Stator manufacturing method and stator manufacturing device

Abstract

To provide a manufacturing method for a stator that can sufficiently accommodate a smaller diameter of the stator by suppressing a size of a device for bending and forming a portion for a coil end.SOLUTION: A manufacturing method for a stator 100 includes an insertion step for inserting a plurality of segment coils 120 into slots 13 and a bending step in which after the insertion step, portions 123 for coil ends are bent by moving the pressing member 211 that presses and bends portions 123 for coil ends that become coil end portions 23 along a circumferential direction and the support member 221 relative to the stator core 10 in the circumferential direction and relative to an axial direction, and then the portions 123 for the coil ends lined up in the circumferential direction are bent and formed by repeatedly shifting to bending by the pressing member 211 and the supporting member 221 of the next portions 123 for the coil end adjacent to the bent portions 123 for the coil ends.SELECTED DRAWING: Figure 4

Description

[Technical Field]

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

[0002] BACKGROUND ART Conventionally, a stator manufacturing method and a stator manufacturing device are known that perform bending of segment coils arranged in slots of a stator core (see, for example, Patent Document 1).

[0003] The above-mentioned Patent Document 1 discloses a method for manufacturing a stator that includes a step of pressing the coil ends of circumferentially arranged segment coils with multiple forming jigs to bend the coil ends. The multiple forming jigs are provided in the same number as the total number of circumferentially arranged coil ends, and are arranged in a single circumferential row facing the coil ends. In the above-mentioned method for manufacturing a stator, all of the coil ends are bent simultaneously by pressing the coil ends one by one with each of the multiple forming jigs. In other words, in the above-mentioned method for manufacturing a stator, multiple circumferentially arranged coil ends are bent simultaneously all at once using multiple forming jigs arranged circumferentially. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6848130 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the stator manufacturing method (manufacturing apparatus) of Patent Document 1, multiple circumferentially arranged coil ends are bent simultaneously, resulting in an excessively large forming load (reaction force from the multiple coil ends) during bending, requiring the apparatus that bends the coil ends to have relatively high rigidity. This results in a relatively large apparatus that bends the coil ends. Furthermore, in the manufacturing method (manufacturing apparatus) of Patent Document 1, there is a limit to how small the diameter of the stator to be manufactured can be, given the interference between adjacent forming jigs and the rigidity of the forming jigs. For these reasons, there has been a need for improvements that reduce the size of the apparatus that bends the coil ends and fully accommodate smaller diameter stators.

[0006] The present invention has been made to solve the above-mentioned problems, and one object of the present invention is to provide a stator manufacturing method and a stator manufacturing device that can reduce the size of the device that bends the coil end portion and can fully accommodate the reduction in the diameter of the stator. [Means for solving the problem]

[0007] In order to achieve the above object, a stator manufacturing method in a first aspect of the present invention includes an insertion process for inserting a plurality of segment coils into slots of a stator core so that the coil end portions that become the coil end sections protrude from the axial end face of the stator core and so that the plurality of coil end portions are aligned circumferentially about the stator core, and after the insertion process, a bending process for bending the plurality of coil end portions that are aligned circumferentially by moving a bending member that presses the coil end portions and bends them along the circumferential direction relative to the stator core in both the circumferential and axial directions, thereby bending the coil end portions, and then moving on to bending the next coil end portion adjacent to the bent coil end portion with the bending member, thereby repeating this process and bending the plurality of coil end portions that are aligned circumferentially.

[0008] In a stator manufacturing method according to a first aspect of the present invention, as described above, a bending step is provided in which a bending member that presses a coil end portion to bend it circumferentially is moved circumferentially and axially relative to the stator core to bend the coil end portion, and then the bending member moves to bend the next coil end portion adjacent to the bent coil end portion, repeating this process to bend multiple circumferentially arranged coil end portions. This allows multiple coil end portions to be bent using a single bending member, eliminating the need to bend multiple coil end portions simultaneously as in the conventional method, thereby reducing the rigidity required of an apparatus for bending coil end portions. Furthermore, because multiple adjacent coil end portions can be bent using a single bending member, the circumferentially arranged coil end portions can be bent without providing the same number of bending members as the total number of circumferentially arranged coil end portions. Therefore, when reducing the diameter of the stator to be manufactured, there is no need to consider interference between adjacent bending members as in the past.As a result, the size of the device that bends the coil end portion can be reduced, making it possible to fully accommodate reductions in the diameter of the stator.

[0009] In the method for manufacturing a stator according to the first aspect, the bending step preferably includes moving bending members, the number of which is less than the total number of the coil end portions arranged in the circumferential direction, relative to the stator core in the circumferential direction and in the axial direction, to bend the coil end portions.

[0010] With this configuration, bending is performed using fewer bending members than the total number of coil end portions arranged circumferentially. This prevents all coil end portions from being bent simultaneously, effectively reducing the rigidity required of the device that bends the coil end portions. This effectively reduces the size of the device that bends the coil end portions. Furthermore, for example, when two bending members are arranged circumferentially at an angular interval of 180 degrees, a large distance can be ensured between the two bending members, thereby preventing interference between the bending members and allowing the bending members to be made thicker, thereby increasing rigidity. As a result, the device can more reliably accommodate smaller diameter stators.

[0011] In the method for manufacturing a stator according to the first aspect, the bending step preferably includes moving the bending member relative to the stator core in the circumferential direction and in the axial direction, bending the coil end portion along the circumferential direction while moving the bending member over the coil end portion, thereby transitioning to bending the next coil end portion adjacent to the bent coil end portion with the bending member, and repeating this process to bend and form the plurality of coil end portions.

[0012] With this configuration, for example, compared to a case where, after bending one coil end portion, the bending member is temporarily retracted in the axial direction away from the stator core without going over the first coil end portion, and then the bending member moves on to bending the next adjacent coil end portion, by bending the coil end portion along the circumferential direction while going over the coil end portion, it is possible to continuously and efficiently bend multiple circumferentially adjacent coil end portions.

[0013] In this case, the bending process preferably includes moving the bending member relative to the stator core simultaneously in the circumferential and axial directions to overcome the coil end portions, thereby bending the multiple coil end portions in a spiral shape.

[0014] With this configuration, simply by setting the circumferential speed and axial speed of the bending member, the bending member can be moved in a spiral pattern, making it possible to easily bend multiple coil end portions.

[0015] In the above-described method for manufacturing a stator according to the first aspect, the bending step preferably includes bending the plurality of coil end portions by winding the bending member around the stator core a plurality of times in the circumferential direction and gradually increasing the bending angle of the coil end portions relative to the axial direction.

[0016] With this configuration, each coil end portion can be bent in multiple steps, reducing the bending angle when the bending member presses the coil end portion once, thereby preventing the bent coil end portion from interfering with the next adjacent coil end portion.

[0017] In a configuration in which the bending process includes performing bending using bending members provided in a number less than the total number of multiple coil end portions lined up in the circumferential direction, preferably the bending process includes simultaneously performing bending of multiple coil end portions in a number less than the total number using bending members provided in a number less than the total number of multiple coil end portions lined up in the circumferential direction and at equal angular intervals in the circumferential direction.

[0018] With this configuration, more coil end portions can be bent at the same time compared to when only one bending member is used, so that multiple coil end portions can be bent efficiently.

[0019] In a second aspect of the present invention, a stator manufacturing apparatus includes a bending member that presses a plurality of coil end portions that become a plurality of coil end sections lined up in the circumferential direction of the stator core to bend them along the circumferential direction, and a moving mechanism that moves the bending member relative to the stator core in the circumferential direction and also in the axial direction of the stator core to bend a coil end portion, and then moves on to bending the next coil end portion adjacent to the bent coil end portion using the bending member, repeating this process, thereby bending the plurality of coil end portions lined up in the circumferential direction, and the number of bending members provided is smaller than the total number of the coil end portions lined up in the circumferential direction.

[0020] In a stator manufacturing apparatus according to a second aspect of the present invention, as described above, a moving mechanism is provided that moves a bending member relative to the stator core in the circumferential direction and in the axial direction of the stator core to bend a coil end portion and then move on to bending the next coil end portion adjacent to the bent coil end portion, repeatedly, thereby bending multiple circumferentially arranged coil end portions. The number of bending members is smaller than the total number of circumferentially arranged coil end portions. This allows multiple coil end portions to be bent using a single bending member, eliminating the need to bend multiple coil end portions simultaneously, as in the conventional method, and reducing the rigidity required for an apparatus that bends coil end portions. Furthermore, because multiple adjacent coil end portions can be bent using a single bending member, the circumferentially arranged coil end portions can be bent without providing the same number of bending members as the total number of circumferentially arranged coil end portions. Therefore, when reducing the diameter of the stator to be manufactured, there is no need to consider interference between adjacent bending members as in the past.As a result, the size of the device that bends the coil end portion can be reduced, making it possible to fully accommodate reductions in the diameter of the stator.

[0021] In the above-described method for manufacturing a stator, the following configuration may also be considered.

[0022] (Additional note 1) That is, the bending process includes bending and forming a plurality of coil end portions by alternately repeating relative movement of the bending member relative to the stator core only in the circumferential direction and relative movement of the bending member relative to the stator core only in the axial direction.

[0023] With this configuration, the bending member can be used to bend the multiple coil end portions that are aligned in the circumferential direction while maintaining the position of the bending member in the axial direction, thereby making it possible to uniform the amount of bending of the multiple coil end portions. [Brief explanation of the drawings]

[0024] [Figure 1] FIG. 2 is a perspective view showing a stator according to an embodiment. [Figure 2] 3A and 3B are schematic diagrams for explaining segment coils of a stator according to an embodiment. [Figure 3] FIG. 2 is a perspective view showing a coil end portion of a stator according to an embodiment. [Figure 4] FIG. 2 is a schematic diagram illustrating a stator manufacturing apparatus according to an embodiment. [Figure 5] 4 is a view of a pressing member and a supporting member of the stator manufacturing apparatus according to the embodiment as viewed from the circumferential direction. FIG. [Figure 6] 5A and 5B are schematic diagrams for explaining a spiral track along which a pressing member and a support member of the stator manufacturing apparatus according to the embodiment are moved. [Figure 7] 10 is a view of a pressing member and a supporting member of the stator manufacturing apparatus according to the embodiment as viewed from a radial direction. FIG. [Figure 8] 10 is a diagram showing a state in which portions for coil ends in the outermost row in the radial direction have been bent in the circumferential direction by a pressing member of the stator manufacturing apparatus according to the embodiment. FIG. [Figure 9]FIG. 2 is a perspective view showing a restricting member of the stator manufacturing apparatus according to the embodiment. [Figure 10] 5A to 5C are diagrams illustrating a manufacturing flow of a stator according to an embodiment. [Figure 11] 10A and 10B are diagrams for explaining the segment coil preparation process in the manufacturing flow of the stator according to the embodiment. [Figure 12] 10A to 10C are diagrams for explaining an insertion step in the manufacturing flow of the stator according to the embodiment. [Figure 13] 10 is a plan view showing a state immediately before starting to bend a portion for a coil end in the circumferential direction in a bending step of the manufacturing flow of the stator according to the embodiment. FIG. [Figure 14] 10 is a plan view showing a state in which the coil end portions of the outermost row in the radial direction have been bent in the circumferential direction in a bending step of the manufacturing flow of the stator according to the embodiment. FIG. [Figure 15] 10 is a plan view showing a state in which the coil end portions of the outermost row and the second outermost row in the radial direction have been bent in the circumferential direction in a bending step of the manufacturing flow of the stator according to the embodiment. FIG. [Figure 16] 10A to 10C are diagrams for explaining an operation of slightly bending each of a plurality of coil end portions arranged in the circumferential direction in a bending process of the manufacturing flow of the stator according to the embodiment. [Figure 17] 10A and 10B are schematic diagrams for explaining zigzag tracks along which pressing members and support members of a stator manufacturing device according to a modified example are moved. DETAILED DESCRIPTION OF THE INVENTION

[0025] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0026] 1 to 16, the configuration of a manufacturing apparatus 200 for a stator 100 according to an embodiment and a manufacturing method for the stator 100 will be described. Below, the configuration of the stator 100 to be manufactured will be described, and then the configuration of the manufacturing apparatus 200 for the stator 100 and the manufacturing method for the stator 100 will be described in order.

[0027] (Stator configuration) The configuration of the stator 100 will be described with reference to FIGS.

[0028] In the following description, the axial, radial, and circumferential directions of the stator core 10 (see FIG. 1) of the stator 100 are referred to as the Z direction, the R direction, and the C direction, respectively. Furthermore, one side and the other side in the axial direction (Z direction) are referred to as the Z1 side and the Z2 side, respectively. Furthermore, the inner side and the outer side in the radial direction (R direction) are referred to as the R1 side and the R2 side, respectively. Furthermore, one side and the other side in the C direction are referred to as the C1 side and the C2 side, respectively. In this embodiment, a bending process is performed in which a coil end portion 123 (see FIG. 12), which will be described later, is bent from the Z2 side of the stator core 10 by a manufacturing apparatus 200 for the stator 100 (see FIG. 4).

[0029] 1, the stator 100 constitutes a part of an inner rotor type rotating electric machine (not shown) together with a rotor (not shown) arranged on the R1 side of the stator 100 so as to face the stator 100. The rotating electric machine is, for example, a motor, a generator, or a motor / generator.

[0030] The stator 100 includes a stator core 10 having a cylindrical shape with a central axis A along the Z direction as the central axis, and a coil 20.

[0031] The stator core 10 is formed by stacking a plurality of electromagnetic steel plates in the Z direction. The stator core 10 includes an annular back yoke 11 and a plurality of teeth 12 protruding from the back yoke 11 toward the R1 side. A slot 13 is formed between each of the teeth 12 adjacent to each other in the C direction. That is, the stator core 10 includes a plurality of slots 13. Each of the plurality of slots 13 is provided to extend in the Z direction.

[0032] Coil 20 is configured to generate magnetic flux when supplied with three-phase AC power. As an example, coil 20 is configured from a conductor wire whose main component is any of copper, copper alloy, aluminum, and aluminum alloy, and an insulating coating that covers the conductor wire.

[0033] 2, the coil 20 is formed by joining a plurality of segment coils 20a. Each of the segment coils 20a includes a pair of slot-receiving portions 21 housed in the slot 13, a coil end portion 22 protruding in the Z1 direction from the Z1-side end face 10a of the stator core 10, and two coil end portions 23 protruding in the Z2 direction from the Z2-side end face 10a of the stator core 10 (the axial end face of the stator core 10).

[0034] Each of the pair of slot-accommodated portions 21 is accommodated (inserted) in a different slot 13. That is, each of the pair of slot-accommodated portions 21 is arranged to extend along the Z direction. The coil end portion 22 connects the pair of slot-accommodated portions 21. As a result, in each of the segment coils 20a, the portion composed of the pair of slot-accommodated portions 21 and the coil end portion 22 is formed in a U-shape.

[0035] Each of the two coil end portions 23 is disposed on the Z2 side of the stator core 10. Each of the two coil end portions 23 is connected to the opposite side of the coil end portions 22 of each of the pair of slot-accommodated portions 21. Each of the tip portions 23a (opposite the slot-accommodated portions 21) of the two coil end portions 23 is joined (connected) by welding to the tip portion 23a of the coil end portion 23 of the other segment coil 20a on the Z2 side of the stator core 10. As an example, the total number of coil end portions 23 aligned in the circumferential direction is 48.

[0036] The figure shows a state in which no insulating coating is formed on each of the tip portions 23a of the two coil end portions 23 (the conductor wire is exposed) so that each of the tip portions 23a of the two coil end portions 23 can be connected to the tip portion 23a of the coil end portion 23 of another segment coil 20a by welding. Although not shown, the tip portion 23a of the coil end portion 23 is insulated with a resin material such as varnish after the tip portion 23a of its own coil end portion 23 is connected to the tip portion 23a of the coil end portion 23 of the other segment coil 20a.

[0037] 3, each of the two coil end portions 23 is bent in a direction along the C direction with respect to the slot-accommodating portion 21 extending in the Z direction, with the root portion 23b of the coil end portion 23 as a bending fulcrum. As a result, each of the two coil end portions 23 extends obliquely with respect to the Z direction.

[0038] In the stator 100, the tip ends 23a of the multiple coil end portions 23 are arranged at approximately equal angular intervals along the C direction. Sets of the tip ends 23a of the multiple coil end portions 23 arranged along the C direction are arranged along the R direction.

[0039] The multiple coil end portions 23 aligned in the C direction in the first row from the R2 side (hereinafter referred to as first-row coil end portions 23) are bent toward the C1 side so as to align with the C direction relative to the slot-accommodated portions 21 extending in the Z direction. The multiple coil end portions 23 aligned in the C direction in the second row from the R2 side (hereinafter referred to as second-row coil end portions 23) are bent toward the C2 side so as to align with the C direction relative to the slot-accommodated portions 21 extending in the Z direction. The tip ends 23a of the multiple first-row coil end portions 23 and the tip ends 23a of the multiple second-row coil end portions 23 face each other in the R direction and are joined to each other. The configuration of the coil end portions 23 arranged on the R1 side of the second-row coil end portions 23 is also substantially similar to the configurations of the first-row coil end portions 23 and the second-row coil end portions 23.

[0040] (Stator manufacturing equipment) A manufacturing apparatus 200 for the stator 100 according to this embodiment will be described with reference to FIGS.

[0041] As shown in FIG. 4, the manufacturing apparatus 200 for the stator 100 includes a pressing member 211 (an example of the "bending member" in the claims), a pressing member motor 212, a support member 221 (an example of the "bending member" in the claims), a support member motor 222, a support unit 231, a support unit motor 232, a regulating member 241 (see FIG. 9), a regulating member motor 242, a stator support portion 251, and a stator support portion motor 252.

[0042] The pressing member motor 212, the support member motor 222, the support unit motor 232, and the stator support motor 252 constitute a movement mechanism 200a that moves the pressing member 211 and the support member 221 relative to the stator core 10.

[0043] The movement mechanism 200a is configured to move the pressing member 211 and the support member 221 relative to the stator core 10 in the circumferential direction (C direction) and also in the axial direction (Z direction) of the stator core 10 to bend the coil end portion 123, and then move on to bending the next coil end portion 123 adjacent to the bent coil end portion 123 using the pressing member 211 and support member 221, repeating this process to bend the multiple coil end portions 123 lined up in the circumferential direction. Details of the bending (bending process) will be described later.

[0044] The manufacturing apparatus 200 is provided with a plurality of pairs of pressing members 211 and support members 221, with one pressing member 211 and one support member 221 as one pair. As an example, the manufacturing apparatus 200 of this embodiment is provided with two pairs of pressing members 211 and support members 221. The two pairs of pressing members 211 and support members 221 are arranged at equal angular intervals (180-degree intervals) in the circumferential direction. Note that the manufacturing apparatus 200 is provided with a smaller number (two pairs) of pressing members 211 and support members 221 (one pair) than the total number (48 pieces) of the plurality of coil end portions 123 lined up in the circumferential direction.

[0045] In this way, the manufacturing apparatus 200 is configured to simultaneously bend a plurality (two) of coil end portions 123, a number that is fewer than the total number (48) of coil end portions 123 lined up in the circumferential direction, using (two sets of) pressing members 211 and support members 221 that are provided at equal angular intervals in the circumferential direction. Note that, if the forming load is compared with that of a manufacturing apparatus that bends all 48 coil end portions simultaneously, it goes without saying that the manufacturing apparatus 200 can keep the forming load extremely small.

[0046] The pressing member 211 and the support member 221 are configured to press and bend a plurality of coil end portions 123 that become a plurality of coil end sections 23 arranged in the circumferential direction (direction C) of the stator core 10 along the circumferential direction.

[0047] Pressing member 211 is configured to be movable in the Z direction relative to stator core 10 by driving pressing member motor 212. That is, pressing member 211 is configured to be movable in the Z direction relative to stator core 10. Furthermore, supporting member 221 is configured to be movable in the Z direction relative to stator core 10 by driving supporting member motor 222. That is, supporting member 221 is configured to be movable in the Z direction relative to stator core 10.

[0048] Support unit 231 supports pressing member 211 and support member 221. Support unit 231 is configured to be movable in the R direction relative to stator core 10 by driving support member motor 222. That is, pressing member 211 and support member 221 are configured to be simultaneously movable relative to stator core 10 in the R direction.

[0049] Stator support portion 251 supports stator 100. Stator support portion 251 is configured to be rotatable in direction C around central axis A (see FIG. 1) of stator core 10 by driving stator support portion motor 252. In other words, pressing member 211 and support member 221 are simultaneously configured to be movable relative to stator core 10 in direction C.

[0050] As shown in FIG. 5, the pressing member 211 is configured to be able to bend the coil end portion 123 in the C direction by pressing the tip end portion 123a of the coil end portion 123 that protrudes from the end face 10a on the Z2 side of the stator core 10 and that becomes the coil end portion 23 aligned in the R direction in each of the multiple slots 13 (see FIG. 1) of the stator core 10.

[0051] Specifically, the manufacturing apparatus 200 is configured to perform bending forming of a plurality of coil end portions 123 by causing the pressing member 211 and the support member 221 to make multiple turns (for example, 20 turns) in the circumferential direction of the stator core 10, and gradually increasing the bending angle θ (see Figure 7) of the coil end portions 123 with respect to the axial direction (Z direction).

[0052] At this time, the manufacturing apparatus 200 moves the pressing member 211 and the support member 221 relative to the stator core 10 in the circumferential direction and also in the axial direction, bending the coil end portion 123 in the circumferential direction while climbing over the coil end portion 123, thereby transitioning to bending the next coil end portion 123 adjacent to the bent coil end portion 123 with the bending member, and repeating this process to bend the multiple coil end portions 123. In other words, the manufacturing apparatus 200 is configured to bend one coil end portion 123, and then continuously bend the multiple adjacent coil end portions 123 without having to perform a restart operation such as temporarily retreating in the axial direction in order to bend the next adjacent coil end portion 123.

[0053] Furthermore, the manufacturing apparatus 200 (moving mechanism 200a) is configured to simultaneously move the pressing member 211 and the supporting member 221 relative to the stator core 10 in the circumferential direction and the axial direction to move them over the coil end portions 123, thereby bending the multiple coil end portions 123 (see FIG. 6). That is, the manufacturing apparatus 200 (moving mechanism 200a) is configured to move the pressing member 211 and the supporting member 221 so that they gradually approach the stator core 10 while moving them on a trajectory that is continuously inclined in an oblique direction when viewed from direction C.

[0054] As an example, the axial and circumferential moving speeds of the pressing member 211 and the support member 221 at this time are each substantially constant. However, in the final stage where the pressing member 211 approaches the stator core 10 and the bending is completed, the manufacturing apparatus 200 sets the axial moving speed of the pressing member 211 to substantially zero (including zero) so that the bending angles θ (see FIG. 7) of the multiple coil end portions 123 lined up in the circumferential direction become the same.

[0055] 5, the support member 221 is disposed on the R2 side of the pressing member 211. The support member 221 is configured to be able to support the tip portion 123a of the coil end portion 123 from the R2 side.

[0056] Specifically, when starting to press the pressing member 211 against the tip portion 123a of the coil end portion 123, the pressing member 211 and the support member 221 are arranged so that the tip portion 221a of the support member 221 on the stator core 10 side is closer to the stator core 10 than the tip portion 211a of the pressing member 211 on the stator core 10 side. Also, as shown in Fig. 7, the position of the support member 221 in the R direction is substantially the same as the position of the pressing member 211 in the R direction. As a result, when the tip portion 211b of the pressing member 211 presses the tip portion 123a of the coil end portion 123, the tip portion 123a of the coil end portion 123 is supported from the R2 side by the support member 221.

[0057] The pressing member 211 is configured to be movable relative to the stator core 10 in the Z direction independently of the support member 221. In other words, the relative position between the pressing member 211 and the support member 221 in the Z direction is changeable.

[0058] The restricting member 241 is disposed on the Z2 side of the stator core 10. As shown in FIG. 9, a plurality of restricting members 241 are provided so as to extend radially from an annular restricting unit 243 toward the R2 side. The plurality of restricting members 241 are disposed at positions overlapping with the plurality of teeth 12 (see FIG. 1) when viewed from the Z direction. Each of the plurality of restricting members 241 is configured to be movable in the R direction relative to the restricting unit 243 by driving a restricting member motor 242. That is, each of the plurality of restricting members 241 is configured to be movable in the R direction relative to the stator core 10.

[0059] 8, the restricting members 241 are configured to restrict movement of the coil end portion 123, which is bent in the C direction, toward the R1 side. Specifically, when bending the coil end portion 123 in the C direction, the restricting members 241 are moved relative to the stator core 10 in the R direction so that, as viewed from the R direction, the R2-side end faces 241a of the plurality of restricting members 241 are adjacent to the R1 side of the coil end portion 123 where the pressing member 211 is pressed against the tip end portion 123a of the coil end portion 123.

[0060] As shown in Fig. 9, the manufacturing apparatus 200 for the stator 100 includes a scratch prevention member 261 that prevents the root portion 123b of the coil end portion 123 from being scratched by the corners of the slots 13 when the coil end portion 123 is bent in the C direction. The scratch prevention member 261 is disposed on the Z2 side of the stator core 10. The scratch prevention member 261 is disposed at a position corresponding to the plurality of teeth 12 (see Fig. 1). The scratch prevention member 261 has a substantially triangular shape when viewed from the R direction.

[0061] (Method of manufacturing a stator) A method for manufacturing the stator 100 according to this embodiment will be described with reference to FIGS. 5 to 8 and 9 to 16.

[0062] (Stator core preparation process) As shown in Fig. 11, a stator core preparing step is performed in step S10. The stator core preparing step (S10) is a step of preparing a stator core 10 (see Fig. 1).

[0063] (Coil preparation process) In step S20, a segment coil preparation step is performed. The segment coil preparation step (S20) is a step of preparing a segment coil 120 (see FIG. 11). Specifically, as shown in FIG. 11, a U-shaped segment coil 120 is prepared, which is composed of a pair of legs 121 extending in the Z direction and a connection part 122 connecting the pair of legs 121 to each other.

[0064] (Insertion process) As shown in Fig. 10, an insertion process is performed in step S30. As shown in Fig. 12, the insertion process (S30) is a process of inserting multiple segment coils 120 into slots 13 so that the coil end portions 123 protrude from the end face 10a on the Z2 side of the stator core 10 and are aligned in the R direction in each of the multiple slots 13 of the stator core 10. In the insertion process (S30), the connection portions 122 of the U-shaped segment coils 120 prepared in the segment coil preparation process (S20) become coil end portions 22 that protrude from the stator core 10 to the Z1 side. In addition, each of a pair of leg portions 121 of the segment coil 120 becomes a slot-accommodating portion 21 and a coil end portion 123.

[0065] (Bending process) As shown in Fig. 10, a bending step is performed in step S40. The bending step (S40) is a step of bending each of the plurality of coil end portions 123 along the C direction.

[0066] In detail, the bending process (S40) is a process in which, after the insertion process, the pressing member 211 and the support member 221, which press the coil end portion 123 and bend it circumferentially, are moved circumferentially and axially relative to the stator core 10 to bend the coil end portion 123, and then the next coil end portion 123 adjacent to the bent coil end portion 123 is bent by the pressing member 211 and the support member 221, and this process is repeated to bend multiple (48) coil end portions 123 lined up circumferentially.

[0067] The bending step (S40) also includes bending the plurality of coil end portions 123 by moving the pressing members 211 and the support members 221, which are provided in a number (two pairs) smaller than the total number (48) of the plurality of coil end portions 123 lined up in the circumferential direction, relative to the stator core 10 in the circumferential direction and in the axial direction. In short, the bending step (S40) is not a step in which all of the pressing members 211 (support members 221) are matched one-to-one with all of the coil end portions 123 and all of the coil end portions 123 are bent simultaneously, but rather a step in which all of the pressing members 211 (support members 221) are matched to some (the same number as the pressing members 211) of the coil end portions 123 and bent.

[0068] The bending step also includes simultaneously bending a plurality (two) of the coil end portions 123, the number of which is less than the total number (48) of the coil end portions 123 lined up in the circumferential direction, using a plurality (two pairs) of pressing members 211 and support members 221 that are provided at equal angular intervals (180 degree intervals) in the circumferential direction. In other words, the bending step is a step of bending the coil end portions 123 using two pairs of pressing members 211 and support members 221 that face each other across the central axis A.

[0069] The bending process also includes moving the pressing member 211 and the support member 221 relative to the stator core 10 in the circumferential direction and in the axial direction, bending the coil end portion 123 in the circumferential direction while climbing over the coil end portion 123, thereby transitioning to bending the next coil end portion 123 adjacent to the bent coil end portion 123 with the pressing member 211 and support member 221, and repeating this process to bend a plurality of coil end portions 123. In short, in the bending process, the pressing member 211 and support member 221 continuously bend a plurality of adjacent coil end portions 123.

[0070] In detail, the bending step includes moving the pressing member 211 and the support member 221 relative to the stator core 10 in the circumferential direction and in the axial direction (simultaneous relative movement in the circumferential and axial directions), bending the coil end portion 123 along the circumferential direction while climbing over the coil end portion 123, thereby transitioning to bending the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the support member 221, and repeating this process to bend the multiple coil end portions 123. More specifically, the bending step is configured to move the pressing member 211 and the support member 221 along a spiral trajectory that is slightly inclined with respect to a direction perpendicular to the axial direction, gradually bringing them closer to the stator core 10.

[0071] Furthermore, the bending process includes bending the multiple coil end portions 123 by wrapping the pressing member 211 and the support member 221 around the stator core 10 multiple times (for example, 20 times) in the circumferential direction and gradually increasing the bending angle θ (see FIG. 7) of the coil end portions 123 with respect to the axial direction. At this time, the bending is performed by the pressing member 211 and the support member 221 so that the bent coil end portion 123 does not come into contact with the next coil end portion 123 adjacent to it in the circumferential direction.

[0072] The bending process is performed by setting the axial movement speed of the pressing member 211 to approximately zero (including zero) for each row of radially arranged coil end portions 123 so that in the final stage when the bending is completed, the bending angles θ (see Figure 7) of the multiple circumferentially arranged coil end portions 123 are the same.

[0073] 13 and 14, the bending of the coil end portions 123 in the C direction is first performed on a plurality of coil end portions 123 that will become a first row (the outermost row) of coil end portions 23 lined up in the circumferential direction. Then, as shown in FIGS. 15 and 16, the bending of the coil end portions 123 in the C direction is performed on a plurality of coil end portions 123 that will become a second row (the row one radially inward from the outermost row) of coil end portions 23 lined up in the circumferential direction. Then, the bending of the coil end portions 123 in the C direction is performed on each row in turn toward the R1 side.

[0074] (Segment coil joining process) As shown in Fig. 10, a segment coil joining process is performed in step S50. The segment coil joining process (S50) is a process of joining the segment coils 20a (see Fig. 2) together. Specifically, as shown in Fig. 2, each of the tip ends 23a of the coil end portions 23 is joined (connected) by welding to the tip ends 23a of the coil end portions 23 of other segment coils 20a on the Z2 side of the stator core 10.

[0075] In the above flow, the order of the stator core preparation step (S10) and the segment coil preparation step (S20) may be reversed.

[0076] (Effects of the embodiment) In this embodiment, the following effects can be obtained.

[0077] (Effect of stator manufacturing method) As described above, the manufacturing method of the stator 100 of this embodiment includes a bending step in which the pressing member 211 and the support member 221, which press the coil end portion 123 to bend it circumferentially, are moved circumferentially and axially relative to the stator core 10 to bend the coil end portion 123, and then the pressing member 211 and the support member 221 move to bend the next coil end portion 123 adjacent to the bent coil end portion 123, repeating this process to bend a plurality of coil end portions 123 lined up in the circumferential direction. In this way, the process of bending a coil end portion 123 and then the process of bending the next coil end portion 123 adjacent to the bent coil end portion 123 by the pressing member 211 and the support member 221 is repeated, so that a plurality of coil end portions 123 can be bent using one set (one) of pressing member 211 and support member 221. Therefore, it is no longer necessary to bend multiple coil end portions at once, as in the conventional method, and the rigidity required for the device (manufacturing device 200) that bends the coil end portions 123 can be reduced. Furthermore, since multiple adjacent coil end portions 123 can be bent using one set (one) of pressing member 211 and support member 221, it is possible to bend the circumferentially arranged coil end portions 123 without providing the same number of pressing members 211 and support members 221 as the total number of circumferentially arranged coil end portions 123. Therefore, when reducing the diameter of the stator 100 to be manufactured, it is not necessary to consider interference between adjacent pressing members 211 and support members 221, as in the conventional method. As a result, the size of the device (manufacturing device 200) that bends the coil end portions 123 can be reduced, making it possible to fully accommodate reductions in the diameter of the stator 100.

[0078] In the manufacturing method of the stator 100 of this embodiment, as described above, the bending step includes bending the coil end portions 123 by moving the pressing members 211 and the support members 221, the number of which is smaller than the total number of the coil end portions 123 arranged in the circumferential direction, relative to the stator core 10 in the circumferential direction and in the axial direction. As a result, bending is performed using the pressing members 211 and the support members 221, the number of which is smaller than the total number of the coil end portions 123 arranged in the circumferential direction, so that not all of the coil end portions 123 are bent at the same time, and the rigidity required of the device (manufacturing device 200) that bends the coil end portions 123 can be effectively reduced. As a result, the size of the device (manufacturing device 200) that bends the coil end portions 123 can be effectively reduced. Furthermore, for example, when two sets (two) of pressing members 211 and support members 221 are provided at an angular interval of 180 degrees in the circumferential direction, a large gap can be secured between the two sets (two) of pressing members 211 and support members 221, which can suppress interference between the pressing members 211 and support members 221 and also enable the pressing members 211 and support members 221 to be manufactured thicker to increase rigidity. As a result, it is possible to more reliably accommodate a reduction in the diameter of stator 100.

[0079] In the manufacturing method of the stator 100 of this embodiment, as described above, the bending step includes moving the pressing member 211 and the support member 221 relative to the stator core 10 in the circumferential direction and in the axial direction to bend the coil end portion 123 along the circumferential direction while causing the pressing member 211 and the support member 221 to climb over the coil end portion 123, thereby moving on to bending the next coil end portion 123 adjacent to the bent coil end portion 123 with the pressing member 211 and the support member 221, and repeating this process, thereby bending a plurality of coil end portions 123. As a result, compared to, for example, a case in which, after bending one coil end portion, the pressing member and the support member are temporarily retracted in the axial direction away from the stator core without climbing over the first coil end portion, and then moving on to bending the next adjacent coil end portion, by bending the coil end portion 123 along the circumferential direction while causing the pressing member and the support member to climb over the coil end portion 123, it is possible to continuously and efficiently bend a plurality of circumferentially adjacent coil end portions 123.

[0080] In the manufacturing method of stator 100 of this embodiment, as described above, the bending step includes moving pressing member 211 and supporting member 221 relative to stator core 10 simultaneously in the circumferential and axial directions to move them over coil end portions 123, thereby spirally bending multiple coil end portions 123. In this way, by simply setting the circumferential speed and the axial speed of pressing member 211 and supporting member 221, it is possible to easily spirally move pressing member 211 and supporting member 221 and easily bend multiple coil end portions 123.

[0081] In the manufacturing method of the stator 100 of this embodiment, as described above, the bending step includes bending the multiple coil end portions 123 by wrapping the pressing member 211 and the support member 221 around the stator core 10 multiple times in the circumferential direction and gradually increasing the bending angle θ of the coil end portion 123 relative to the axial direction. This allows the bending of each coil end portion 123 to be performed multiple times, making it possible to reduce the bending angle θ resulting from a single pressing of the pressing member 211 and the support member 221 against the coil end portion 123. This makes it possible to prevent the bent coil end portion 123 from interfering with the next adjacent coil end portion 123.

[0082] In the manufacturing method of the stator 100 of this embodiment, as described above, the bending step includes simultaneously bending a number of coil end portions 123 that is less than the total number of coil end portions 123 lined up in the circumferential direction, using pressing members 211 and support members 221 that are provided at equal angular intervals in the circumferential direction and in a number that is less than the total number of coil end portions 123. This allows more coil end portions 123 to be bent simultaneously compared to when there is only one set (one pair) of pressing member 211 and support member 221, and therefore allows the bending of a number of coil end portions 123 to be performed efficiently.

[0083] (Effect of stator manufacturing method) In the manufacturing apparatus 200 for the stator 100 of this embodiment, as described above, the pressing member 211 and the support member 221 are moved relative to the stator core 10 in the circumferential direction and in the axial direction of the stator core 10 to bend the coil end portion 123, and then the next coil end portion 123 adjacent to the bent coil end portion 123 is bent by the pressing member 211 and support member 221. This process is repeated, and a moving mechanism 200a is provided to bend and form a plurality of coil end portions 123 that are lined up in the circumferential direction, and the number of pressing members 211 and support members 221 provided is smaller than the total number of the plurality of coil end portions 123 that are lined up in the circumferential direction. As a result, after bending a coil end portion 123, the pressing member 211 and the support member 221 move on to bending the next coil end portion 123 adjacent to the bent coil end portion 123, and this process is repeated, so that multiple coil end portions 123 can be bent using one set (one) of pressing member 211 and support member 221. This eliminates the need to bend multiple coil end portions at once, as was conventional, and reduces the rigidity required of the device (manufacturing device 200) that bends the coil end portions 123. Furthermore, because multiple adjacent coil end portions 123 can be bent using one set (one) of pressing member 211 and support member 221, the circumferentially arranged coil end portions 123 can be bent without providing the same number of pressing members 211 and support members 221 as the total number of coil end portions 123 arranged in the circumferential direction. Therefore, when reducing the diameter of the stator 100 to be manufactured, there is no need to consider interference between adjacent pressing members 211 and between adjacent support members 221, as was conventional. As a result, the size of the device (manufacturing device 200) that bends the coil end portion 123 can be reduced, making it possible to adequately accommodate reductions in the diameter of the stator 100.

[0084] (Variation) The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims rather than the above description of the embodiments, and further includes all modifications (variations) within the meaning and scope of the claims.

[0085] For example, in the above embodiment, the bending process includes simultaneously moving the pressing member and the support member as the bending member of the present invention in the axial and circumferential directions. However, the present invention is not limited to this. In the present invention, the bending process may include bending a plurality of coil end portions 123 by alternately moving the pressing member 211 and the support member 221 relative to the stator core 10 only in the circumferential direction and only in the axial direction, as in the manufacturing apparatus 300 of the stator 100 shown in FIG. 17 . In this case, for example, if the manufacturing apparatus 300 includes two sets of pressing members 211 and support members 221 arranged circumferentially at 180-degree intervals, the relative movement in the circumferential direction may be continued for at least 180 degrees or more, and then the relative movement in the axial direction may be switched to. With this configuration, the pressing member 211 and the support member 221 can be used to bend a plurality of coil end portions 123 arranged in the circumferential direction while maintaining the positions of the pressing member 211 and the support member 221 in the axial direction. Therefore, the pressing member 211 and the support member 221 can make the bending amount of the plurality of coil end portions 123 uniform.

[0086] In the above embodiment, an example is shown in which a motor is provided on the pressing member (support member) side to move the pressing member (support member) relative to the stator core in the axial direction, but the present invention is not limited to this. In the present invention, a motor may be provided on the stator core side to move the pressing member (support member) relative to the stator core in the axial direction.

[0087] In the above embodiment, an example is shown in which a motor is provided on the stator core side to move the pressing member (support member) relative to the stator core in the circumferential direction, but the present invention is not limited to this. In the present invention, a motor may be provided on the pressing member (support member) side to move the pressing member (support member) relative to the stator core in the circumferential direction.

[0088] In the above embodiment, an example in which two bending members (pairs of pressing member and support member) of the present invention are provided is shown, but the present invention is not limited to this. In the present invention, one bending member, or three or more bending members may be provided. However, the maximum number of bending members is set to be less than the total number of coil end portions arranged in the circumferential direction.

[0089] In the above embodiment, the bending member of the present invention is configured by two separate members, a pressing member and a support member, but the present invention is not limited to this. In the present invention, the bending member may be configured by a single member. In other words, the pressing member and the support member may be configured integrally.

[0090] In the above embodiment, the stator manufacturing apparatus is configured to be capable of manufacturing two stators simultaneously, but the present invention is not limited to this. In the present invention, the stator manufacturing apparatus may be configured to be capable of manufacturing only one stator or three or more stators simultaneously.

[0091] In the above embodiment, the bending members (pressing member and support member) of the present invention are moved relative to the stator core in the circumferential direction and in the axial direction to bend the coil end portion in the circumferential direction while climbing over the coil end portion, but the present invention is not limited to this. Instead of climbing over the coil end portion, the present invention may, for example, bend one coil end portion while keeping the bending member in contact with only a predetermined location of the one coil end portion, and then temporarily retract the bending member in the axial direction away from the stator core without climbing over the one coil end portion, before moving on to bending the next adjacent coil end portion.

[0092] In the above embodiment, the bending members (pressing members and supporting members) of the present invention are arranged at equal angular intervals in the circumferential direction, but the present invention is not limited to this. In the present invention, the bending members do not have to be arranged at equal angular intervals in the circumferential direction.

[0093] In the above embodiment, the bending members (pressing members and supporting members) of the present invention are wound 20 times around the circumferential direction of the stator core, but the present invention is not limited to this. In the present invention, the bending members (pressing members and supporting members) may be wound a number of times other than 20 around the circumferential direction of the stator core. [Explanation of symbols]

[0094] 10 stator core 10a (axial end face of stator core) 13 slots 23 Coil end 100 Stator 120 segment coil 123 Coil end part 200, 300 Stator manufacturing equipment 200a Moving mechanism 211 Pressing members (bending members) 221 Support members (bending members) θ Bending angle (relative to the axial direction of the coil end part)

Claims

1. an insertion process of inserting a plurality of segment coils into slots of the stator core so that coil end portions that become coil end portions protrude from an end face of the stator core in the axial direction and the plurality of coil end portions are aligned in the circumferential direction of the stator core; and a bending step, after the inserting step, of bending a bending member that presses the coil end portion and bends it along the circumferential direction relative to the stator core in the circumferential direction and in the axial direction to bend the coil end portion, and then moving on to bending the next coil end portion adjacent to the bent coil end portion with the bending member, thereby repeating this process to bend the multiple coil end portions lined up in the circumferential direction.

2. 2. The method for manufacturing a stator according to claim 1, wherein the bending process includes moving the bending members, which are provided in a number smaller than the total number of the plurality of coil end portions arranged in the circumferential direction, relative to the stator core in the circumferential direction and in the axial direction, to perform the bending of the plurality of coil end portions.

3. 2. The method for manufacturing a stator according to claim 1, wherein the bending step includes moving the bending member relative to the stator core in the circumferential direction and in the axial direction, bending the coil end portion along the circumferential direction while climbing over the coil end portion, thereby transitioning to bending the next coil end portion adjacent to the bent coil end portion with the bending member, and repeating this process to perform the bending of the multiple coil end portions.

4. 4. The method for manufacturing a stator according to claim 3, wherein the bending step includes moving the bending member relative to the stator core simultaneously in the circumferential direction and the axial direction to overcome the coil end portions, thereby bending the multiple coil end portions in a spiral shape.

5. 2. The method for manufacturing a stator according to claim 1, wherein the bending process includes performing the bending of the plurality of coil end portions by wrapping the bending member around the stator core a plurality of times in the circumferential direction and gradually increasing the bending angle of the coil end portions relative to the axial direction.

6. 3. The method for manufacturing a stator according to claim 2, wherein the bending step includes simultaneously bending a number of the coil end portions that is less than the total number of the coil end portions arranged in the circumferential direction using bending members that are less than the total number of the coil end portions arranged in the circumferential direction and that are provided at equal angular intervals in the circumferential direction.

7. a bending member that presses and bends a plurality of coil end portions that become a plurality of coil end portions arranged in a circumferential direction of the stator core along the circumferential direction; a movement mechanism that moves the bending member relative to the stator core in the circumferential direction and in the axial direction of the stator core to bend the coil end portion, and then moves to bending the next coil end portion adjacent to the bent coil end portion with the bending member, repeating this process, thereby bending the multiple coil end portions that are arranged in the circumferential direction, A stator manufacturing device, wherein the number of bending members provided is less than the total number of the plurality of coil end portions arranged in the circumferential direction.

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