Stator manufacturing method

Abstract

To provide a stator manufacturing method where an assembling step of a segment coil to a stator core is more simplified.SOLUTION: A stator manufacturing method comprises an insertion step of inserting a lead side segment coil 20A coated with an insulation coated film and an opposite lead side segment coil 20B coated with the insulation coated film along a shaft direction of an annular yoke 11 into a plurality of slots 13 formed between a plurality of teeth 12 projected in a radial direction from the yoke 11, and electrically coupling the segment coils 20A and 20B by using a coupling member 25. In the insertion step, an exposure step is further provided, for integrally inserting the plurality of segment coils 20A and 20B into each slot 13, forming a hole 26 that penetrates the insulation coated film in a crossover part 23 of the segment coils 20A and 20B inserted into each slot 13, and forming a conductive exposure part.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a stator.

Background Art

[0002] Patent Document 1 describes a method for manufacturing a stator in which a lead-side segment coil and an anti-lead-side segment coil are electrically connected using a hollow connecting member. In the manufacturing method described in Patent Document 1, a lead-side segment coil and an anti-lead-side segment coil are inserted into the slots of the stator core one pair at a time, and the two segment coils are connected by a connecting member. Next, a probe is brought into contact with the conductor exposed portions of the two segment coils located within the slots, and resistance measurement is performed to inspect the electrical connection of the two segment coils.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in Patent Document 1, since the conductor exposed portions of the segment coils are located within the slots, each time a pair of segment coils is inserted into the slots from the outer peripheral side to the inner peripheral side of the stator core, it is necessary to perform an inspection by resistance measurement. In other words, it is necessary to repeat the process of inserting a pair of segment coils into the slots and performing an inspection by resistance measurement. Therefore, there is a problem that the man-hours for the process of assembling the segment coils into the stator core are large.

[0005] The present invention has been made to solve such problems, and an object thereof is to provide a method for manufacturing a stator in which the process of assembling segment coils into a stator core is further simplified.

Means for Solving the Problem

[0006] The stator manufacturing method according to the first aspect of the present invention includes an insertion step of inserting a lead-side segment coil covered with an insulating film and an anti-lead-side segment coil covered with an insulating film along the axial direction of the yoke into a plurality of slots formed between a plurality of teeth protruding radially from an annular yoke, and electrically connecting an end of the lead-side segment coil and an end of the anti-lead-side segment coil using a connecting member. In the insertion step, a plurality of the lead-side segment coils and a plurality of the anti-lead-side segment coils are inserted into the slots at once, and a hole penetrating the insulating film is formed in a coil end of the lead-side segment coil and a coil end of the anti-lead-side segment coil inserted into the slot to form a conductor exposed portion, and an exposure step is further provided.

Effect of the Invention

[0007] According to the stator manufacturing method according to the first aspect of the present invention, in the exposure step, a conductor exposed portion can be formed at the coil end of the segment coil, a probe can be brought into contact with the conductor exposed portion, and resistance measurement can be performed for inspection. Therefore, it becomes possible to insert a plurality of segment coils into the slots at once. Further, after inserting a plurality of segment coils into the slots, the plurality of segment coils can be collectively inspected by resistance measurement. Thus, it is possible to provide a stator manufacturing method in which the step of assembling the segment coils to the stator core is further simplified.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Mode for Carrying Out the Invention

[0009] Embodiment 1 Hereinafter, Embodiment 1 of the present invention will be described with reference to the drawings. However, the present invention is not limited to the following Embodiment 1. Also, for clarity of explanation, the following description and drawings are appropriately simplified.

[0010] FIG. 1 is a perspective view showing an example of a stator 1 according to Embodiment 1 of the present invention. FIG. 2 is a cross-sectional view showing an example of a stator core 10. FIG. 2 shows a cross-section obtained by cutting the stator core 10 in a plane perpendicular to the axial direction (Z-axis direction) of the stator 1. FIGS. 3 and 4 are cross-sectional views for explaining a stator manufacturing method according to Embodiment 1 of the present invention. Note that FIGS. 3 and 4 show cross-sections obtained by cutting the stator 1 in a plane parallel to the axial direction (Z-axis direction) of the stator 1.

[0011] The stator 1 is a stator used in a rotating electrical machine. The rotating electrical machine in which the stator 1 is used is composed of the stator 1 shown in FIG. 1 and a rotor (not shown) arranged at a predetermined interval on the inner peripheral side of the stator 1. Note that the rotating electrical machine in which the stator 1 is used may be composed of a rotor (not shown) arranged at a predetermined interval on the outer peripheral side of the stator 1. As shown in FIGS. 1 and 2, the stator 1 includes a stator core 10, a plurality of segment coils 20, and the like.

[0012] The stator core 10 is formed by laminating annular thin magnetic plates in the axial direction of the stator 1 (the Z-axis direction in FIG. 1), and has a generally cylindrical shape as a whole. In FIG. 2, the radial direction and the circumferential direction are shown. The axial direction is the direction along the central axis of the central hole of the stator core 10. The radial direction is a radial direction passing through the central axis in a plane perpendicular to the axial direction, and the circumferential direction is a direction along the circumferential direction centered on the central axis.

[0013] The stator core 10 includes a yoke 11, teeth 12, and slots 13. A plurality of teeth 12 protruding in the radial direction are formed at a plurality of positions on the inner peripheral surface of the annular yoke 11 at predetermined intervals. Slots 13 are formed in the spaces between adjacent teeth 12, 12.

[0014] The slot 13 has an opening shape extending in the radial direction of the stator core 10 as the longitudinal direction. Also, the slot 13 opens toward the inner peripheral surface of the stator core 10. Here, an example is shown in which the circumferential width of the slot 13 is formed to be constant over the radial direction. Note that the width of the slot 13 may be formed to widen as it goes toward the outer side in the radial direction, or conversely, may be formed to narrow as it goes toward the outer side in the radial direction.

[0015] Three-phase (U-phase, V-phase, W-phase) coils are wound around each slot 13 of the stator core 10. The number of slots 13 formed in the stator core 10 is formed corresponding to the number of poles of the rotor. A plurality of segment coils 20 are arranged side by side in the longitudinal direction of the slot 13.

[0016] The segment coil 20 is formed using a plurality of substantially U-shaped conductor segments. The conductor segments are formed by, for example, bending a flat conductor with a rectangular cross-section into a substantially U shape. Also, the segment coil 20 is covered with an insulating coating. Specifically, as shown in FIGS. 3 and 4, the segment coil 20 has two legs 21 and 22 that are parallel to each other and a connecting wire portion 23 that connects them. Also, one of the two legs 21 and 22 is longer than the other. In the example shown in FIGS. 3 and 4, the leg 21 is longer than the leg 22. Also, insertion portions 24 that can be inserted into a connecting member 25, which will be described later, are provided at the ends of the two legs 21 and 22. Also, the insertion portion 24 of the leg 22 is pre-inserted into the connecting member 25, which is a metallic tube such as a hollow copper tube. Then, the segment coil 20 is inserted into the slot 13 along the axial direction of the stator core 10 from the two legs 21 and 22. And the connecting wire portion 23 that connects the two legs 21 and 22 protrudes outside the axial end face of the stator core 10.

[0017] Also, the segment coil 20 inserted into the slot 13 from the lead side (the upper side in FIGS. 3 and 4) of the stator core 10 is referred to as the lead side segment coil 20A, and the segment coil 20 inserted into the slot 13 from the anti-lead side (the lower side in FIGS. 3 and 4) of the stator core 10 is referred to as the anti-lead side segment coil 20B. When there is no particular need to distinguish between the lead side segment coil 20A and the anti-lead side segment coil 20B, it is simply referred to as the segment coil 20. And the insertion portion 24 of the leg 21 of the lead side segment coil 20A is inserted into the connecting member 25 into which the insertion portion 24 of the leg 22 of the anti-lead side segment coil 20B facing the lead side segment coil 20A is pre-inserted. Thereby, the lead side segment coil 20A and the anti-lead side segment coil 20B are electrically connected. Note that the insertion portion 24 inserted into the connecting member 25 and the connecting member 25 are not covered with an insulating coating.

[0018] Although FIGS. 3 and 4 are simplified, actually, a plurality of segment coils 20 are inserted into two slots 13 separated in the circumferential direction while being arranged side by side in the radial direction of the stator core 10. The portion of the segment coil 20 protruding from one end face in the axial direction of the stator core 10 is bent so as to be inclined with respect to the axial direction of the stator core 10.

[0019] Next, with reference to FIGS. 3 and 4, a stator manufacturing method according to Embodiment 1 of the present invention will be described. Hereinafter, among the steps of the stator manufacturing method, an assembling step of assembling the segment coil 20 to the stator core 10 will be described. Specifically, the assembling step includes an insertion step and an exposure step.

[0020] In the insertion step, the lead-side segment coil 20A and the anti-lead-side segment coil 20B are inserted into the plurality of slots 13 of the stator core 10, and the end of the lead-side segment coil 20A and the end of the anti-lead-side segment coil 20B are electrically connected by the connecting member 25. Specifically, in the stator manufacturing method according to the first embodiment, in the insertion step, a plurality of lead-side segment coils 20A and a plurality of anti-lead-side segment coils 20B are inserted into the slots 13 at once. Note that the insertion of the plurality of segment coils 20 into the slots 13 is performed, for example, by pressing with a jig (not shown) whose surface facing the coil end (jumper wire portion 23) of the segment coil 20 has a flat shape.

[0021] In the exposure step, holes 26 (described later) that penetrate the insulating coating are formed in the coil ends of the lead-side segment coil 20A and the anti-lead-side segment coil 20B inserted into the slots 13 to form conductor exposed portions. Note that in the exposure step, the holes 26 may be formed in the insulating coating by piercing the insulating coating with a probe for resistance measurement.

[0022] Then, as shown in FIG. 4, resistance measurement is performed by bringing a probe into contact with a conductor exposed portion formed by forming a hole 26 in an insulating film, and it is inspected whether the electrical connection between the lead-side segment coil 20A and the anti-lead-side segment coil 20B is properly made.

[0023] FIG. 5 shows a diagram for explaining the holes 26 for conductor exposure formed at the coil ends. The upper side of FIG. 5 shows an enlarged cross-section of the segment coil 20 obtained by cutting the stator 1 along a plane parallel to the axial direction of the stator core 10. The lower side of FIG. 5 is a top view showing the holes 26 formed in a plurality of adjacent segment coils 20. As shown in FIG. 5, in the above exposure step, in the plurality of holes 26 formed in the coil ends (jumper wire portions 23) of the plurality of segment coils 20, the distances D1, D2, D3 between adjacent holes 26 are such that the holes 26 are formed so as to be distances that enable insulation between the plurality of segment coils. Note that the distances D1, D2, D3 between adjacent holes 26 are the distances between the edge portions at the upper ends of the holes 26. Further, the diameter of the hole 26 is small enough to enable insulation between the plurality of segment coils and large enough for a probe for resistance measurement to reliably contact the conductor exposed portion. Also, the shape of the hole 26 is not limited to the shape shown in FIG. 5, and for example, a hole having substantially the same diameter along the depth direction may be used.

[0024] Comparative Example Next, with reference to FIG. 6, the manufacture of the stator of the comparative example will be described. Among the components of the stator 30 according to the comparative example, those having the same configuration as the stator 1 according to the first embodiment are denoted by the same reference numerals. In the comparative example, the insulating coatings at the ends of the legs 21 and 22 of the segment coil 31 are peeled off, and conductor exposed portions 32 are formed. Then, as shown in FIG. 6, a pair of lead-side segment coils 31A and anti-lead-side segment coils 31B are inserted into the slots of the stator core 10 one by one, and both segment coils 31A and 31B are connected by a connecting member 25. Next, a probe is brought into contact with the conductor exposed portions 32 located within the slots 13 of both segment coils 31A and 31B, resistance measurement is performed, and the electrical connection of both segment coils 31A and 31B is inspected.

[0025] Therefore, in the comparative example, since the conductor exposed portions 32 are located within the slots 13, each time a pair of segment coils 31A and 31B are inserted into the slots 13 from the outer peripheral side to the inner peripheral side of the stator core 10, it is necessary to perform an inspection by resistance measurement. In other words, it is necessary to repeatedly perform the steps of inserting a pair of segment coils 31A and 31B into the slots 13 one by one and performing an inspection by resistance measurement. Therefore, there is a problem in that the man-hours for the step of assembling the segment coil 31 to the stator core 10 are large.

[0026] Further, in the comparative example, as shown in FIG. 7, in order to ensure insulation between adjacent segment coils 31 within the slots 13, notches 33 are formed in the conductor exposed portions 32 of the legs 21 and the portions facing the connecting member 25. The notches 33 can be formed by pressing the corresponding portions of the legs 21. However, since the treatment of the meat (metal) generated by the pressing process is generally difficult, the wider the pressing range, the more difficult it is to process the segment coil 31.

[0027] On the other hand, according to the stator manufacturing method according to Embodiment 1, in the exposure step, a conductor exposed portion is formed at the coil end (jumper portion 23) of the segment coil 20, and a probe is brought into contact with the conductor exposed portion to perform resistance measurement for inspection. Therefore, it becomes possible to insert a plurality of segment coils 20 into the slot 13 at once. Further, after inserting a plurality of segment coils 20 into the slot 13, inspection by resistance measurement can be performed collectively on the plurality of segment coils 20. Thus, it is possible to provide a stator manufacturing method in which the assembling step of the segment coil 20 to the stator core 10 is further simplified.

[0028] In addition, since it is not necessary to form the conductor exposed portion 32 at the ends of the leg portions 21 and 22, the range in which the notch portion 33 is formed in the leg portion 21 can be narrowed. Specifically, in Embodiment 1, the notch portion 33 may be provided only in the portion of the leg portion 21 facing the connecting member 25. Therefore, the range in which the pressing process is performed on the leg portion 21 can be reduced, and the processing of the segment coil 31 can be performed more easily.

[0029] In addition, in the exposure step, by piercing the probe for resistance measurement into the insulating film to form holes 26 in the insulating film, the formation of the conductor exposed portion and the contact of the probe to the conductor exposed portion can be performed simultaneously, and furthermore, the stator manufacturing method can be simplified.

[0030] In addition, in the plurality of holes 26 formed at the coil ends (jumper portions 23) of the plurality of segment coils 20, the distances D1, D2, D3 between adjacent holes 26 are distances that enable insulation between the plurality of segment coils. Thereby, the adverse effects due to forming the holes 26 in the insulating film can be suppressed.

[0031] Note that the present invention is not limited to the above-described embodiment, and can be appropriately changed without departing from the gist.

Explanation of Reference Numerals

[0032] 1 Stator 10 Stator core 11 Yoke 12 Teeth 13 Slots 20 Segment coil 20A Lead-side segment coil 20B Anti-lead-side segment coil 21, 22 Legs 23 Jumper section 24 Insertion section 25 Connecting member 26 Hole

Claims

【Claim 1】 An insertion step of inserting a lead-side segment coil coated with an insulating film and an anti-lead-side segment coil coated with an insulating film along the axial direction of the yoke into a plurality of slots formed between a plurality of teeth protruding radially from an annular yoke, and electrically connecting an end of the lead-side segment coil and an end of the anti-lead-side segment coil using a connecting member, comprising: In the insertion step, a plurality of the lead-side segment coils and a plurality of the anti-lead-side segment coils are inserted into the slots in a batch, further comprising an exposure step of forming holes penetrating the insulating film in a coil end of the lead-side segment coil inserted into the slot and a coil end of the anti-lead-side segment coil to form conductor exposed portions, In the exposure step, the holes are formed in the insulating film by piercing a probe for resistance measurement into the insulating film, In the exposure step, the positions of the holes formed in one of the adjacent coil ends are different from the positions of the holes formed in the other coil end along the direction in which the coil ends extend, In the exposure step, among the plurality of holes formed in the coil ends of the plurality of lead-side segment coils and the coil ends of the plurality of anti-lead-side segment coils, the distance between adjacent holes is a distance that enables insulation between the plurality of lead-side segment coils and insulation between the plurality of anti-lead-side segment coils, A stator manufacturing method.

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