attached to the slot. In Patent Document 1, the coil is configured so that the coated conductor is wound around the teeth through the slot. As a result, the inner surface of the slot is covered by the slot paper, and the coil and teeth are insulated by the slot paper positioned between them. However, because the slit portion is not blocked by the slot paper, the portion of the coil facing the slit portion is exposed to the inner periphery of the stator. A stator with a coil wound in this manner is referred to as a wound-coil stator in this specification. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-200505 Summary of the Invention [Problem to be solved by the invention]

[0004] The inventors have been developing an assembled coil stator. In an assembled coil stator, the coil has a segment portion formed by joining two coated conductor wires inside a slot. In an assembled coil stator, the two coated conductor wires are inserted into the slot through insertion openings on both sides of the slot along the central axis of the stator so that they face each other. Note that the coating on one end of the two coated conductor wires is stripped, and the other end is equipped with a coated copper tube. As a result, when one coated conductor wire is inserted into the coated copper tube, the two coated conductor wires are joined inside the slot.

[0005] For this reason, in an assembled coil stator, a seam in the coating is formed at the joint of the coated conductor. In other words, in an assembled coil stator, the conductor is easily exposed at the joint of the coated conductor, making it more difficult to ensure insulation than a wound coil stator, which has no seam in the coating. For this reason, the inventors formed the slot paper into a closed cylindrical shape so that it could cover the slit portion. The cylindrical slot paper is formed by folding a single sheet of insulating paper so that it has a rectangular hollow cross section. As a result, inside the slot, the coil is covered by the slot paper, improving the insulation performance of the coil.

[0006] The opening end of the cylindrical slotted paper is rectangular. The folded slotted paper has an overlapping portion where both edges of the insulating paper overlap on a side including one short side of the opening end of the slotted paper. Because the edges of the slotted paper are not fixed to each other at the overlapping portion, the edges open in the space of the slit, easily exposing the coil. For this reason, the inventors attached the slotted paper to the slot so that the side of the folded slotted paper facing the overlapping portion is positioned in the slit. This prevents the edges of the slotted paper from opening in the slit, preventing the coil from being exposed on the inner periphery of the stator. However, the stator manufacturing device used by the inventors applies force to the slotted paper to move the pair of long sides at the opening end of the slotted paper away from each other while holding them in place in order to insert the coated conductor into the slotted paper. As a result, the centers of the pair of long sides bend away from each other, causing the pair of short sides located at both ends of the long sides to bend toward each other. As a result, the overlapping portions located on the short sides may bend more toward the inside of the slot, causing the edges to open toward the inside of the slot. Therefore, for example, if a covered conductor is inserted with the overlapping portion open, the portion of the coil facing the overlapping portion may become exposed. Therefore, in an assembled coil stator, the slot paper may not adequately cover the coil inside the slot, which may prevent the insulation performance of the coil from being improved. [Means for solving the problem]

[0007] The present disclosure can be realized in the following forms.

[0008] (1) According to one aspect of the present disclosure, there is provided a method for manufacturing an assembled coil stator, the assembled coil stator comprising: a cylindrical stator having a plurality of slots along a central axis of the cylinder on an inner surface thereof; an assembled coil having two coated conductors inserted into and joined to each of the slots; and a cylindrical slot paper made of a folded sheet of insulating paper, the hollow cross section perpendicular to the central axis of the cylinder being rectangular and arranged to cover the inner surface of the slots, the slots comprising a pair of slot insertion openings located at both ends of the central axis of the stator, the pair of slot insertion openings having rectangular shapes that are elongated in a radial direction away from the central axis; and a slit portion connecting the inside of the slots to the outside toward the central axis, the slit portion extending in the central axis direction, the folded slot paper having a pair of slot paper openings located inside the pair of slot insertion openings and a pair of slot paper openings located on side surfaces of the slots facing the slit portions, the both end edges of the folded slot paper overlapping each other. and an overlapping portion arranged so as to overlap with the slotted paper opening, and the manufacturing device for the assembled coil stator includes a cuff holder that holds the slotted paper opening in an open state, the cuff holder having a protrusion that is inserted into the slotted paper opening, and the protrusion can be moved in the radial direction, and the cuff holder further includes a rectangular cuff holder slit that opens facing one of the pair of slot insertion openings, and the protrusion is provided along two of the four corners of the cuff holder slit that are located far from the central axis, and At each of the two corners, the cuffs are configured with a first protrusion extending along the long side of the cuffs slit portion and a second protrusion extending along the short side of the cuffs slit portion, and the manufacturing method of the assembled coil stator includes a preparation step of preparing the stator, the assembled coil members, the slot paper, and the manufacturing apparatus, and an arrangement step of arranging the slot paper inside the slot portion so that the slot paper covers the inner surface of the slot portion and the overlapping portion is located on the side of the slot portion facing the slit portion.The method includes an installation process in which the stator is installed in the manufacturing device so that the overlapping portion faces the second protrusion and each of the pair of long sides of the slotted paper opening faces the first protrusion; a mouth widening process in which the protrusions are moved in the radial direction, so that the first protrusion applies force to the slotted paper so that the pair of long sides of the slotted paper opening move away from each other, and the second protrusion applies force to move the edge of the overlapping portion away from the central axis; and an insertion process in which one of the two covered conductor wires is inserted into the slotted paper. In this embodiment, the second protrusions prevent both edge portions of the overlapping portion from bending further toward the inside of the slit paper. This allows the method for manufacturing an assembled coil stator to insert the covered conductor with the slot paper opening appropriately widened. Therefore, the method for manufacturing an assembled coil stator can improve the insulation performance between the assembled coil and the stator by covering the assembled coil inside the slot with the slot paper. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 2 is a perspective view showing a stator and a slot paper. [Figure 2] FIG. 2 is a perspective view showing a manufacturing apparatus for an assembled coil stator. [Figure 3] FIG. 2 is an explanatory diagram showing a segment portion. [Figure 4] 10A and 10B are explanatory diagrams showing the relationship between slot paper and protrusions. [Figure 5] FIG. [Figure 6] 10 is a flowchart showing a method for manufacturing an assembled coil stator. [Figure 7] FIG. 7 is an explanatory view showing a cross section taken along the line VII-VII in FIG. 4. DETAILED DESCRIPTION OF THE INVENTION

[0010] A. First embodiment: A-1. Composition of assembled coil stator: FIG. 1 is a perspective view showing the configuration of a stator 110. The assembled coil stator is used, for example, in a motor for driving a vehicle. Specifically, the motor is an inner rotor type motor having a cylindrical stator 110 and a cylindrical rotor coaxially arranged. The assembled coil stator includes the stator 110, a coil 120, and a slot paper 130. The coil 120 is not shown in FIG. 1 to facilitate understanding of the technology. FIG. 2 is a perspective view showing a manufacturing apparatus 200 for an assembled coil stator. The manufacturing process of the assembled coil stator is shown in FIG. 2. The stator 110 is not shown in FIG. 2, but the slot paper 130 attached to the stator 110 and a portion of the coil 120 inserted into the stator 110 are shown. In this specification, the assembled coil stator manufacturing apparatus 200 is also simply referred to as the manufacturing apparatus 200. In the following description, an XYZ Cartesian coordinate system is set to facilitate understanding of the technology. The Z-axis is a direction parallel to the central axis CL of the cylindrical stator 110. Furthermore, a circumferential direction Dc around the central axis CL, a central axis direction Dcl along the central axis CL, a radial direction Dr perpendicular to the central axis CL, and a radial direction Dr1 that moves away from the central axis CL within the radial direction Dr. 1 and 2 show a configuration that falls within a 180-degree range of the central angle centered on the central axis CL.

[0011] 1, the stator 110 has a cylindrical shape centered on a central axis CL. The stator 110 includes slot portions 111, teeth portions 112, and a back yoke portion 113.

[0012] The teeth portion 112 is provided on the inner circumferential side of the stator 110 and is composed of a plurality of protrusions extending from the back yoke portion 113 toward the central axis CL. The tip 112e of each of the plurality of protrusions extends in the circumferential direction Dc. Therefore, the gap between adjacent protrusions is narrowest at the tip 112e of the protrusion. The gap defined by the tip 112e of the protrusions is the slit portion 111s, which will be described later. The back yoke portion 113 has a cylindrical shape with the central axis coincident with the central axis CL. The back yoke portion 113 is a portion of the stator 110 that extends in the circumferential direction Dc about the central axis CL.

[0013] The slot portion 111 is a space defined by the teeth portion 112 and the back yoke portion 113 on the cylindrical inner surface 110si of the stator 110 along the central axis CL of the cylinder. That is, the slot portion 111 is a gap in the stator 110 defined by the protruding portions of the teeth portion 112. The stator 110 is provided with a plurality of slot portions 111. Each slot portion 111 includes a pair of slot insertion openings 111oi and a slit portion 111s. The pair of slot insertion openings 111oi are located at both ends of the central axis direction Dcl along the central axis CL of the stator 110. Furthermore, the pair of slot insertion openings 111oi have a rectangular shape that is elongated in the radial direction Dr1. Note that the hollow cross section of the slot portion 111 perpendicular to the central axis CL is also rectangular. The slit portion 111s is a space connecting the inside of the slot portion 111 to the outside toward the central axis CL. The slit portion 111s extends along the central axis direction Dcl. That is, the slit portion 111s is located on one of the short sides of each of the pair of slot insertion openings 111oi.

[0014] The coil 120 is formed so as to be wound around each of the multiple protrusions of the tooth portion 112. However, the coil 120 is not shown in FIG. 1. The coil 120 includes a segment portion 121. FIG. 3 is an explanatory diagram showing the segment portion 121. The segment portion 121 includes a coated conductor wire 121w and a coated copper tube 121p. The surface of the conductor portion 121wb of the coated conductor wire 121w is covered with an insulating coating C. However, the insulating coating C is not present at the end portion 121we of the coated conductor wire 121w, and the conductor portion 121wb is exposed. The coated copper tube 121p is a copper tube whose outer surface 121po is covered with an insulating coating C and whose inner surface 121pi is exposed. The segment 121 connects the two coated conductor wires 121w by fitting the ends 121we of the two coated conductor wires 121w into the coated copper tubes 121p inside the slots 111. This electrically connects the two coated conductor wires 121w via the coated copper tubes 121p. In this specification, the coil 120 having the two coated conductor wires 121w inserted into and joined inside the slots 111 is also referred to as an assembled coil.

[0015] The slotted paper 130 insulates the coil 120 from the stator 110. As shown in FIG. 1, the slotted paper 130 is arranged to cover the inner surface of the slot portion 111. The slotted paper 130 is formed into a cylindrical shape from a single folded sheet of insulating paper. That is, the hollow cross section of the slotted paper 130 perpendicular to the central axis CL is rectangular, similar to the slot portion 111. FIG. 4 is an explanatory diagram showing the relationship between the slotted paper 130 and the protrusion 211. FIG. 4 illustrates the slotted paper 130 and the cuff support 210, which will be described later, when viewed along the central axis direction Dcl, as indicated by arrow A in FIG. 2. The slotted paper 130 includes an overlapping portion 131 and a pair of slotted paper openings 132. When the slotted paper 130 is arranged in the slot portion 111, as shown in FIG. 1, the pair of slotted paper openings 132 are located inside the pair of slot insertion openings 111oi. 4, the overlapping portion 131 is a portion of the slotted paper 130 where both edge portions of the folded slotted paper 130 overlap. When the slotted paper 130 is placed in the slot 111, the overlapping portion 131 is located on the side of the slot 111 that faces the slit 111s. In other words, the overlapping portion 131 is located on the short side of the slot insertion opening 111oi on the radial direction Dr1 side.

[0016] A-2. Manufacturing equipment configuration: The manufacturing apparatus 200 shown in FIG. 2 widens the slotted paper opening 132 to assemble the coil 120 to the stator 110. The manufacturing apparatus 200 includes a support unit 220 and a cuff support 210. The support unit 220 includes a circular member. The circular member of the support unit 220 shares a central axis CL with the stator 110 when the stator 110 is installed in the manufacturing apparatus 200. The support unit 220 supports the cuff support 210, which is provided on the outer periphery of the circular member, so that the cuff support 210 can move in a radial direction Dr of the central axis CL.

[0017] The cuff support 210 holds the slotted paper opening 132 open. More specifically, the cuff support 210 is composed of multiple rod-shaped members extending from the support member 220 along the radial direction Dr1. The rod-shaped members are arranged at equal intervals in the circumferential direction Dc. Each of the rod-shaped members is movable in the radial direction Dr. As shown in FIG. 4, each rod-shaped member has a pair of notches 210c at its end opposite the radial direction Dr1. The cuff support 210 has a protrusion 211 and a cuff support slit 212 at its end opposite the radial direction Dr1. The cuff support slit 212 receives the coated conductor wire 121w. When the stator 110 is placed in the manufacturing apparatus 200, the cuff support slit 212 opens to face one of the pair of slot insertion openings 111oi. The cuff slits 212 are defined by the notches 210c in the adjacent rod-shaped members.

[0018] The protrusions 211 are inserted into the slotted paper opening 132. The protrusions 211 are provided along two of the four corners 212e of the cuff slit 212 that are located farthest from the central axis CL. At each of the two corners 212e, the protrusions 211 are composed of a first protrusion 211p1 extending along the long side 212L of the cuff slit 212 and a second protrusion 211p2 extending along the short side 212S of the cuff slit 212. FIG. 5 is a perspective view showing the protrusions 211. The side surfaces of the first protrusion 211p1 and the second protrusion 211p2 are tapered toward the inside of the cuff slit 212 and inclined toward the outside of the rod-shaped member. For example, the angle of inclination R1 of the side surfaces is 20 degrees.

[0019] A-3. Manufacturing method for assembled coil stator: FIG. 6 is a flowchart showing a manufacturing method of an assembled coil stator. Manufacturing of an assembled coil stator begins in step S1, when an operator prepares the components and manufacturing equipment 200 necessary for the assembled coil stator. In the following explanation, each step is named with a step number. In the preparation step S1, the operator prepares the stator 110, components of the coil 120, slot paper 130, and the manufacturing equipment 200. The components of the coil 120 are, specifically, multiple coated conductor wires 121w with coated copper tubes 121p attached to one end 121we. In the placement step S2, the operator places the slot paper 130 inside the slot portion 111 so that the slot paper 130 covers the inner surface 121pi of the slot portion 111 and the overlapping portion 131 is positioned on the side of the slot portion 111 facing the slit portion 111s. In the installation step S3, the worker installs the stator 110 in the manufacturing apparatus 200 so that the overlapping portion 131 faces the second protrusion 211p2 and each of the pair of long sides 132L of the slotted paper opening 132 faces the first protrusion 211p1.

[0020] In the neck widening process S4, the manufacturing apparatus 200 moves the protrusions 211 in the radial direction Dr1 as shown by arrow D1 in FIG. 4, causing the first protrusions 211p1 to apply force to the slotted paper 130 so that the pair of long sides 132L of the slotted paper opening 132 move away from each other. At the same time, the manufacturing apparatus 200 applies force to the second protrusions 211p2 as shown by arrow D2 in FIG. 4 so that the edge of the overlapping portion 131 moves away from the central axis CL. That is, the manufacturing apparatus 200 moves the multiple rod-shaped members of the cuff support 210 in the radial direction Dr1 to widen the spacing between adjacent rod-shaped members. As a result, the first protrusions 211p1 move to push the long sides 132L of the slotted paper opening 132 outward from the slot portion 111, and the second protrusions 211p2 move to push the edge of the overlapping portion 131 outward from the slot portion 111. Therefore, the slot paper opening 132 is maintained in an open state.

[0021] FIG. 7 is a cross-sectional view taken along the line VII-VII in FIG. 4 and is an explanatory diagram illustrating the insertion step S5. In the insertion step S5 shown in FIG. 6, the manufacturing apparatus 200 inserts one of the two coated conductor wires 121w in the segment 121 into the slotted paper 130. That is, as shown in FIGS. 2 and 7, the manufacturing apparatus 200 inserts one coated conductor wire 121w from one of the pair of slotted paper openings 132 in the direction of arrow D3 toward the inside of the stator 110 in the central axis direction Dcl. More specifically, as shown in FIG. 2, multiple coated conductor wires 121w are inserted simultaneously. If a coated conductor wire 121w has already been inserted before the insertion step S5, inserting another coated conductor wire 121w to form the segment 121 will join the two coated conductor wires 121w. In this case, in the confirmation step S6 shown in FIG. 6, the worker completes the assembly of the coil 120 and ends the manufacture of the assembled coil stator. However, if the coated conductor wire 121w has not yet been inserted before the insertion step S5, the assembly of the coil 120 is not complete. In such a case, in the confirmation step S6, the worker decides to perform the installation step S3 again. As a result, in the installation step S3, the worker reverses the orientation of the stator 110 in the central axis direction Dcl, and installs the stator 110 in the manufacturing apparatus 200 so that the protrusion 211 is inserted into the slotted paper opening 132 on the side where the coated conductor wire 121w has not been inserted. In other words, the installation steps S3 to S5 are performed again. This completes the assembly of the coil 120, and ends the manufacture of the assembled coil stator.

[0022] As described above, in the present embodiment, when the first protrusion 211p1 applies force to the long side 132L of the slotted paper opening 132 in the opening-mouth widening step S4, both edge portions of the overlapping portion 131 located on the short side 132S of the slotted paper opening 132 tend to bend more toward the inside of the slotted paper 130. However, the second protrusion 211p2 applies force to move the edge of the overlapping portion 131 away from the central axis CL. In other words, the second protrusion 211p2 prevents both edge portions of the overlapping portion 131 from bending more toward the inside of the slotted paper. This allows the manufacturing method of the assembled coil stator to insert the covered conductor wire 121w with the slotted paper opening 132 appropriately widened. Therefore, the manufacturing method of the assembled coil stator disclosed herein can improve the insulation performance between the assembled coil and the stator by covering the assembled coil inside the slot with the slotted paper 130.

[0023] B. Other Embodiments: (1) In the above embodiment, the steps performed by an operator may be automatically performed by the manufacturing apparatus 200. For example, the manufacturing apparatus 200 may be provided with a mechanism for inserting the slotted paper 130 into the slot portion 111, a mechanism for installing the stator 110 in the manufacturing apparatus 200, a mechanism for inverting the stator 110, and the like, so that each step may be automatically performed. (2) In the above embodiment, the side surface of the protrusion 211 is inclined toward the outside of the rod-shaped member so as to form a tapered shape toward the inside of the cuff slit portion 212. However, the side surface of the protrusion 211 does not have to be inclined.

[0024] The present disclosure is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit of the present disclosure. For example, the technical features of the embodiments corresponding to the technical features in each aspect described in the Summary of the Invention section can be appropriately replaced or combined to solve some or all of the above problems or achieve some or all of the above effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted. [Explanation of symbols]

[0025] 110... stator, 110si, 121pi... inner surface, 111... slot portion, 111oi... slot insertion opening, 111s... slit portion, 112... teeth portion, 112e... tip, 113... back yoke portion, 120... coil, 121... segment portion, 121e... end portion, 121p... coated copper tube, 121po... outer surface, 121w... coated conductor, 121wb... conductor portion, 130... slot paper, 132S, 212S... short side , 131...overlapping portion, 132...slot paper opening, 200...manufacturing apparatus, 210...cuff support, 210c...notch portion, 211...projection portion, 211p1...first projection portion, 211p2...second projection portion, 212...cuff support slit portion, 132L, 212L...long side, 212e...corner portion, 220...support portion, C...insulating coating, CL...central axis, Dc...circumferential direction, Dcl...central axis direction, Dr...radial direction, Dr1...radial direction, R1...angle

Claims

[Claim 1] A method for manufacturing an assembled coil stator, comprising: The assembled coil stator comprises: a cylindrical stator having a plurality of slots on an inner surface of the cylinder along a central axis of the cylinder; an assembled coil having two coated conductor wires each inserted into the slot portion and joined; a cylindrical slotted paper made of a single folded sheet of insulating paper, the hollow cross section perpendicular to the central axis of the tube being rectangular, and the slotted paper being arranged to cover the inner surface of the slot portion; The slot portion is a pair of slot insertion openings located at both ends in a central axis direction along the central axis of the stator, the pair of slot insertion openings having a rectangular shape that is long in a radial direction away from the central axis; a slit portion connecting an inside of the slot portion and an outside toward the central axis, the slit portion extending in the central axis direction, The folded slotted paper is a pair of slot paper openings located inside the pair of slot insertion openings, respectively; an overlapping portion located on a side surface of the slot portion facing the slit portion, where both end edges of the folded slot paper are overlapped, The manufacturing apparatus for the assembled coil stator includes: a cuff holder for holding the slotted paper opening in an open state, the cuff holder having a protrusion that is inserted into the slotted paper opening; The protrusion can be moved in the radial direction, The cuffs further include a rectangular cuff slit portion that opens facing one of the pair of slot insertion openings, The protrusion is The cuff slit is provided along two corners of the four corners of the cuff slit that are located far from the central axis, At each of the two corners, a first protrusion extending along the long side of the cuff slit portion and a second protrusion extending along the short side of the cuff slit portion are provided, The manufacturing method of the assembled coil stator includes: a preparation process in which the stator, the assembled coil members, the slot paper, and the manufacturing apparatus are prepared; an arrangement step of arranging the slot paper inside the slot portion so that the slot paper covers the inner surface of the slot portion and the overlapping portion is located on the side of the slot portion facing the slit portion; an installation process in which the stator is installed in the manufacturing device so that the overlapping portion faces the second protrusion portion and each of a pair of long sides of the slotted paper opening faces the first protrusion portion; a mouth widening step in which the first protrusion applies force to the slotted paper so that a pair of long sides of the slotted paper opening are separated from each other by moving the protrusions in the radial direction, and the second protrusion applies force to the edge of the overlapping portion so that the edge is separated from the central axis; A manufacturing method for an assembled coil stator, comprising an inserting step of inserting one of the two coated conductor wires into the slot paper.

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