Armature manufacturing apparatus and armature manufacturing method

Abstract

To provide a device for manufacturing an armature and a method for manufacturing an armature that can suppress reduction of the cross section of a coil after the coil is plastically deformed.SOLUTION: A manufacturing device 60 includes: a holding jig 80 for holding a first coil end 32 by pressing the coil from both sides in a circumferential direction; and a pressing jig for plastically deforming a segment coil 40 in the inside of a slot 23 by pressing the segment coil to the inside of the slot 23 in a radial direction.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to an armature manufacturing apparatus and an armature manufacturing method. [Background technology]

[0002] 2. Description of the Related Art Conventionally, an armature such as a stator of a rotating electric machine includes an iron core having a plurality of slots and coils disposed inside the slots. In such a method for manufacturing a stator, Patent Document 1 discloses that a coil arranged inside a slot is pressed and plastically deformed, thereby changing the cross-sectional shape of the coil. In the method described in Patent Document 1, a coil with a circular cross section is arranged inside a slot, and then the coil is pressed in the radial direction of the iron core and plastically deformed, thereby forming the coil into a rectangular cross section. This reduces the gap between the coils inside the slot, thereby increasing the space factor of the coil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2002-125338 A Summary of the Invention [Problem to be solved by the invention]

[0004] When the cross-sectional shape of a coil changes due to plastic deformation of the coil, the coil undergoes plastic deformation both in the axial direction of the core and in a planar direction perpendicular to the axial direction. In the case of plastic deformation of the coil in the axial direction, the coil stretches in the axial direction, and the cross-sectional area of ​​the coil changes before and after the plastic deformation. In other words, the cross-sectional area of ​​the coil after plastic deformation is smaller than the cross-sectional area of ​​the coil before plastic deformation. In this case, the electrical resistance of the coil increases, so it is desirable to suppress the reduction in the cross-sectional area of ​​the coil after plastic deformation. [Means for solving the problem]

[0005] The armature manufacturing apparatus for solving the above problems is an armature manufacturing apparatus including a cylindrical core having a plurality of slots and coils arranged inside the slots, and includes a holding jig that applies pressure to and holds coil ends of the coils protruding from the slots in the axial direction of the core from both sides in the circumferential direction of the core, and a pressing jig that presses the coils arranged inside the slots toward the inner surface of the slots in the radial direction of the core, thereby plastically deforming them.

[0006] According to this configuration, the coil ends are pressed and held by the holding jig from both sides in the circumferential direction of the core. This makes it easier to restrict the plastic deformation of the coil in the axial direction when the coil is plastically deformed by being pressed by the pressing jig. Therefore, the coil is more likely to plastically deform in a planar direction perpendicular to the axial direction, but is less likely to plastically deform in the axial direction. As a result, the elongation of the coil in the axial direction is reduced. This makes it possible to suppress a reduction in the cross-sectional area of ​​the coil after plastic deformation.

[0007] A method for manufacturing an armature to solve the above problem is a method for manufacturing an armature including a cylindrical core having a plurality of slots and coils arranged inside the slots, and includes a coil arrangement process for arranging the coils inside the slots, a holding process for holding coil ends of the coils arranged inside the slots that protrude from the slots in the axial direction of the core by applying pressure from both sides in the circumferential direction of the core with a holding jig, and a pressing process for pressing the coils held by the holding jig toward the inner surface of the slot in the radial direction of the core with a pressing jig, thereby plastically deforming the coils along the inner surface of the slot.

[0008] According to this method, in the holding step, the coil ends are pressed and held by a holding jig from both sides in the circumferential direction of the core. This makes it easier to restrict plastic deformation of the coil in the axial direction when the coil is pressed by the pressing jig and plastically deformed in the pressing step. Therefore, the coil is more likely to plastically deform in a planar direction perpendicular to the axial direction, but is less likely to plastically deform in the axial direction. As a result, elongation of the coil in the axial direction is reduced. Therefore, it is possible to suppress a reduction in the cross-sectional area of ​​the coil after plastic deformation.

[0009] The armature manufacturing apparatus for solving the above problem is an armature manufacturing apparatus including a cylindrical core having a plurality of slots and a coil arranged inside the slots, and further including a pressing tool that presses the coil arranged inside the slot toward the inner surface of the slot in the radial direction of the core to plastically deform the coil, and the pressing surface of the pressing tool that presses the coil is provided with a rough surface portion that has a greater surface roughness than other portions.

[0010] According to this configuration, the coil is pressed by the pressing surface provided with a rough surface portion. Therefore, compared to a pressing tool that does not have a rough surface portion on its pressing surface, the frictional force generated between the pressing surface and the outer surface of the coil is larger. As a result, when the coil is pressed by the pressing tool and plastically deformed, plastic deformation of the coil in the axial direction of the core is less likely to occur. Therefore, the elongation of the coil in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the coil after plastic deformation.

[0011] A method for manufacturing an armature to solve the above problem is a method for manufacturing an armature including a cylindrical core having a plurality of slots and a coil arranged inside the slots, the method including a coil arrangement step of arranging the coil inside the slot, and a pressing step of pressing the coil arranged inside the slot toward the inner surface of the slot in the radial direction of the core using a pressing tool, thereby plastically deforming the coil along the inner surface of the slot, wherein the pressing tool has a rough surface portion on its pressing surface that presses the coil and has a surface roughness greater than other portions.

[0012] According to this method, in the pressing step, the coil is pressed by a pressing surface provided with a rough surface portion. Therefore, compared to a pressing tool that does not have a rough surface portion on its pressing surface, the frictional force generated between the pressing surface and the outer surface of the coil is larger. As a result, when the coil is pressed by the pressing tool and plastically deformed, plastic deformation of the coil in the axial direction of the iron core is less likely to occur. Therefore, the elongation of the coil in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the coil after plastic deformation. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a cross-sectional view showing a stator in the first embodiment. [Diagram 2] FIG. 2 is an enlarged cross-sectional view showing the stator in the first embodiment. [Diagram 3] FIG. 3 is a front view of the stator in the first embodiment as viewed from inside the stator. [Figure 4] FIG. 4 is a cross-sectional perspective view showing a segment coil in the first embodiment. [Diagram 5] FIG. 5 is a cross-sectional perspective view showing the pressing jig in the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view showing a holding jig in the first embodiment. [Figure 7]Figure 7(a) is a cross-sectional view showing the state of the segment coil held by the holding jig in the first embodiment before it is plastically deformed, and Figure 7(b) is a cross-sectional view showing the state of the segment coil held by the same holding jig after it is plastically deformed. [Figure 8] FIG. 8 is a cross-sectional view showing a coil arrangement step in the first embodiment. [Figure 9] FIG. 9 is a cross-sectional view showing the holding step in the first embodiment. [Figure 10] FIG. 10 is a cross-sectional view showing a state in which the pressing process of the five segment coils in the first embodiment has been completed. [Figure 11] FIG. 11 is a cross-sectional view showing a state in which the pressing step of the eight segment coils in the first embodiment has been completed. [Figure 12] FIG. 12 is a cross-sectional perspective view showing a pressing jig in the second embodiment. [Figure 13] FIG. 13 is a cross-sectional view showing a coil arrangement step in the second embodiment. [Figure 14] FIG. 14 is a cross-sectional view showing a state in which the pressing step of one segment coil in the second embodiment has been completed. [Figure 15] FIG. 15 is a cross-sectional view showing a state in which the pressing step of the three segment coils in the second embodiment has been completed. [Figure 16] FIG. 16 is a cross-sectional view showing a state in which the pressing step of the eight segment coils in the second embodiment has been completed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] First Embodiment Hereinafter, with reference to Figs. 1 to 11, a first embodiment in which an armature manufacturing apparatus and an armature manufacturing method are embodied as a stator manufacturing apparatus and a stator manufacturing method will be described.

[0015] In the drawings, for the convenience of explanation, some components may be shown exaggerated or simplified, and the dimensional ratios of each part may differ from the actual ones. (Stator 10) As shown in Fig. 1 and Fig. 2, the stator 10 includes a stator core 20, a coil 30, and a plurality of insulating sheets 50. The stator core 20 is cylindrical. The coil 30 is wound around the stator core 20. Each insulating sheet 50 covers the outer surface of the coil 30. The stator core 20 corresponds to an "iron core."

[0016] The stator 10 of this embodiment is used in a three-phase synchronous rotating electric machine, and is provided so as to surround a rotor (not shown). Hereinafter, the axial direction, radial direction, and circumferential direction of the stator core 20 will be simply referred to as the axial direction, radial direction, and circumferential direction, respectively.

[0017] (Stator core 20) The stator core 20 has a yoke 21, a plurality of teeth 22, and a plurality of slots 23. The yoke 21 has an annular shape. The plurality of teeth 22 protrude radially inward from the yoke 21 and are spaced apart from one another in the circumferential direction. The slots 23 are formed one by one between adjacent teeth 22 in the circumferential direction. Each slot 23 is open radially inward and on both sides in the axial direction. The stator core 20 of this embodiment has a total of 48 slots 23.

[0018] 1, the stator core 20 has three fixing portions 24 protruding radially outward from the yoke 21. The three fixing portions 24 are provided at intervals from one another in the circumferential direction. Each fixing portion 24 is provided with a bolt hole 24a penetrating the fixing portion 24 in the axial direction. A bolt (not shown) is inserted into the bolt hole 24a and fastened to a housing (not shown), thereby fixing the stator core 20 to the housing.

[0019] The stator core 20 is formed, for example, by joining together a plurality of electromagnetic steel plates that are laminated in the axial direction. (Coil 30) The coil 30 is configured with three phase windings constituting a U phase, a V phase, and a W phase. Each phase winding is wound across a plurality of teeth 22.

[0020] The coil 30 has a conductor and an insulating coating that covers the outer circumference of the conductor. The conductor is made of a metal material such as an aluminum alloy. The insulating coating is not shown in each drawing.

[0021] As shown in FIG. 3, the coil 30 has a plurality of arrangement portions 31, a plurality of first coil ends 32, and a plurality of second coil ends 33. The arrangement portions 31 are arranged inside the slots 23. The arrangement portions 31 extend linearly in the axial direction. Eight arrangement portions 31 are provided inside the slots 23 and aligned in the radial direction.

[0022] The cross-sectional shape of the coil 30 perpendicular to the longitudinal direction is a rectangle having long and short sides. The long side of the cross-sectional shape of the arrangement portion 31 extends in the width direction of the slot 23, and the short side of the cross-sectional shape of the arrangement portion 31 extends in the radial direction. The long side of the arrangement portion 31 is the same as the opening width of the insulating sheet 50. The width direction of the slot 23 is a direction perpendicular to both the axial direction and the radial direction.

[0023] The first coil end 32 extends from the arrangement portion 31. The first coil end 32 protrudes from the slot 23 on one side in the axial direction and is bent in the circumferential direction. The first coil end 32 connects two arrangement portions 31 arranged inside two different slots 23 to each other.

[0024] The first coil end 32 has a general portion 32a and a gradual change portion 32b. The gradual change portion 32b is a portion adjacent to the arrangement portion 31, and is provided between the arrangement portion 31 and the general portion 32a.

[0025] The width of the general portion 32 a is smaller than the width of the arrangement portion 31 . The cross-sectional area of ​​the gradually changing portion 32b gradually decreases with increasing distance from the arrangement portion 31, i.e., toward the general portion 32a. The width of the gradually changing portion 32b gradually decreases with increasing distance from the arrangement portion 31.

[0026] The second coil end 33 extends from the arrangement portion 31. The second coil end 33 protrudes from the slot 23 on the other side opposite to one side in the axial direction and is bent in the circumferential direction. The second coil end 33 connects two arrangement portions 31 arranged inside two different slots 23 to each other.

[0027] The second coil end 33 has a general portion 33a and a gradual change portion 33b. The configurations of the general portion 33a and the gradual change portion 33b are the same as the configurations of the general portion 32a and the gradual change portion 32b of the first coil end 32. Therefore, a detailed description of the configurations of the general portion 33a and the gradual change portion 33b will be omitted.

[0028] (Segment coil 40) 2, each phase winding of the coil 30 described above is formed by joining together a plurality of segment coils 40. In this embodiment, eight segment coils 40 are arranged radially inside one slot 23.

[0029] 4, the segment coil 40 has two straight portions extending in parallel and a connecting portion connecting the ends of the two straight portions to each other. The segment coil 40 is U-shaped.

[0030] The two straight portions of the segment coil 40 are inserted into two different slots 23 from one side in the axial direction. Then, a part of the straight portion protruding from the slot 23 is bent in one or the other direction in the circumferential direction. Then, the straight portion of one segment coil 40 is joined to the straight portion of another segment coil 40. In this way, each phase winding is formed.

[0031] The straight portions constitute a part of the first coil end 32, the arrangement portion 31, and the second coil end 33. The connecting portion constitutes a part of the second coil end 33. Thus, the segment coil 40 has two arrangement portions 31, two first coil ends 32, and one second coil end 33. The two first coil ends 32 in the segment coil 40 extend in a cantilevered manner from the two arrangement portions 31, respectively. The second coil end 33 connects the parts of the two arrangement portions 31 on the opposite side to the first coil end 32.

[0032] (Insulation sheet 50) 2, one insulating sheet 50 is disposed inside each slot 23. The insulating sheet 50 is disposed between the inner surface of the slot 23 and the outer surface of the coil 30. The insulating sheet 50 covers the entire inner surface of the slot 23. The insulating sheet 50 is open on the radially inner side and on both sides in the axial direction, similar to the slot 23, for example. Both ends of the insulating sheet 50 in the axial direction protrude from the slot 23.

[0033] (Stator manufacturing device 60) 5 and 6, a stator manufacturing apparatus 60 (hereinafter referred to as manufacturing apparatus 60) includes a pressing jig 70 and a holding jig 80. The pressing jig 70 presses and plastically deforms the segment coil 40 arranged inside the slot 23. The holding jig 80 presses and holds the first coil end 32 and the second coil end 33 of the segment coil 40.

[0034] (Pressing tool 70) 5, the pressing jig 70 has, for example, a columnar shape extending in the axial direction. The length of the pressing jig 70 is greater than the length of the segment coil 40 in the axial direction.

[0035] The pressing jig 70 may be made of, for example, a metal material such as an iron-based material. The pressing jig 70 has a facing portion 71 facing the arrangement portion 31. The width of the facing portion 71 is larger than the width of other portions of the pressing jig 70. The width of the facing portion 71 is approximately the same as the opening width of the insulating sheet 50. The length of the facing portion 71 in the axial direction is larger than the length of the slot 23 in the axial direction, and is, for example, approximately the same as the length of the insulating sheet 50 in the axial direction.

[0036] The opposing portion 71 has a pressing surface 70a that presses the outer surface of the segment coil 40. The pressing surface 70a is a flat surface that is perpendicular to the radial direction. (Holding jig 80) 6, the holding jig 80 has a plurality of holding members 81 arranged on both axial end faces of each tooth 22. Each holding member 81 has a columnar shape extending in the radial direction. The length of each holding member 81 is greater than the length of the slot 23 in the radial direction.

[0037] The material of the holding member 81 may be, for example, a metal material such as an iron-based material. As shown in FIGS. 7(a) and 7(b), the holding members 81 include a holding member 81A that holds the first coil end 32 and a holding member 81B that holds the second coil end 33.

[0038] The retaining members 81A are arranged one on each circumferential side of the multiple first coil ends 32 protruding from one slot 23. Similarly, the retaining members 81B are arranged one on each circumferential side of the multiple second coil ends 33 protruding from one slot 23.

[0039] Hereinafter, the two retaining members 81A located on opposite sides in the circumferential direction across the multiple first coil ends 32 protruding from one slot 23 will be simply referred to as the "two retaining members 81A." Additionally, the two retaining members 81B located on opposite sides in the circumferential direction across the multiple second coil ends 33 protruding from one slot 23 will be simply referred to as the "two retaining members 81B."

[0040] The configuration of the holding member 81A is the same as that of the holding member 81B. Therefore, in the following, the configuration of the holding member 81A will be described, and a description of the configuration of the holding member 81B may be omitted.

[0041] Each of the holding members 81A is provided so as to be movable forward and backward in the radial direction. Each of the holding members 81A is disposed on one end face of the teeth 22 in the axial direction by, for example, moving from the outer side to the inner side in the radial direction.

[0042] The two holding members 81A are configured so as to be capable of moving toward and away from each other in the circumferential direction. The two holding members 81A are configured so as to be capable of holding the first coil end 32 by applying pressure to both sides in the circumferential direction.

[0043] Two retaining members 81A are provided corresponding to each slot 23. In this embodiment, one retaining member 81A is disposed on one end face in the axial direction of each tooth 22. Also, one retaining member 81B is disposed on the other end face opposite to the one end face of each tooth 22. Note that in each drawing, only two retaining members 81A out of the multiple retaining members 81A are shown, and only two retaining members 81B out of the multiple retaining members 81B are shown.

[0044] As shown in FIG. 7(b), the retaining member 81A has a protruding portion 82 that protrudes toward the general portion 32a, and a relief portion 83 that allows the gradually changing portion 32b to escape. The general portion 32a is pressed and held from both sides in the circumferential direction by the protruding portions 82 of the two holding members 81A.

[0045] The relief portions 83 in the two holding members 81A prevent interference between the gradually changing portions 32b and the holding members 81A. (Method of manufacturing the stator) The method for manufacturing a stator includes an insulating sheet arrangement step, a coil arrangement step, a holding step, a pressing step, and a joining step. In this embodiment, the insulating sheet arrangement step, the coil arrangement step, the holding step, the pressing step, and the joining step are performed in this order. However, the coil arrangement step, the holding step, and the pressing step are repeated multiple times in this order.

[0046] (Insulation sheet placement process) 8, in the insulating sheet arrangement step, the insulating sheet 50 is arranged inside the slot 23. At this time, the insulating sheet 50 may be inserted into the slot 23 from the radially inner side, or may be inserted into the slot 23 from the axial direction.

[0047] (Coil placement process) In the coil arrangement process, a plurality of segment coils 40 are arranged inside the slot 23. In this embodiment, first, of the total eight segment coils 40 arranged inside one slot 23, five segment coils 40 are arranged radially inside the slot 23.

[0048] In the coil arrangement process, the arrangement portion 31 having a width smaller than the width of the slot 23, more specifically, a width smaller than the opening width of the insulating sheet 50, is arranged inside the slot 23. Therefore, a gap is provided between the arrangement portion 31 and the insulating sheet 50 in the width direction of the slot 23.

[0049] (holding process) 9, in the holding process, the first coil ends 32 of the five segment coils 40 are held by pressure applied from both sides in the circumferential direction by the holding member 81A of the holding jig 80. Although not shown, at this time, the second coil ends 33 of the five segment coils 40 are held by pressure applied from both sides in the circumferential direction by the holding member 81B. By holding in this manner by the holding member 81, marks caused by pressure applied by the holding member 81 are formed on the first coil ends 32 and the second coil ends 33, respectively.

[0050] (Pressing process) 10, in the pressing step, the placement portion 31 of the segment coil 40 held by the holding jig 80 is pressed by the pressing jig 70 toward the inner surface of the slot 23 on the radially outer side. This causes the placement portion 31 to plastically deform along the inner surface of the slot 23. This eliminates the gap between the placement portion 31 and the insulating sheet 50 described above. Therefore, the width of the placement portion 31 becomes the same as the opening width of the insulating sheet 50.

[0051] As shown in FIG. 7(b), in the pressing step, gradual change portions 32b and 33b are formed on both sides of arrangement portion 31 in the axial direction as arrangement portion 31 is plastically deformed. 11, next, the coil arrangement step, holding step, and pressing step are performed in this order for the two remaining segment coils 40, and then the coil arrangement step, holding step, and pressing step are performed in this order for the remaining one segment coil 40. Note that the coil arrangement step, holding step, and pressing step may be performed in this order for the three remaining segment coils 40.

[0052] (Joining process) Although not shown, in the joining process, one first coil end 32 in each segment coil 40 is twisted in one circumferential direction by an annular twisting jig that engages with each first coil end 32, and the other first coil end 32 is twisted in the other circumferential direction. As a result, an end of a first coil end 32 in a segment coil 40 and an end of a first coil end 32 in a segment coil 40 other than the segment coil 40 are adjacent in the radial direction. These ends are then joined together by welding to manufacture the coil 30.

[0053] The operation and effects of this embodiment will be described. (1-1) The manufacturing apparatus 60 includes a holding jig 80 and a pressing jig 70. The holding jig 80 applies pressure to the first coil end 32 and the second coil end 33 from both sides in the circumferential direction to hold them. The pressing jig 70 presses the segment coil 40 arranged inside the slot 23 radially toward the inner surface of the slot 23 to plastically deform it.

[0054] According to this configuration, the first coil end 32 and the second coil end 33 are pressed and held by the holding jig 80 from both sides in the circumferential direction of the stator core 20. As a result, when the segment coil 40 is plastically deformed by being pressed by the pressing jig 70, the plastic deformation of the segment coil 40 in the axial direction is more likely to be restricted. Therefore, the segment coil 40 is more likely to plastically deform in the planar direction perpendicular to the axial direction, but is less likely to plastically deform in the axial direction. As a result, the elongation of the segment coil 40 in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0055] (1-2) The method for manufacturing a stator includes a coil arrangement step, a holding step, and a pressing step. In the coil arrangement step, the segment coil 40 is arranged inside the slot 23. In the holding step, the first coil end 32 and the second coil end 33 of the segment coil 40 arranged inside the slot 23 are pressed from both sides in the circumferential direction by a holding jig 80 and held. In the pressing step, the segment coil 40 held by the holding jig 80 is pressed radially toward the inner surface of the slot 23 by a pressing jig 70, thereby plastically deforming the segment coil 40 along the inner surface of the slot 23.

[0056] According to this method, in the holding process, the first coil end 32 and the second coil end 33 are pressed and held from both sides in the circumferential direction by the holding jig 80. As a result, when the segment coil 40 is pressed by the pressing jig 70 and plastically deformed in the pressing process, the plastic deformation of the segment coil 40 in the axial direction is more likely to be restricted. Therefore, the segment coil 40 is more likely to plastically deform in the planar direction perpendicular to the axial direction, but is less likely to plastically deform in the axial direction. As a result, the elongation of the segment coil 40 in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0057] Incidentally, in the segment coil 40, the two first coil ends 32 extend in a cantilevered manner from the two arrangement portions 31, respectively, and the second coil end 33 connects the two arrangement portions 31. For this reason, when the arrangement portion 31 undergoes plastic deformation in the axial direction, the arrangement portion 31 is more likely to extend in the axial direction toward the first coil end 32 than in the axial direction toward the second coil end 33.

[0058] According to the above method, the first coil end 32 is pressurized and held by the holding jig 80. Therefore, in the pressing process, elongation of the arrangement portion 31 in the direction toward the first coil end 32 is reduced. Furthermore, the second coil end 33 is pressurized and held by the holding jig 80, so elongation of the arrangement portion 31 in the direction toward the second coil end 33 is reduced. Therefore, it is possible to effectively suppress a reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0059] (1-3) In the coil arrangement process, the arrangement portion 31, which has a width smaller than the width of the slot 23, is arranged inside the slot 23. In the pressing process, the arrangement portion 31 is pressed by a pressing jig 70 to plastically deform the arrangement portion 31, thereby forming gradual-change portions 32b, 33b in the portions of the first coil end 32 and the second coil end 33 adjacent to the arrangement portion 31. In the holding process, the portions of the first coil end 32 and the second coil end 33 that are farther from the arrangement portion 31 than the portions where the gradual-change portions 32b, 33b are to be formed are held by a holding jig 80.

[0060] When the arrangement portion 31, which has a width smaller than the width of the slot 23, is pressed by the pressing jig 70 and plastically deformed, the width of the arrangement portion 31 becomes larger. With such plastic deformation of the arrangement portion 31, a gradually changing portion 32b is formed adjacent to the arrangement portion 31 between the arrangement portion 31 and the general portion 32a, which is a portion of the first coil end 32 whose cross-sectional area does not change. Similarly, a gradually changing portion 33b is formed in the second coil end 33. Therefore, when the portions of the first coil end 32 and the second coil end 33 adjacent to the arrangement portion 31 are held by the holding jig 80 in the holding process, the cross-sectional area of ​​the portions is less likely to change. Therefore, the portions corresponding to the gradually changing portions 32b and 33b are formed at the ends of the arrangement portion 31 in the axial direction. As a result, the cross-sectional area of ​​the arrangement portion 31 may be partially reduced.

[0061] In this regard, according to the above method, in the holding step, the portions of the first coil end 32 and the second coil end 33 that are farther from the arrangement portion 31 than the planned portions are held by the holding jig 80. This prevents the planned portions from being held by the holding jig 80. Therefore, it is possible to prevent the above-mentioned inconvenience from occurring.

[0062] <Second embodiment> Hereinafter, with reference to Figs. 12 to 16, a second embodiment in which the armature manufacturing apparatus and the armature manufacturing method are embodied as a stator manufacturing apparatus and a stator manufacturing method will be described.

[0063] In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and redundant explanations will be omitted. In the drawings, for the convenience of explanation, some components may be shown exaggerated or simplified, and the dimensional ratios of each part may differ from the actual ones.

[0064] (Stator manufacturing device 160) As shown in FIG. 12, a stator manufacturing apparatus 160 (hereinafter referred to as manufacturing apparatus 160) includes a pressing jig 170.

[0065] (Pressing tool 170) The pressing jig 170 has, for example, a columnar shape extending in the axial direction. The length of the pressing jig 170 is greater than the length of the segment coil 40 in the axial direction.

[0066] The pressing jig 170 may be made of, for example, a metal material such as an iron-based material. The width of the pressing jig 170 is approximately the same as the width of the opening in the insulating sheet 50 . The pressing jig 170 has a pressing surface 170a that presses the outer surface of the segment coil 40. The pressing surface 170a is provided with a rough surface portion that has a larger surface roughness than the other portions.

[0067] The rough surface portion has fine irregularities. The rough surface portion is formed, for example, by shot blasting or etching the pressing surface 170a. The maximum height of the irregularities in the rough surface portion is preferably smaller than the thickness of the insulating coating of the segment coil 40, and more preferably equal to or less than half of the thickness.

[0068] (Method of manufacturing the stator) The method for manufacturing a stator includes an insulating sheet arrangement step, a coil arrangement step, a pressing step, and a joining step. In this embodiment, the insulating sheet arrangement step, the coil arrangement step, the pressing step, and the joining step are performed in this order. However, the coil arrangement step and the pressing step are repeated multiple times in this order.

[0069] The insulating sheet arranging step and the joining step in this embodiment are the same as the insulating sheet arranging step and the joining step in the first embodiment, so detailed description of the insulating sheet arranging step and the joining step will be omitted below.

[0070] In addition, in the following description, for convenience, the eight segment coils 40 arranged inside one slot 23 will be referred to as segment coil S1 to segment coil S8 in order from the outermost radial direction.

[0071] (Coil placement process) As shown in FIG. 13, in the coil arrangement step, first, one segment coil S1 is arranged inside the slot 23.

[0072] In the coil arrangement step, the arrangement portion 31 having a width smaller than the width of the slot 23 is arranged inside the slot 23. Therefore, a gap is provided between the arrangement portion 31 and the slot 23 in the width direction of the slot 23.

[0073] (Pressing process) 14, in the pressing step, the placement portion 31 of the segment coil S1 is pressed toward the inner surface of the slot 23 on the radially outer side by the pressing jig 170. This causes the placement portion 31 to plastically deform along the inner surface of the slot 23. This eliminates the gap between the placement portion 31 and the insulating sheet 50 described above. Therefore, the width of the placement portion 31 becomes the same as the opening width of the insulating sheet 50.

[0074] At this time, similarly to the first embodiment, gradually changing portions 32b and 33b are formed on both sides of the arrangement portion 31 in the axial direction. In the pressing process, the rough surface of the pressing surface 170a is pressed against the outer surface of the segment coil S1. As a result, a transfer surface 40a is formed on the outer surface of the segment coil S1, to which the uneven shape of the rough surface is transferred. The surface roughness of the transfer surface 40a is greater than the surface roughness of other parts of the segment coil S1. The transfer surface 40a is formed by deformation of the insulating coating of the segment coil S1.

[0075] As shown in Fig. 15, next, a coil arrangement process is performed in which two segment coils S2 and S3 are arranged inside the slot 23. Then, a pressing process is performed on these two segment coils S2 and S3. At this time, the rough surface portion of the pressing surface 170a is pressed against the outer surface of the segment coil S3, so that the transfer surface 40a is formed on the outer surface in the same manner as the segment coil S1. Also, the segment coil S2 is pressed against the transfer surface 40a of the segment coil S1.

[0076] As shown in Fig. 16, next, the coil arrangement process and the pressing process are performed on the segment coils S4 and S5 in the same manner as the segment coils S2 and S3. After that, the coil arrangement process and the pressing process are performed on the segment coils S6 and S7 in the same manner. Finally, the coil arrangement process and the pressing process are performed on the segment coil S8.

[0077] By repeating the coil arrangement process and the pressing process as described above, the transfer surface 40a is formed on the outer surface of each of the segment coils S1, S3, S5, S7, and S8. In addition, in the pressing process, the segment coils S2, S4, S6, and S8 are pressed against the transfer surface 40a of the segment coils S1, S3, S5, and S7, respectively.

[0078] The operation and effects of this embodiment will be described. (2-1) The manufacturing device 160 includes a pressing jig 170 that presses the segment coil 40 arranged inside the slot 23 in the radial direction toward the inner surface of the slot 23 to plastically deform the segment coil 40. A pressing surface 170a of the pressing jig 170 that presses the segment coil 40 is provided with a rough surface portion that has a surface roughness greater than other portions.

[0079] According to this configuration, the segment coil 40 is pressed by the pressing surface 170a provided with a rough surface portion. Therefore, compared to a pressing tool in which the pressing surface 170a is not provided with a rough surface portion, the frictional force generated between the pressing surface 170a and the outer surface of the segment coil 40 is larger. As a result, when the segment coil 40 is pressed by the pressing tool 170 and plastically deformed, plastic deformation of the segment coil 40 in the axial direction is less likely to occur. Therefore, the elongation of the segment coil 40 in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0080] (2-2) The manufacturing method of the stator includes a coil arrangement step and a pressing step. In the pressing step, a pressing jig 170 is used, the pressing surface 170a of which presses the segment coil 40 has a rough surface portion having a larger surface roughness than other portions.

[0081] According to this method, in the pressing process, the segment coil 40 is pressed by the pressing surface 170a provided with a rough surface portion. Therefore, compared to a pressing tool in which the pressing surface 170a is not provided with a rough surface portion, the frictional force generated between the pressing surface 170a and the outer surface of the segment coil 40 is larger. As a result, when the segment coil 40 is pressed by the pressing tool 170 and plastically deformed, plastic deformation of the segment coil 40 in the axial direction is less likely to occur. Therefore, the elongation of the segment coil 40 in the axial direction is reduced. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0082] (2-3) In the pressing step, the two segment coils 40 arranged radially are pressed by a pressing jig 170 toward the segment coil 40 on which the transfer surface 40a is formed. According to this method, one of the two segment coils 40 is pressed against the transfer surface 40a. Since the transfer surface 40a is a surface to which the shape of the rough surface portion is transferred, the frictional force generated between the segment coil 40 on which the transfer surface 40a is formed and the segment coil 40 pressed against the segment coil 40 is large. As a result, plastic deformation in the axial direction of the segment coil 40 pressed against the transfer surface 40a is unlikely to occur. Therefore, the elongation of the segment coil 40 in the axial direction is reduced. In addition, the other of the two segment coils 40 is pressed by the pressing jig 170, thereby reducing the elongation in the axial direction. Therefore, it is possible to suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0083] <Modification> This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that there is no technical contradiction.

[0084] In the first embodiment, the holding jig 80 may include only the holding member 81A. That is, in the holding step, the first coil end 32 is held by the holding jig 80, but the second coil end 33 is not necessarily held.

[0085] In the first embodiment, the portions where the gradual change portions 32b and 33b are to be formed may be held by a holding jig 80 in the holding step. In the first embodiment, two retaining members 81A may be arranged on one axial end face of each tooth 22. Two retaining members 81B may be arranged on the other axial end face of each tooth 22.

[0086] In the first embodiment, the rough surface portion of the second embodiment may be provided on the pressing surface 70a of the pressing jig 70. In this case, it is possible to further suppress the reduction in the cross-sectional area of ​​the segment coil 40 after plastic deformation.

[0087] In the second embodiment, the rough surface portions may be provided only on both ends in the axial direction of the portion of the pressing surface 170a that presses the arrangement portion 31. In the second embodiment, the rough surface portion may be formed of a plurality of ridges extending in the width direction and spaced apart from one another in the axial direction. With this configuration, the plastic deformation of the segment coil 40 in the axial direction is restricted, while the plastic deformation of the segment coil 40 in the width direction is more easily permitted.

[0088] In the coil arrangement step in each embodiment, the number of segment coils 40 arranged inside the slot 23 at one time may be changed as appropriate. In each embodiment, the number of arrangement portions 31 arranged inside the slot 23 may be changed as appropriate.

[0089] In each embodiment, the insulating sheet 50 may be omitted from the stator 10. In this case, the insulating sheet arrangement step is omitted. In addition, the width of the arrangement portion 31 after plastic deformation is the same as the width of the slot 23.

[0090] The material of the conductor of the coil 30 may be a metal material other than an aluminum alloy, such as a copper alloy. Although the coil 30 in each embodiment is formed by bending and joining a plurality of segment coils 40, the coil 30 may be formed by a winding in which a conductor and a conducting wire having an insulating coating are formed into a ring shape in advance.

[0091] In each embodiment, a manufacturing apparatus for a stator of a rotating electric machine is illustrated as an example of an armature manufacturing apparatus, but a similar configuration can also be applied to a manufacturing apparatus for a rotor of a rotating electric machine. Also, in each embodiment, a manufacturing method for a stator of a rotating electric machine is illustrated as an example of an armature manufacturing method, but a similar method can also be applied to a manufacturing method for a rotor of a rotating electric machine. [Explanation of symbols]

[0092] S1, S2, S3, S4, S5, S6, S7, S8...Segment coils 10...Stator 20…Stator core 21…York 22…Teeth 23. Slots 24…Fixed part 24a...Bolt hole 30…Coil 31…Arrangement section 32…First coil end 32a…General section 32b... Gradually changing part 33…Second coil end 33a…General section 33b... Gradually changing part 40…Segment coil 40a…Transfer surface 50…Insulating sheet 60...Manufacturing equipment 70...Pressing tool 70a...Pressing surface 71…Facing part 80…Holding jig 81, 81A, 81B...Holding members 82...Protruding part 83…Relief section 160...Manufacturing equipment 170...Pressing tool 170a...Pressing surface

Claims

1. An apparatus for manufacturing an armature comprising a cylindrical core having a plurality of slots and a coil disposed inside the slots, a holding jig that holds coil ends of the coils protruding from the slots in the axial direction of the core by applying pressure from both sides in the circumferential direction of the core; a pressing tool for pressing the coil disposed inside the slot toward an inner surface of the slot in a radial direction of the core to plastically deform the coil, The holding jig is two protruding portions that pressurize and hold the coil end from both sides in the circumferential direction; two relief portions that are provided closer to the slot in the axial direction of the core than the two protruding portions and that face each other in the circumferential direction, A distance between the two protrusions in the circumferential direction is smaller than a width of the slot, a distance between the two relief portions in the circumferential direction is greater than a distance between the two protruding portions in the circumferential direction; Armature manufacturing equipment.

2. A method for manufacturing an armature including a cylindrical core having a plurality of slots and a coil disposed inside the slots, comprising the steps of: a coil placement step of placing the coil inside the slot; a holding step of holding coil ends of the coils arranged inside the slots, the coil ends protruding from the slots in the axial direction of the core, by applying pressure from both sides in the circumferential direction of the core with a holding jig; a pressing process in which the coil held by the holding jig is pressed toward the inner surface of the slot in the radial direction of the iron core by a pressing jig, thereby plastically deforming the coil along the inner surface of the slot, The holding jig is two protruding portions that pressurize and hold the coil end from both sides in the circumferential direction; two relief portions that are provided closer to the slot in the axial direction of the core than the two protruding portions and that face each other in the circumferential direction, A distance between the two protrusions in the circumferential direction is smaller than a width of the slot, a distance between the two relief portions in the circumferential direction is greater than a distance between the two protruding portions in the circumferential direction; Manufacturing method of armatures.

3. When a portion of the coil that is arranged inside the slot is defined as an arrangement portion, In the coil placement step, the placement portion having a width smaller than a width of the slot is placed inside the slot, In the pressing step, the arrangement portion is pressed by the pressing jig to cause plastic deformation, thereby forming a gradually changing portion in which a cross-sectional area gradually decreases with increasing distance from the arrangement portion in a portion of the coil end adjacent to the arrangement portion, In the holding step, a portion of the coil end that is farther from the arrangement portion than a portion where the gradual change portion is to be formed is held by the holding jig. A method for manufacturing the armature according to claim 2.

4. When the portion of the coil that is arranged inside the slot is defined as the arrangement portion, In the coil arrangement step, a segment coil having two arrangement sections that are respectively arranged inside two different slots, two first coil ends that extend in a cantilever shape from the two arrangement sections, and a second coil end that connects the portions of the two arrangement sections on the opposite side to the first coil ends is used as the coil, In the holding step, the first coil end is held by the holding jig while being pressed from both sides in the circumferential direction. The method for manufacturing the armature according to claim 2 or 3.

5. An apparatus for manufacturing an armature comprising a cylindrical core having a plurality of slots and a coil disposed inside the slots, a pressing tool for pressing the coil disposed inside the slot toward an inner surface of the slot in a radial direction of the core to plastically deform the coil, The pressing surface of the pressing jig that presses the coil is provided with a rough surface portion having fine irregularities and a surface roughness greater than that of other portions, The coil has a conductor and an insulating coating that covers an outer periphery of the conductor, The maximum height of the projections and recesses is smaller than the thickness of the insulating coating. Armature manufacturing equipment.

6. A method for manufacturing an armature including a cylindrical core having a plurality of slots and a coil disposed inside the slots, comprising the steps of: a coil placement step of placing the coil inside the slot; a pressing process in which the coil disposed inside the slot is pressed toward an inner surface of the slot in a radial direction of the iron core by a pressing jig, thereby plastically deforming the coil along the inner surface of the slot, The pressing tool used has a pressing surface that presses the coil and has a rough surface portion that has fine irregularities and is greater in surface roughness than other portions, The coil has a conductor and an insulating coating that covers an outer periphery of the conductor, The maximum height of the projections and recesses is smaller than the thickness of the insulating coating. Manufacturing method of armatures.

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