Stator manufacturing method

Abstract

This facilitates the insertion and installation of stator coils, which are capable of carrying high currents, into the stator. [Solution] A single coil with a flat rectangular cross-section, formed by die casting or the like, is inserted in a stepped manner from the axial direction into the stator core for each phase.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a stator used in a rotating electric motor (hereinafter referred to as a motor) in which a large current flows at a low voltage.

Background Art

[0002] In order to achieve miniaturization and high torque density, motors that are wave-wound using flat wires are widely used. In the wave winding of the windings of such motors, both ends of a pine-leaf-shaped pine-leaf coil segment obtained by bending the central portion of a flat wire into a pine-leaf shape are inserted from the insertion side of a pair of slots of the stator, and one end of a winding segment protruding from the non-insertion side of the slot is welded to one end of another winding segment protruding from the non-insertion side of a slot that is separated from the pair of slots by a predetermined pitch in the rotational direction (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in a wave-wound coil using a pine-leaf coil segment, there is a problem that the welding operation of the coil segment becomes complicated because the shape of the welded portion is different between the inner peripheral side and the outer peripheral side of the stator core.

[0005] In addition, if there is a welding defect in the welded portion, there is a problem that disconnection occurs during the manufacturing line or after shipment.

[0006] Therefore, the present invention provides a method for manufacturing a coil and a stator that do not require complicated welding operations.

Means for Solving the Problems

[0007] Claim 1 invention is a method for manufacturing a stator that constitutes a rotating electric machine together with a rotor, characterized in that an insulating film is inserted into a stator core having an annular shape and a plurality of slots that are inwardly opening at a plurality of positions in the circumferential direction and extending radially, an insulating film is inserted into the stator core, a wave-wound coil without insulating coating having a flat rectangular cross-section and consisting of coil sides inserted into the plurality of slots and coil ends connecting the plurality of coil sides, the coil sides located in the slots being in the shape of thin plates that match the slots, and the radial thickness of the coil ends being thicker than the circumferential thickness of the coil sides, one winding for each phase before inserting the coil sides into the plurality of slots, the stator core is inserted into the slots from one side in the axial direction, and the vertical gaps between the coil ends of the wave-wound coils of each phase inserted into the plurality of slots are molded with insulating resin.

[0008] The invention described in claim 2 is a method for manufacturing a stator that constitutes a rotating electric machine together with a rotor, characterized in that an insulating film is inserted into a stator core having an annular shape and a plurality of slots that are inwardly opening at a plurality of positions in the circumferential direction and extending radially, an insulating film is inserted into the stator core, a wave-wound coil is formed into one winding for each phase before inserting the coil sides into the plurality of slots, the wave-wound coil is made of a flat rectangular cross-section and is covered with an insulating resin containing enamel, polyurethane, or polyester, and consists of coil sides that are inserted into the plurality of slots and coil ends that connect the plurality of coil sides, the coil sides located in the slots being in the shape of thin plates that match the slots, and the radial thickness of the coil ends being thicker than the circumferential thickness of the coil sides, the wave-wound coil is made into one winding for each phase, the coil sides are inserted into the slots from one side in the axial direction of the stator core, and vertical gaps are formed between the coil ends of the wave-wound coils of each phase inserted into the plurality of slots.

[0009] The invention described in claim 3 is a method for manufacturing a stator according to either claim 1 or claim 2, characterized in that the wave-wound coils, each having a flat rectangular cross-section and one turn per phase, are manufactured by die-casting (mold casting), from strip material, or from plate-shaped material. The invention described in claim 4 is a method for manufacturing a stator according to any one of claims 1 to 3, characterized in that when forming or manufacturing the wave-wound coils, each having a flat rectangular cross-section and one turn per phase, the ends of the wave-wound coils are shaped to be mates with a connector for power supply connection of an external power source. [Effects of the Invention]

[0010] According to the present invention, a coil can be formed without complicated welding work by inserting a single coil having a cross-sectional shape that matches the molded or manufactured slot shape into the stator core from one side such that the positions of the coil ends of each phase are stepped.

[0011] According to the present invention, by covering the molded or manufactured wave-wound coil having a flat rectangular cross-section with an insulating resin containing enamel, polyurethane, or polyester, the work of inserting insulating films into multiple slots of the stator core can be reduced.

[0012] According to the present invention, by shaping the end of the molded or manufactured wave-wound coil having a rectangular cross-section so that it can be fitted with a connector for power supply connection of an external power source, the complicated terminal processing work can be reduced. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view showing one phase coil in the stator of the present invention. [Figure 2] This is a plan view of the stator core of the present invention. [Figure 3] This is a front view of the stator of the present invention with one phase of coils inserted. [Figure 4] This is a plan view showing an extracted portion of the stator of the present invention with one phase of coils inserted. [Figure 5] This is a front view of the stator of the present invention, with three phase coils inserted. [Figure 6] This is a perspective view of the stator of the present invention, with three phase coils inserted.

[0014] Embodiment 1 of the present invention will be described with reference to Figures 1 and 3. Figure 1 is a perspective view showing one phase of coils constituting the stator A (see Figure 3) of the present invention, and Figure 2 is a plan view of the stator core 2. 1 is a single-turn coil with a corrugated winding and a flat rectangular cross-section, manufactured by die-casting, manufacturing from strip material, or press-forming a plate-shaped material, and 2 is the stator core in a rotary motor.

[0015] Since the coil end 3a is located on the central side of the stator core 2 and does not interfere with the stator core 2, the coil 1 can be inserted into the slot 4 from one side (upper side in the drawing) of the stator core 2, as shown in Figure 3. Furthermore, as shown in Figure 4, which shows a portion of the stator A with one phase of coils inserted, the coil 1 has a flat rectangular cross-sectional shape that matches the slot 4, allowing for efficient use of the cross-sectional area of ​​the slot 4. This makes it possible to conduct large currents without winding the wire multiple times. The coil 1 and the stator core 2 are insulated by an insulating film (not shown) inserted between the coil 1 and the slot 4.

[0016] Figure 5 is a front view of stator A with three phase coils inserted according to the present invention, and Figure 6 is a perspective view of stator A with three phase coils inserted. As shown in Figures 5 and 6, the U-phase coil 1u, V-phase coil 1v, and W-phase coil 1w are inserted in different amounts so that the coil ends of each phase are stepped, thereby providing an insulating distance between the coil ends of each phase. In this state, the stator core 2 and each phase coil 1u, 1v, and 1w are molded with insulating resin, and the stator core 2 and each phase coil 1u, 1v, and 1w are fixed together to ensure reliable insulation between each phase coil 1u, 1v, and 1w. The neutral points 5u, 5v, and 5w of each phase coil are connected by a neutral coil 6.

[0017] Thus, by constructing the stator of a rotating electric machine using a single coil, it is possible to eliminate the complicated operations such as winding wires around the stator core multiple times to conduct a large current, and welding each of the numerous pine leaf coil segments after inserting them.

[0018] Further, after forming or manufacturing the coils 1u, 1v, and 1w, coating them with an insulating resin such as enamel, polyurethane, or polyester, and inserting them into the stator core 2 to form the stator A, it is possible to reduce the operation of inserting an insulating film into the plurality of slots 4 of the stator core 2.

[0019] As shown in FIG. 1, since the end portion 7 of the coil 1 is flat, further, by shaping the end portions 7u, 7v, and 7w of the coils 1u, 1v, and 1w into a shape that can be fitted with a power supply connection connector of an external power source, it is only necessary to attach the power supply connection connector to the end portion of each phase coil, so that complicated terminal processing operations can be reduced.

Industrial Applicability

[0020] It is applicable to a method for manufacturing a stator in a rotating electric machine that needs to conduct a large current at a low voltage.

Explanation of Signs

[0021] 1 Coil for one phase 1u Coil for U phase 1v Coil for V phase 1w Coil for W phase 2 Stator core 3a Coil end on the insertion side 3b Coil end on the side opposite to the insertion side 4 Slot 5 Neutral point of the coil 5u Neutral point of the U-phase coil 5v Neutral point of the V-phase coil ​​​​​​​​End of 7V V-phase coil 7W W-phase coil end A stata

Claims

1. A method for manufacturing a stator, comprising: inserting an insulating film into a stator core that is annular in shape and has a plurality of slots that are inwardly opening and extending radially at a plurality of positions in the circumferential direction; forming a flat rectangular, uninsulated wave-wound coil with a cross-sectional shape such that the radial thickness of the coil end is thicker than the circumferential thickness of the coil side, into one winding for each phase before inserting the coil side into the plurality of slots; inserting into the slots from one side in the axial direction of the stator core; and molding the vertical gaps between the coil ends of the wave-wound coils of each phase inserted into the plurality of slots with insulating resin.

2. A method for manufacturing a stator, comprising a stator that constitutes a rotating electric machine together with a rotor, characterized in that an insulating film is inserted into a stator core having an annular shape and a plurality of slots that open inward at a plurality of positions in the circumferential direction and extend radially, and a wave-wound coil made of an insulating resin containing enamel, polyurethane, or polyester with a flat rectangular cross-section, consisting of coil sides inserted into the plurality of slots and coil ends connecting the plurality of coil sides, wherein the coil sides located in the slots are thin plates that match the slots, and the radial thickness of the coil ends is thicker than the circumferential thickness of the coil sides, is formed into one winding for each phase before inserting the coil sides into the plurality of slots, and is inserted into the slots from one side in the axial direction of the stator core, and vertical gaps are formed between the coil ends of the wave-wound coils of each phase inserted into the plurality of slots.

3. The method for manufacturing a stator according to claim 1 or claim 2, characterized in that the wave-wound coils, each having a flat rectangular cross-section, are manufactured by die-casting (mold casting), from strip material, or from plate-shaped material.

4. A method for manufacturing a stator according to any one of claims 1 to 3, characterized in that when forming or manufacturing a wave-wound coil with one turn for each phase having a rectangular cross-sectional shape, the end of the wave-wound coil is shaped to be mates with a connector for power supply connection of an external power source.

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