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 variations of positions of a plurality of segment coils in a peripheral direction after the coils are plastically deformed.SOLUTION: A manufacturing device 60 includes a regulation jig 80 and a pressing jig. The regulation jig 80 is brought into contact with a first coil end 32 from both sides in a peripheral direction to allow for movement in the radial direction of the segment coil 40, and regulates movement in a peripheral direction. The pressing jig plastically deforms the segment coil 40 by pressing the segment coil arranged in a slot 23 against the inner surface 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. A known example of such a coil is one that is made up of multiple segment coils joined together. The segment coil has two straight sections that extend in parallel and a connecting section that connects the ends of the two straight sections together.

[0003] Patent Document 1 discloses a method for manufacturing a stator in which straight portions of two different segment coils are joined together. In this method, first, a plurality of segment coils are inserted into a slot. As a result, the ends of the two straight portions of each segment coil protrude from the slot in the axial direction. Next, each of the ends of the straight portions is twisted in the circumferential direction of the core by an annular twisting tool that engages with the ends of the straight portions. At this time, one straight portion of each segment coil is twisted in one circumferential direction, and the other straight portion of each segment coil is twisted in the other circumferential direction. As a result, the end of the straight portion of the segment coil and the end of the straight portion of a segment coil other than the segment coil are adjacent to each other in the radial direction. Then, these ends are joined by welding to manufacture a coil.

[0004] On the other hand, Patent Document 2 discloses a method for manufacturing a stator in which a plurality of segment coils arranged in a row in the radial direction of the core inside a slot are pressed by a jig to cause plastic deformation. The plastic deformation of the segment coils inside the slot increases the space factor of the coils. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2016-131453 A [Patent Document 2] Patent Publication No. 2021-87284 Summary of the Invention [Problem to be solved by the invention]

[0006] However, in the method described in Patent Document 2, a segment coil having a width smaller than the width of the slot is placed inside the slot. Therefore, the positions of the multiple segment coils before plastic deformation may differ from each other in the circumferential direction. In this case, the positions of the straight portions of the multiple segment coils after plastic deformation may vary in the circumferential direction. As a result, it may become difficult to engage the ends of the multiple straight portions with a twisting jig, making it difficult to twist the segment coil. For this reason, it is desirable to suppress the variation in the positions of the multiple segment coils in the circumferential direction after plastic deformation. [Means for solving the problem]

[0007] The armature manufacturing apparatus for solving the above problem includes a cylindrical core having a plurality of slots, and a coil arranged inside the slots, the coil having coil ends protruding from the slots in the axial direction of the core and composed of a plurality of segment coils arranged in a row in the radial direction of the core, and includes a restricting jig that contacts the coil ends from both sides in the circumferential direction of the core to allow radial movement of the segment coils inside the slots while restricting movement in the circumferential direction, and a pressing jig that presses the segment coils arranged inside the slots in the radial direction toward the inner surface of the slot, thereby plastically deforming them.

[0008] According to this configuration, the restraining jig contacts the coil ends of the segment coils arranged inside the slot from both circumferential sides of the core. This allows the segment coils to move radially inside the slot, while restricting their movement in the circumferential direction. This causes the multiple segment coils that have been pressed and plastically deformed by the pressing jig to be aligned radially inside the slot. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils after plastic deformation.

[0009] A method for manufacturing an armature to solve the above problem is an armature manufacturing device that includes a cylindrical core having a plurality of slots and a coil arranged inside the slots, the coil having a coil end protruding from the slot in the axial direction of the core and composed of a plurality of segment coils arranged side by side in the radial direction of the core, the method including a coil arrangement process for arranging the segment coils inside the slots, and a restraining jig that contacts the coil ends of the segment coils arranged inside the slots from both sides in the circumferential direction of the core, thereby allowing the segment coils to move in the radial direction inside the slots while restricting their movement in the circumferential direction. The method includes a restraining process in which the segment coil is restrained by a restraining jig, and a pressing process in which the segment coil, with the restraining jig in contact with it, is pressed toward the inner surface of the slot in the radial direction with a pressing jig, thereby plastically deforming the segment coil along the inner surface of the slot.In the coil arrangement process, the segment coil has two arrangement sections that are respectively arranged inside two different slots, two first coil ends extending in a cantilevered manner from the two arrangement sections, and a second coil end that connects the parts of the two arrangement sections opposite the first coil ends, and in the restraining process, the restraining jig is brought into contact with the first coil end from both sides in the circumferential direction.

[0010] According to this method, a restraining jig contacts the first coil end of the segment coil arranged inside the slot from both circumferential sides of the core. This allows the segment coil to move radially inside the slot, but restricts its movement in the circumferential direction. As a result, the multiple segment coils that have been pressed and plastically deformed by the pressing jig are aligned radially inside the slot. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils after plastic deformation.

[0011] A method for manufacturing an armature for solving the above-mentioned problems includes a cylindrical core having a plurality of slots, a coil arranged inside the slots, and a cuff provided on an end surface of the core in the axial direction, the coil having a coil end protruding from the slot in the axial direction of the core and being constituted by a plurality of segment coils arranged side by side in the radial direction of the core, the method comprising the steps of: a cuff arranger arrangement step of arranging the cuff on the end surface of the core; a coil arrangement step of arranging the segment coil inside the slot after or before the cuff arranger arrangement step; and a cuff arranged on both sides in the circumferential direction of the core to bring the cuff into contact with the coil ends of the segment coil arranged inside the slot, thereby forming a cuff of the segment coil inside the slot. The method includes a restricting process for allowing movement of a segment coil in the radial direction while restricting movement in the circumferential direction, and a pressing process for pressing the segment coil with the cuffs in contact with it toward the inner surface of the slot in the radial direction using a pressing tool, thereby plastically deforming the segment coil along the inner surface of the slot, in which the coil arrangement process uses a segment coil having two arrangement portions that are arranged inside two different slots, two first coil ends that extend in a cantilevered manner from the two arrangement portions, and a second coil end that connects parts of the two arrangement portions on the opposite sides to the first coil ends, and in the restricting process, the cuffs are brought into contact with the first coil ends from both sides in the circumferential direction.

[0012] According to this method, the cuffs contact the first coil ends of the segment coils arranged inside the slots from both circumferential sides of the core. This allows the segment coils to move radially inside the slots, while restricting their movement in the circumferential direction. This causes the multiple segment coils that have been pressed and plastically deformed by the pressing tool to be aligned radially inside the slots. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils 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 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 restricting jig in the first embodiment. [Figure 7] FIG. 7 is a cross-sectional view showing a state before the segment coil in contact with the restraining jig in the first embodiment is plastically deformed. [Figure 8] FIG. 8 is a cross-sectional view showing a state after the segment coil in contact with the restraining jig in the first embodiment has been plastically deformed. [Figure 9] FIG. 9 is a cross-sectional view showing a coil arrangement step in the first embodiment. [Figure 10] FIG. 10 is a cross-sectional view showing the restricting step in the first embodiment. [Figure 11]FIG. 11 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 12] FIG. 12 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 13] FIG. 13 is an enlarged cross-sectional view showing a stator in the second embodiment. [Figure 14] FIG. 14 is a front view of the stator according to the second embodiment, as viewed from the inside of the stator. [Figure 15] FIG. 15 is a plan view showing a cuffs arrangement step in the second embodiment. [Figure 16] FIG. 16 is a cross-sectional view showing a coil arrangement step in the second embodiment. [Figure 17] FIG. 17 is a cross-sectional view showing a state in which the pressing process of the five segment coils in the second embodiment has been completed. [Figure 18] FIG. 18 is a cross-sectional view showing a state in which the pressing process 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 12, 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 restricting jig 80. The pressing jig 70 presses and plastically deforms the segment coil 40 arranged inside the slot 23. The restricting jig 80 contacts the first coil end 32 and the second coil end 33 from both circumferential sides, thereby allowing radial movement of the segment coil 40 inside the slot 23 while restricting movement in the circumferential direction.

[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. (Regulation jig 80) 6 and 7, the regulating jig 80 has a plurality of regulating members 81 arranged on both end faces of each tooth 22 in the axial direction. Each regulating member 81 has a columnar shape extending in the radial direction. The length of each regulating member 81 is greater than the length of the slot 23 in the radial direction.

[0037] The restricting member 81 may be made of, for example, a metal material such as an iron-based material. As shown in FIG. 7, the restricting members 81 include a restricting member 81A that contacts the first coil end 32 and a restricting member 81B that contacts the second coil end 33.

[0038] One restricting member 81A is disposed on each circumferential side of the multiple first coil ends 32 protruding from one slot 23. Similarly, one restricting member 81B is disposed on each circumferential side of the multiple second coil ends 33 protruding from one slot 23.

[0039] Hereinafter, the two regulating 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 regulating members 81A." Additionally, the two regulating 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 regulating members 81B."

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

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

[0042] The two restricting members 81A are configured to be able to come into contact with the first coil end 32 from both sides in the circumferential direction. Two restricting members 81A are provided corresponding to each slot 23. In this embodiment, one restricting member 81A is disposed on one end face in the axial direction of each tooth 22. Also, one restricting 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 restricting members 81A out of the multiple restricting members 81A are illustrated, and only two restricting members 81B out of the multiple restricting members 81B are illustrated.

[0043] As shown in FIG. 8, the restricting member 81A has a protruding portion 82 that protrudes toward and comes into contact with the general portion 32a, and a relief portion 83 that allows the gradually changing portion 32b to escape. The two protrusions 82, which face each other in the circumferential direction, extend parallel to each other in the radial direction. The distance between the two protrusions 82 is approximately the same as the width of the general parts 32a, 33a of the segment coil 40. Therefore, by disposing the segment coil 40 between the two restricting members 81A, the protrusions 82 of the two restricting members 81A contact the general part 32a of the first coil end 32 from both sides in the circumferential direction. This allows the segment coil 40 to move radially inside the slot 23, while restricting its movement in the circumferential direction.

[0044] The relief portions 83 in the two restricting members 81A prevent interference between the gradually changing portions 32b and the restricting members 81A. (Method of manufacturing the stator) The method for manufacturing a stator includes an insulating sheet arrangement step, a coil arrangement step, a restricting step, a pressing step, and a joining step. In this embodiment, the insulating sheet arrangement step, the coil arrangement step, the restricting step, the pressing step, and the joining step are performed in this order. However, the coil arrangement step, the restricting step, and the pressing step are repeated multiple times in this order.

[0045] (Insulation sheet placement process) 9, 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 radial inside, or may be inserted into the slot 23 from the axial direction.

[0046] (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.

[0047] 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.

[0048] (Regulated process) 10, in the restricting step, restricting members 81A of the restricting jig 80 contact the first coil ends 32 of the five segment coils 40 from both sides in the circumferential direction. Although not shown, at this time, restricting members 81B contact the second coil ends 33 of the five segment coils 40 from both sides in the circumferential direction. As a result, radial movement of the segment coils 40 is permitted inside the slots 23, while circumferential movement is restricted.

[0049] (Pressing process) 11 , in the pressing process, the placement portion 31 of the segment coil 40 in contact with the restraining 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.

[0050] As shown in FIG. 8, 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. 12, next, the coil arrangement step, the restriction step, and the pressing step are performed in this order for the two remaining segment coils 40, and then the coil arrangement step, the restriction step, and the pressing step are performed in this order for the remaining one segment coil 40. Note that the coil arrangement step, the restriction step, and the pressing step may be performed in this order for the three remaining segment coils 40.

[0051] (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.

[0052] The operation and effects of this embodiment will be described. (1-1) The manufacturing apparatus 60 includes a restricting jig 80 and a pressing jig 70. The restricting jig 80 contacts the first coil end 32 and the second coil end 33 from both sides in the circumferential direction, thereby allowing the segment coil 40 to move in the radial direction while restricting its movement in the circumferential direction. 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.

[0053] According to this configuration, the restraining jig 80 contacts the first coil end 32 and the second coil end 33 of the segment coil 40 arranged inside the slot 23 from both circumferential sides. This allows the segment coil 40 to move radially inside the slot 23, while restricting its movement in the circumferential direction. This causes the multiple segment coils 40 that have been pressed and plastically deformed by the pressing jig 70 to be aligned radially inside the slot 23. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils 40 after plastic deformation.

[0054] (1-2) The method for manufacturing a stator includes a coil arrangement process, a restricting process, and a pressing process. In the coil arrangement process, the segment coil 40 is arranged inside the slot 23. In the restricting process, a restricting jig 80 is brought into contact with the first coil end 32 and the second coil end 33 from both sides in the circumferential direction. In the pressing process, the segment coil 40 in contact with the restricting 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.

[0055] According to this method, the restraining jig 80 contacts the first coil end 32 and the second coil end 33 of the segment coil 40 arranged inside the slot 23 from both circumferential sides. This allows the segment coil 40 to move radially inside the slot 23, while restricting its movement in the circumferential direction. As a result, the multiple segment coils 40 that have been pressed and plastically deformed by the pressing jig 70 are aligned radially inside the slot 23. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils 40 after plastic deformation.

[0056] (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 portions of the first coil end 32 and the second coil end 33 adjacent to the arrangement portion 31. In the restricting process, a restricting jig 80 is brought into contact with both sides in the circumferential direction with 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.

[0057] 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 increases. 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 where the cross-sectional area does not change. Similarly, a gradually changing portion 33b is formed in the second coil end 33. Therefore, when the restricting jig 80 contacts the portion of the first coil end 32 and the second coil end 33 adjacent to the arrangement portion 31 in the restricting step, the cross-sectional area of ​​the portion is unlikely to change. Therefore, the portion corresponding to the gradually changing portions 32b, 33b is formed at the end 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.

[0058] In this regard, according to the above method, in the restricting step, the restricting jig 80 comes into contact with 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. This prevents the restricting jig 80 from coming into contact with the planned portions. This makes it possible to prevent the above-mentioned inconvenience from occurring.

[0059] <Second embodiment> Hereinafter, with reference to Figs. 13 to 18, a second embodiment in which the method for manufacturing an armature is embodied as a method for manufacturing a stator will be described.

[0060] 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.

[0061] As shown in FIGS. 13 and 14, the stator 110 includes a stator core 20, two cuffs 90, a coil 30, and a plurality of insulating sheets 50. (Cafsa 90) 14, one cuff reinforcing member 90 is provided on each of both axial end faces of the stator core 20. Hereinafter, the cuff reinforcing member 90 provided on the end face of the stator core 20 from which the first coil end 32 protrudes may be referred to as cuff reinforcing member 90A. Also, the cuff reinforcing member 90 provided on the end face of the stator core 20 from which the second coil end 33 protrudes may be referred to as cuff reinforcing member 90B.

[0062] The configuration of cuffs 90A and 90B is the same. Therefore, in the following, the configuration of cuffs 90A will be described, and a description of the configuration of cuffs 90B may be omitted.

[0063] The cuff support 90A is formed of, for example, a resin material having insulating properties. As shown in Fig. 13, the cuffs 90A have an annular portion 91 and a plurality of extension portions 92. The annular portion 91 has a circular ring shape. The extension portions 92 extend radially inward from the annular portion 91 and are spaced apart from one another in the circumferential direction. For convenience, Fig. 13 shows the cuffs 90A partially cut away.

[0064] The annular portion 91 is in contact with one axial end face of the yoke 21. The outer diameter of the annular portion 91 is smaller than the outer diameter of the yoke 21. Each extension portion 92 contacts one axial end face of a tooth 22. The cuff support 90A is provided with the same number of extension portions 92 as the number of teeth 22. The tip surface of each extension portion 92 is flush with the tip surface of the tooth 22. Each extension portion 92 contacts the first coil end 32 on both circumferential sides.

[0065] 14, the extension portion 92 has a protruding portion 93 that protrudes toward and contacts the general portion 32a, and a relief portion 94 that allows the gradual-change portion 32b to escape. The extension portion 92 is provided with one protruding portion 93 and one relief portion 94 on each side in the circumferential direction.

[0066] The two protruding portions 93 protruding from the two adjacent extending portions 92 in the circumferential direction and facing each other are in contact with the general portion 32a from both sides in the circumferential direction. This allows the segment coil 40 to move in the radial direction, while restricting its movement in the circumferential direction.

[0067] The relief portion 94 prevents interference between the gradually changing portion 32b and the extension portion 92. (Method of manufacturing the stator) The method for manufacturing a stator includes a cuff support arrangement step, an insulating sheet arrangement step, a coil arrangement step, a restricting step, a pressing step, and a joining step. In this embodiment, the cuff support arrangement step, the insulating sheet arrangement step, the coil arrangement step, the pressing step, and the joining step are performed in this order. The restricting step is performed simultaneously with the coil arrangement step. However, the coil arrangement step and the pressing step are repeated multiple times in this order.

[0068] 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.

[0069] (Cuffsa placement process) 15, in the cuff support arrangement step, a cuff support 90A is arranged on one axial end face of the stator core 20. Although not shown, a cuff support 90B is arranged on the other end face of the stator core 20 opposite to the one end face.

[0070] (Coil placement process) 16, in the coil arrangement step, 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.

[0071] In the coil arrangement step, 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 (see FIG. 9). Therefore, a gap is provided between the arrangement portion 31 and the insulating sheet 50 in the width direction of the slot 23.

[0072] (Regulated process) In the restricting step, as the segment coil 40 is disposed inside the slot 23, the cuffs 90A come into contact with both circumferential sides of the first coil end 32. Similarly, although not shown, the cuffs 90B come into contact with both circumferential sides of the second coil end 33. As a result, radial movement of the segment coil 40 is permitted inside the slot 23, while circumferential movement is restricted.

[0073] As described above, in the restricting step, the cuff cover 90 comes into contact with the segment coil 40 at the same time as the segment coil 40 is placed inside the slot 23. Therefore, the restricting step is performed simultaneously with the coil placing step.

[0074] (Pressing process) 17, in the pressing process, the segment coil 40 in contact with the cuffs 90 is pressed toward the inner surface of the slot 23 on the radially outer side by the pressing jig 70. This causes each segment coil 40 to plastically deform along the inner surface of the slot 23. This eliminates the gap between the arrangement portion 31 and the insulating sheet 50 described above. Therefore, the width of the arrangement portion 31 becomes the same as the opening width of the insulating sheet 50.

[0075] As shown in FIG. 14, in the pressing step, gradual change portions 32b, 33b are formed on both sides of arrangement portion 31 in the axial direction as arrangement portion 31 is plastically deformed. 18, next, the coil arrangement step, the restriction step, and the pressing step are performed in this order for the two remaining segment coils 40, and then the coil arrangement step, the restriction step, and the pressing step are performed in this order for the remaining one segment coil 40. Note that the coil arrangement step, the restriction step, and the pressing step may be performed in this order for the three remaining segment coils 40.

[0076] Although not shown in the drawings, in the joining process, the first coil end 32 is twisted in one direction or the other in the circumferential direction with the extension portion 92 of the cuff cover 90A as a fulcrum. The operation and effects of this embodiment will be described.

[0077] (2-1) The manufacturing method of a stator includes a cuff support arrangement process, a coil arrangement process, a restricting process, and a pressing process. In the cuff support arrangement process, a cuff support 90 is arranged on both axial end faces of the stator core 20. In the coil arrangement process, the segment coil 40 is arranged inside the slot 23. In the restricting process, the cuff support 90 is brought into contact with the first coil end 32 and the second coil end 33 of the segment coil 40 from both circumferential sides. In the pressing process, the segment coil 40 with the cuff support 90 in contact 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.

[0078] According to this method, the cuffs 90 contact the first coil end 32 and the second coil end 33 of the segment coil 40 arranged inside the slot 23 from both sides in the circumferential direction. This allows the segment coil 40 to move radially inside the slot 23, while restricting its movement in the circumferential direction. This causes the multiple segment coils 40 that have been pressed and plastically deformed by the pressing jig 70 to be aligned radially inside the slot 23. This makes it possible to suppress variation in the circumferential positions of the multiple segment coils after plastic deformation.

[0079] <Example of change> 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.

[0080] In the first embodiment, the regulating jig 80 may have only the regulating member 81A. That is, in the regulating step, the regulating jig 80 may come into contact with the first coil end 32 but may not come into contact with the second coil end 33.

[0081] In the first embodiment, in the restricting step, the restricting jig 80 may come into contact with the portions where the gradual change portions 32b, 33b are to be formed. In the first embodiment, two restricting members 81A may be arranged on one axial end face of each tooth 22. Two restricting members 81B may be arranged on the other axial end face of each tooth 22.

[0082] In the second embodiment, the step of placing the cuffs 90A in the cuffs placement step may be performed after the coil placement step. In this case, the restricting step is performed for the first coil end 32 simultaneously with the step of placing the cuffs 90A.

[0083] In the second embodiment, the cuff support arrangement step may be performed after the insulating sheet arrangement step and before the coil arrangement step. 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.

[0084] In each embodiment, the number of arrangement portions 31 arranged inside the slot 23 may be changed as appropriate. 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.

[0085] 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.

[0086] In the first embodiment, a manufacturing apparatus for a stator of a rotating electric machine is illustrated as an example of a manufacturing apparatus for an armature, but a similar configuration can 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 a manufacturing method for an armature, but a similar method can be applied to a manufacturing method for a rotor of a rotating electric machine. [Explanation of symbols]

[0087] 10,110…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 50…Insulating sheet 60...Manufacturing equipment 70...Pressing tool 70a...Pressing surface 71…Facing part 80...Regulation jig 81, 81A, 81B...Regulation members 82...Protruding part 83…Relief section 90, 90A, 90B…Cuffs 91…Circular section 92...Extension part 93...Protrusion 94…Relief section

Claims

1. An apparatus for manufacturing an armature, comprising: a cylindrical core having a plurality of slots; and a coil disposed inside the slots, the coil having coil ends protruding from the slots in the axial direction of the core and constituted by a plurality of segment coils arranged side by side in a radial direction of the core, A restricting tool that contacts the coil end from both sides in the circumferential direction of the core to allow the segment coil to move in the radial direction inside the slot while restricting the movement in the circumferential direction; A pressing tool that presses the segment coil arranged inside the slot toward the inner surface of the slot in the radial direction to plastically deform the segment coil, The regulating jig is two protruding portions contacting 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 comprising: a cylindrical core having a plurality of slots; and a coil disposed inside the slots, the coil having coil ends protruding from the slots in an axial direction of the core; and a plurality of segment coils disposed side by side in a radial direction of the core, the method comprising the steps of: A coil placement process for placing the segment coil inside the slot; a restricting step of contacting the coil ends of the segment coils arranged inside the slots with restricting jigs from both sides in the circumferential direction of the core to allow the segment coils to move in the radial direction inside the slots while restricting their movement in the circumferential direction; A pressing process in which the segment coil in contact with the regulating jig is pressed toward the inner surface of the slot in the radial direction by a pressing jig, thereby plastically deforming the segment coil along the inner surface of the slot, The regulating jig is two protruding portions contacting 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, In the coil arrangement step, the segment coil is used that has 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, In the restricting step, the restricting jig is brought into contact with the first coil end from both sides in the circumferential direction. Manufacturing method of armatures.

3. 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 first coil end adjacent to the arrangement portion, In the restricting step, the restricting jig is brought into contact with a portion of the first coil end that is farther from the arrangement portion than a portion where the gradual change portion is to be formed, from both sides in the circumferential direction. A method for manufacturing the armature according to claim 2.

4. A method for manufacturing an armature comprising: a cylindrical core having a plurality of slots; a coil disposed inside the slots; and a cuff provided on an end surface in an axial direction of the core, the coil having coil ends protruding from the slots in the axial direction of the core and constituted by a plurality of segment coils arranged side by side in a radial direction of the core, the method comprising the steps of: a cuff cover arrangement step of arranging the cuff cover on the end surface of the iron core; A coil placement step of placing the segment coil inside the slot after or before the cuff placement step; a restricting step of contacting the cuffs with the coil ends of the segment coils arranged inside the slots from both sides in the circumferential direction of the core to allow the segment coils to move in the radial direction inside the slots while restricting the movement in the circumferential direction; A pressing process in which the segment coil in contact with the cuff is pressed toward the inner surface of the slot in the radial direction by a pressing tool, thereby plastically deforming the segment coil along the inner surface of the slot. The cuffs are two protruding portions contacting 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, In the coil arrangement step, the segment coil is used that has 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, In the restricting step, the cuffs are brought into contact with the first coil end from both sides in the circumferential direction. Manufacturing method of armatures.

Images