Stator manufacturing method

Abstract

To improve workability in forming a wedge and to firmly fix the wedge in a slot. [Solution] The stator (10) is formed by stacking magnetic steel plates in the axial direction (Da), and includes a stator core (20) having slots (22) recessed from the inner peripheral surface toward the outer peripheral side and extending in the axial direction (Da), a stator winding (30) housed in the slots (22), and a wedge (40) formed by hardening liquid resin and blocking a slot opening (22A) that connects the internal space (22I) of the slots (22) with the internal space (20I) of the stator core (20).

Description

[Technical Field]

[0001] The present invention 、 The present invention relates to a method for manufacturing a stator, and is suitable for application to a method for forming wedges that secure stator windings in slots of a stator of a rotating electrical machine, for example. [Background technology]

[0002] Conventionally, rotating electric machines having a stator and a rotor are widely known. In some of these rotating electric machines, the stator is composed of a stator core and a stator winding housed in slots on the inner periphery of the stator core. In some of these stators, the openings of the slots are closed with wedges to prevent the stator winding from falling out of the slots to the inner periphery (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-281709 Summary of the Invention [Problem to be solved by the invention]

[0004] It is desirable for such a stator to improve the workability of forming the wedges and to firmly fix the wedges in the slots.

[0005] The present invention has been made in consideration of the above points, and aims to improve the workability of forming a wedge and to make it possible to firmly fix the wedge in the slot. R The present invention proposes a method for manufacturing a stator. [Means for solving the problem]

[0006] In order to solve this problem, the stator of the present invention is provided with a stator core formed by stacking magnetic steel plates in the axial direction, with slots recessed from the inner circumferential surface toward the outer circumferential surface and extending in the axial direction, a stator winding housed in the slot, and a wedge formed by hardening liquid resin that closes the slot opening, connecting the internal space of the slot with the internal space of the stator core.

[0007] Furthermore, in the method for manufacturing a stator of the present invention, which comprises a stator core formed by stacking magnetic steel plates in the axial direction and having slots recessed from the inner peripheral surface toward the outer peripheral side and extending in the axial direction, a stator winding housed in the slot, and a wedge formed by hardening liquid resin that closes the slot opening and connects the internal space of the slot with the internal space of the stator core, the method includes a stator winding installation process for installing the stator winding in the slot, a core insertion process for inserting a core into the internal space of the stator core, a resin filling process for filling the slot with resin, a resin hardening process for hardening the resin, and a core removal process for removing the core from the internal space of the stator core after the resin has hardened.

[0008] The present invention improves the workability of forming a wedge by hardening a liquid resin that flows easily to form a wedge that blocks the slot opening, and the liquid resin fills the slot opening without any gaps, conforming to the shape of the slot opening, thereby firmly fixing the wedge to the slot. [Effects of the Invention]

[0009] According to the present invention, the workability of forming the wedge can be improved by hardening a liquid resin that flows easily to form a wedge that closes the slot opening, and the liquid resin is filled to fit the shape of the slot opening without any gaps, so that the wedge can be firmly fixed in the slot. Thus, the present invention improves the workability of forming the wedge and can firmly fix the wedge in the slot. R A method for manufacturing a stator can be realized. [Brief explanation of the drawings]

[0010] [Figure 1]1 is a cross-sectional view taken along an axial direction, showing the configuration of a stator according to a first embodiment. [Figure 2] 2 is a cross-sectional view taken along the line AA in FIG. 1, showing the configuration of slots, stator windings, and wedges according to the first embodiment. FIG. [Figure 3] 1A to 1C are cross-sectional views taken along the axial direction, showing a method (1) for manufacturing a stator according to a first embodiment. [Figure 4] 4 is a cross-sectional view taken along the line AA in FIG. 3, showing a method (2) for manufacturing the stator according to the first embodiment. FIG. [Figure 5] FIG. 2 is a perspective view showing the configuration of a core according to the first embodiment. [Figure 6] FIG. 10 is a cross-sectional view taken along the axial direction, showing the configuration of a stator according to a second embodiment. [Figure 7] 7 is a cross-sectional view taken along the line AA in FIG. 6, showing the configuration of slots, stator windings, and wedges according to the second embodiment. FIG. [Figure 8] FIG. 10 is a perspective view showing the configuration of a core according to a second embodiment. [Figure 9] FIG. 10 is a perspective view showing the configuration of a pressing jig according to a second embodiment. [Figure 10] 10A and 10B are cross-sectional views showing a method for manufacturing a stator according to a second embodiment, taken along a line axially extending along a slit. [Figure 11] FIG. 10 is a cross-sectional view taken along the axial direction, showing the configuration of a stator of a comparative example. [Figure 12] 12 is a cross-sectional view taken along the line AA in FIG. 11, showing the configuration of slots, stator windings, and wedges of a comparative example. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, modes for carrying out the present invention (hereinafter referred to as embodiments) will be described with reference to the drawings.

[0012] 1. First Embodiment [1-1. Stator configuration] As shown in FIG. 1 , the stator 10 has an overall cylindrical shape and is composed of a stator core 20 with a central axis as its axis, a stator winding 30, and wedges 40. The stator 10 is used in a rotating electric machine. Hereinafter, the direction along the central axis is referred to as the axial direction Da, and the direction along the outer periphery of the stator 10 at a given axial position Da is referred to as the circumferential direction Dc. Furthermore, the direction approaching the central axis when viewed from the axial direction Da is referred to as the inner circumferential direction, and the direction away from the central axis when viewed from the axial direction Da is referred to as the outer circumferential direction. Furthermore, the direction perpendicular to the axial direction Da and extending along the inner and outer circumferential directions is referred to as the radial direction Dd. Furthermore, with regard to the radial direction Dd, the side approaching the central axis is referred to as the inner or inner circumferential side, and the side away from the central axis is referred to as the outer or outer circumferential side.

[0013] The stator core 20 has a cylindrical shape centered on a central axis, and is made up of annular electromagnetic steel sheets stacked in the axial direction Da. In this stator core 20, slots 22 (shown in Fig. 2) are formed at equal intervals in the circumferential direction Dc from one end to the other end in the axial direction Da, recessed in a generally rectangular shape from the inner peripheral surface 20S of the stator core toward the outer periphery. Therefore, the slots 22 are provided radially from the central axis toward the outer periphery around the entire circumference of the stator core inner peripheral surface 20S.

[0014] Specifically, when viewed from the axial direction Da (i.e., in a cross section), the slot 22 is configured to be line-symmetrical about a straight line along the radial direction Dd, and is formed with an outer peripheral side surface 22oS, a one-direction side surface 22cS1, an other-direction side surface 22cS2, a one-direction inclined surface 22sS1, an other-direction inclined surface 22sS2, an inner peripheral one-direction side surface 22iS1, an inner peripheral other-direction side surface 22iS2, and a slot opening 22 A. The outer peripheral side surface 22oS is provided on the outermost side of the slot 22 and is a flat surface that extends substantially along the circumferential direction Dc.

[0015] The one-direction side surface 22cS1 is a plane extending from one end of the outer peripheral side surface 22oS in one direction in the circumferential direction Dc toward the inner periphery along the radial direction Dd, perpendicular to the outer peripheral side surface 22oS. The other-direction side surface 22cS2 is a plane extending from the other end of the outer peripheral side surface 22oS in the other direction in the circumferential direction Dc toward the inner periphery along the radial direction Dd, perpendicular to the outer peripheral side surface 22oS, and faces the one-direction side surface 22cS1 in the circumferential direction Dc.

[0016] The one-directional inclined surface 22sS1 is a flat surface that extends from the inner end of the one-directional side surface 22cS1 so as to incline inward relative to the outer circumferential surface 22oS toward the slot opening 22A. The other-directional inclined surface 22sS2 is a flat surface that extends from the inner end of the other-directional side surface 22cS2 so as to incline inward relative to the outer circumferential surface 22oS toward the slot opening 22A. The inner one-directional side surface 22iS1 is a flat surface that extends from the inner end of the one-directional inclined surface 22sS1 in the radial direction Dd parallel to the one-directional side surface 22cS1 to the stator core inner circumferential surface 20S. The inner other-directional side surface 22iS2 is a flat surface that extends from the inner end of the other-directional inclined surface 22sS2 in the radial direction Dd parallel to the other-directional side surface 22cS2 to the stator core inner circumferential surface 20S, and faces the inner one-directional side surface 22iS1 in the circumferential direction Dc.

[0017] The slot opening 22A is open to connect the internal space 22I of the slot 22 with the internal space 20I of the stator core 20, and its width in the circumferential direction Dc is narrowed to about half the distance between the one-side surface 22cS1 and the other-side surface 22cS2.

[0018] The stator winding 30 is formed by aligning and bundling multiple copper wires 32, each having a circular cross section, and wrapping and insulating these copper wires 32 in insulating paper 34, and is housed in each slot 22. The outer circumferential side of the insulating paper 34 abuts against the outer circumferential side surface 22oS, and the side surface on the circumferential direction Dc abuts against the one-direction side surface 22cS1 and the other-direction side surface 22cS2. An intra-slot gap 22G is formed in the space surrounded by the side surface of the insulating paper 34 on the slot opening 22A side, the one-direction inclined surface 22sS1, the other-direction inclined surface 22sS2, the inner circumferential one-direction side surface 22iS1, and the inner circumferential other-direction side surface 22iS2.

[0019] The wedges 40 are formed by hardening a liquid filler 42 that has filled the slot gaps 22G without any gaps, and by closing the slot openings 22A, they prevent the copper wires 32 and insulating paper 34 from falling out of the slot openings 22A to the inner periphery of the slots 22. The inner periphery of the wedge 40 is flush with the stator core inner periphery 20S without any steps. In this embodiment, the filler 42 is made of, for example, an epoxy resin that hardens over time.

[0020] [1-2. Stator manufacturing method] Next, a method for manufacturing the stator 10 will be described. First, the stator windings 30 are inserted into the slots 22 of the stator core 20, which is formed by laminating annular electromagnetic steel sheets in the axial direction Da (stator winding installation process). Next, as shown in Figures 3 and 4, the core 50 is moved upward, which is one direction in the axial direction Da, with the cylindrical portion 50C at the forefront in the moving direction, and inserted into the internal space 20I of the stator core 20 (core insertion process).

[0021] As shown in FIG. 5, the core 50 is composed of a cylindrical portion 50C and a flange 50F. The cylindrical portion 50C occupies the majority of the core 50 and has a solid cylindrical shape centered on a central axis. The length of this cylindrical portion 50C in the axial direction Da is at least equal to or greater than the stator core 20, and its outer diameter is approximately the same as the inner diameter of the stator core 20. Therefore, the outer peripheral surface of the cylindrical portion 50C is in close contact with the stator core inner peripheral surface 20S over the entire circumference in the circumferential direction Dc. In addition, the outer peripheral surface of the cylindrical portion 50C is subjected to a release treatment, such as a coating, to improve release properties (non-adhesiveness), so that the filler 42 does not stick to the outer peripheral surface.

[0022] Flange 50F is disk-shaped and formed on the lower side, that is, the other end side in the axial direction Da, of cylindrical portion 50C, and is formed to have a larger outer diameter than cylindrical portion 50C. Therefore, when core 50 is inserted into internal space 20I of stator core 20 (FIGS. 3 and 4), flange 50F covers and closes the lower side of intra-slot gap 22G, preventing the lower opening of intra-slot gap 22G from being exposed to the outside.

[0023] Next, the filler 42 is poured into the slot gaps 22G from the upper side, where the cylindrical portion 50C of the core 50 is located in the axial direction Da of the stator core 20, to fill the gaps without leaving any gaps (resin filling process). Therefore, the filler 42 also flows into the slot openings 22A. Furthermore, if a gap is formed between the insulating paper 34 and the inner surface of the slot 22, the filler 42 also flows into the gap between the insulating paper 34 and the inner surface of the slot 22. At this time, the outer surface of the cylindrical portion 50C of the core 50 is in close contact with the stator core inner peripheral surface 20S. Therefore, the core 50 can prevent the filler 42 from leaking inward from the slot openings 22A. At this time, the flange 50F of the core 50 closes the lower opening of the slot gap 22G. Therefore, the core 50 can prevent the filler 42 from leaking out from the lower end of the slot gap 22G to the outside. When the filler 42 hardens, the wedge 40 is formed (resin hardening step).

[0024] Next, the core 50 is moved downward, which is the other direction of the axial direction Da, and is pulled out from the internal space 20I of the stator core 20 (core removal process). At this time, the outer peripheral surface of the cylindrical portion 50C has been subjected to a release treatment. Therefore, the core 50 can be pulled out without being bitten by the filler 42 after the filler 42 has hardened.

[0025] [1-3. Effects, etc.] In the stator 10 having the above configuration, when the stator 10 is manufactured, the core 50 is inserted into the internal space 20I of the stator core 20, and while the outer surface of the cylindrical portion 50C of the core 50 is kept in close contact with the inner surface 20S of the stator core, the filler 42, which is a liquid epoxy resin, is poured into the slot gaps 22G to fill them without any gaps, and when the filler 42 hardens, the wedges 40 are formed.

[0026] As a result, the stator 10 can fix the stator winding 30 within the slot 22, and can also block the slot opening 22A of the slot 22 with the wedge 40, preventing the stator winding 30 from falling out of the slot opening 22A to the inner periphery.

[0027] Here, as a comparative example, in the manufacturing process of stator 210 shown in Figures 11 and 12, in which the same reference numerals are used for parts corresponding to those in Figures 1 and 2, respectively, a thin plate-shaped wedge 240 is struck with a hammer or the like to be inserted into slot gap 22G, and wedge 240 is held in slot 22 by the frictional force between wedge 240 and the inner surface of slot 22, and by closing slot opening 22A, stator winding 30 is prevented from falling out to the inner periphery side from slot opening 22A.

[0028] However, in this case, it was not easy to insert the wedges 240 into the slots 22, and there was a possibility that the wedges 240 would be damaged when they were inserted into the slots 22. In addition, the thin plate-shaped wedges 240 had to be inserted into all of the slots 22, which required a lot of work. Furthermore, depending on the manufacturing dimensional errors of the slots 22 and the thin plate-shaped wedges 240, the friction force between the wedges 240 and the inner surfaces of the slots 22 was small, and there was a possibility that the wedges 240 would fall out of the slots 22.

[0029] In contrast to this, in the stator 10 according to the present embodiment, the core 50 is inserted into the internal space 20I of the stator core 20, and the filler 42, which is a liquid epoxy resin with high fluidity and easy flow, is poured into the slot gap 22G without leaving any gaps, filling it, and when the filler 42 hardens, the wedge 40 is formed.

[0030] Therefore, in the stator 10, the wedges 40 can be formed by simply filling the slots 22 with the filler 42, which is a liquid epoxy resin, and then allowing the filler 42 to harden over time to form the wedges 40. This simplifies the work and reduces the work time, thereby improving workability. In particular, the greater the number of slots 22 in the stator 10, the more the workability improves. The stator 10 also prevents damage to the wedges 40. Furthermore, in the stator 10, the filler 42, which is a liquid epoxy resin, fills the slot gaps 22G without any gaps, following the fine shape of the slot gaps 22G, and hardens in a state of close contact with the inner surfaces of the slots 22, thereby forming the wedges 40. This firmly bonds the wedges 40 to the inner surfaces of the slots 22, preventing the wedges 40 from falling out of the slots 22.

[0031] In addition, in the conventional manufacturing process of a stator, a ball-shaped filler made of a mixture of glass fiber, iron powder, and epoxy resin and having a predetermined plasticity is filled into the slot opening 22A of the slot 22 and hardened to form a magnetic wedge.

[0032] In contrast, in the stator 10 according to the present embodiment, with the core 50 inserted in the internal space 20I of the stator core 20, the filler 42, a highly fluid, easily flowing liquid epoxy resin, is poured into the slot gaps 22G, filling them completely, and the wedges 40 are formed when the filler 42 hardens. Therefore, compared to such conventional stators, the stator 10 allows for easier work and shorter work time, thereby improving workability. In particular, the greater the number of slots 22 in the stator 10, the more workability the stator 10 has. Furthermore, compared to such conventional stators, the filler 42 is more tightly packed into the slot openings 22A, following the fine shape of the slot openings 22A, ensuring close contact with the inner surfaces of the slots 22. The filler 42 also adheres to the irregularities between adjacent electromagnetic steel sheets and solidifies. This allows the wedges 40 in the stator 10 to be more firmly fixed, preventing the wedges 40 from coming off the slots 22.

[0033] According to the above configuration, the stator 10 is formed by stacking magnetic steel plates in the axial direction Da, and includes a stator core 20 having slots 22 recessed from the inner peripheral surface toward the outer peripheral side and extending in the axial direction Da, a stator winding 30 housed in the slots 22, and a wedge 40 formed by hardening a liquid resin and blocking a slot opening 22A that connects the internal space 22I of the slot 22 with the internal space 20I of the stator core 20.

[0034] In addition, the manufacturing method of the stator 10 includes a stator core 20 formed by stacking magnetic steel plates in the axial direction Da, with slots 22 recessed from the inner peripheral surface toward the outer peripheral side and extending in the axial direction Da, a stator winding 30 housed in the slot 22, and a wedge 40 formed by hardening a liquid resin and closing a slot opening 22A that connects an internal space 22I of the slot 22 with an internal space 20I of the stator core 20, and the manufacturing method of the stator 10 includes a stator winding installation process for installing the stator winding 30 in the slot 22, a core insertion process for inserting a core 50 into the internal space 20I of the stator core 20, a resin filling process for filling the slot 22 with a filler 42 that is a liquid resin, and a core removal process for removing the core 50 from the internal space 20I of the stator core 20 after the filler 42 has hardened.

[0035] This allows the stator 10 to improve the workability of forming the wedge 40 by hardening the easily flowing liquid resin to form the wedge 40 that blocks the slot opening 22A, and the liquid resin fills the slot opening 22A without any gaps, conforming to the shape of the slot opening 22A, allowing the wedge 40 to be firmly fixed to the slot 22.

[0036] 2. Second Embodiment [2-1. Stator configuration] 6 and 7, in which the same reference numerals are used to denote corresponding parts to those in Figures 1 and 2, stator 110 according to the second embodiment differs from stator 10 according to the first embodiment in that it has wedges 140 instead of wedges 40, but is otherwise configured similarly. Each of the wedges 140, which are arranged at the same position in the circumferential direction Dc and extend in the axial direction Da, is arranged such that, compared to wedges 40, positions corresponding to, for example, four rectangular prism-shaped slits 150S along the axial direction Da in core 150 shown in Figure 8 are omitted.

[0037] [2-2. Stator manufacturing method] Next, a method for manufacturing the stator 110 will be described. First, the stator windings 30 are inserted into the slots 22 of the stator core 20, which is formed by laminating annular electromagnetic steel sheets in the axial direction Da (stator winding installation process). Next, the core 150 (FIG. 8) is moved upward, which is one direction in the axial direction Da, with the cylindrical portion 150C at the forefront of the moving direction, and inserted into the internal space 20I of the stator core 20 (core insertion process).

[0038] As shown in FIG. 8, in which the same reference numerals are used for corresponding components to those in FIG. 5, core 150 differs from core 50 in that it has a cylindrical portion 150C instead of columnar portion 50C, but is otherwise similarly configured. Cylindrical portion 150C occupies most of core 150 and has a hollow cylindrical shape centered on a central axis. This cylindrical portion 150C has a length in the axial direction Da that is at least equal to or greater than stator core 20, and an outer diameter that is substantially the same as the inner diameter of stator core 20. Therefore, cylindrical portion 150C is in close contact with stator core inner peripheral surface 20S over the entire circumference in the circumferential direction Dc. Furthermore, the cylindrical portion 150C has a release treatment applied to its outer peripheral surface to prevent filler 42 from adhering to the outer peripheral surface.

[0039] A rectangular prism-shaped slit 150S penetrates the cylindrical portion 150C from the inside to the outside at a location that faces the slot opening 22A when the core 150 is inserted into the internal space 20I. For example, four slits 150S are formed at equal intervals along the axial direction Da and are arranged at the same position in the circumferential direction Dc. Hereinafter, for example, four slits 150S arranged at the same position in the circumferential direction Dc will also be collectively referred to as a slit row 150SL.

[0040] 9 is inserted into the internal space of the core 150, and is inserted into each of, for example, four slits 150S in the slit row 150SL so that the protrusions 60P protrude to the outside of the core 150, as shown in Fig. 10. Therefore, the pressing jig 60 inserts the protrusions 60P into the slots 22, abuts the stator winding 30, and presses it toward the outer periphery so as to press it against the outer periphery side surface 22oS (stator winding pressing process).

[0041] This pressing jig 60 is inserted into the slits 150S in all slit rows 150SL so that the protrusions 60P protrude to the outside of the core 150. Therefore, the pressing jig 60 inserts the protrusions 60P into all slots 22, abuts against the stator winding 30, and presses it toward the outer periphery so as to press it against the outer periphery side surface 22oS.

[0042] The pressing jig 60 is composed of a main body 60B and protrusions 60P. The main body 60B is a linearly extending plate-like member. The protrusions 60P are rectangular parallelepiped-shaped members protruding from the side surface of the main body 60B at intervals equal to the axial spacing Da of the slits 150S in the cylindrical portion 150C. The number of protrusions 60P is the same as the number of slits 150 in one slit row 150SL, for example, four. When the protrusions 60P are inserted into the slits 150S, the protrusions 60P have the same shape and size as the slits 150S when viewed along the radial direction Dd, and their width in the circumferential direction Dc is slightly narrower than the width of the slot opening 22A. The surfaces of the protrusions 60P of the pressing jig 60 are subjected to a release treatment to prevent the filler 42 from adhering to the surface.

[0043] Next, the filler 42 is poured into the slot gaps 22G from the upper side, which is the side surface on which the cylindrical portion 150C of the core 150 is disposed in the axial direction Da of the stator core 20, to fill the slot gaps 22G without leaving any gaps (resin filling process). Therefore, the filler 42 is also poured into the slot openings 22A. At this time, the outer peripheral surface of the cylindrical portion 150C of the core 150 is in close contact with the stator core inner peripheral surface 20S. Therefore, the core 150 can prevent the filler 42 from leaking inward from the slot openings 22A. At this time, the flange 50F of the core 150 closes the lower opening of the slot gaps 22G. Therefore, the core 150 can prevent the filler 42 from leaking out from the lower end of the slot gaps 22G to the outside.

[0044] Furthermore, at this time, the protrusions 60P of the pressing jig 60 press the stator winding 30 against the outer peripheral side surface 22oS. Therefore, the pressing jig 60 can prevent the shape of the stator winding 30 from collapsing inside the slots 22 while the filler 42 is still soft until it hardens. When the filler 42 hardens, the wedges 140 are formed (resin hardening process).

[0045] Next, the pushing jig 60 is pulled out toward the inner periphery, and the protrusions 60P are pushed out from the slots 22 (protrusion returning process). At this time, the surfaces of the protrusions 60P have been subjected to a release treatment. Therefore, the pushing jig 60 can be pulled out without being stuck to the filler 42 after the filler 42 has hardened.

[0046] Next, the core 150 is moved downward, which is the other direction of the axial direction Da, and is pulled out from the internal space 20I of the stator core 20 (core removal process). At this time, the outer peripheral surface of the cylindrical portion 150C has been subjected to a release treatment. Therefore, the core 150 can be pulled out without being bitten by the filler 42 after the filler 42 has hardened.

[0047] [2-3. Effects, etc.] In the stator 110 configured as described above, during manufacturing of the stator 110, the core 150 is inserted into the internal space 20I of the stator core 20, and the protrusions 60P of the pressing jig 60 are inserted so as to protrude to the outside of the core 150, so that the protrusions 60P press the stator winding 30 against the outer peripheral side surface 22oS of the slot 22. Furthermore, while the protrusions 60P keep the stator winding 30 pressed against the outer peripheral side surface 22oS of the stator 110, the filler 42, which is a liquid epoxy resin, is poured into the slot gaps 22G without leaving any gaps, filling them, and when the filler 42 hardens, the wedges 140 are formed.

[0048] Therefore, the pressing jig 60 maintains the posture of the stator winding 30 from the time the filler 42 is poured into the slot gap 22G until it hardens, and prevents the shape of the stator winding 30 from collapsing within the slot 22 until the filler 42 hardens.

[0049] In other respects as well, the stator 110 according to the second embodiment can achieve the same effects as the stator 10 according to the first embodiment.

[0050] 3. Other Embodiments In the first embodiment described above, the stator 10 is described as being filled with the filler 42 so that the slot gaps 22G are tightly filled with the filler 42, and the slot openings 22A are blocked by the filler 42. The present invention is not limited to this, and even if there is space in the slot gaps 22G that is not filled with the filler 42, the stator 10 is only required to be able to prevent the stator winding 30 from falling out of the slot openings 22A to the inner periphery by blocking at least the slot openings 22A with the filler 42. The same applies to the second embodiment.

[0051] In the first embodiment described above, the stator 10 is described as being made of filler 42, which is an epoxy resin, an adhesive that hardens over time. However, the present invention is not limited to this. The filler 42 of the stator 10 may be made of various other adhesives, such as various resins that harden over time, or may be made of various other materials, such as an ultraviolet-curing adhesive, an adhesive that hardens with an accelerator, an adhesive that hardens due to temperature changes, or a mixture of these. The same applies to the second embodiment.

[0052] Furthermore, in the above-described first embodiment, stator 10 has been described as having cylindrical portion 50C of core 50 in a solid cylindrical shape. However, the present invention is not limited to this, and stator 10 may have cylindrical portion 50C of core 50 in a hollow cylindrical shape.

[0053] Furthermore, in the second embodiment described above, the stator 110 has four slits 150S in each slit row 150SL, and the pressing jig 60 has four protrusions 60P, which is the same number as the number of slits 150 in one slit row 150SL. However, the present invention is not limited to this, and the stator 110 may have any other number of slits 150S in each slit row 150SL, and the pressing jig 60 may have the same number of protrusions 60P as the number of slits 150 in one slit row 150SL.

[0054] Furthermore, the present invention is not limited to the above-described embodiments and other embodiments. That is, the scope of application of the present invention also extends to embodiments in which the above-described embodiments are combined in part or in whole with any of the above-described other embodiments. The scope of application of the present invention also extends to embodiments in which part of the configuration described in any of the above-described embodiments and other embodiments is extracted and used as part of the configuration of any of the above-described embodiments and other embodiments, or in which part of the extracted configuration is added to any of the above-described embodiments.

[0055] Furthermore, in the above-described embodiment, the stator 10 or 110 is configured by the stator core 20 as the stator core, the stator winding 30 as the stator winding, and the wedges 40 or 140 as the wedges. However, the present invention is not limited to this, and the stator may be configured by a stator core, stator windings, and wedges having various other configurations. [Industrial Applicability]

[0056] The present invention can be used in a stator. [Explanation of symbols]

[0057] 10, 110, 210... Stator, 20... Stator core, 20S... Stator core inner surface, 20I... Internal space, 22... Slot, 22I... Internal space, 22oS... Outer side surface, 22cS1... One-way side surface, 22cS2... Other-way side surface, 22sS1... One-way inclined surface, 22sS2... Other-way inclined surface, 22iS1... Inner side surface in one direction, 22iS2... Inner side surface in the other direction, 22A... Slot opening part, 22G...gap in slot, 30...stator winding, 32...copper wire, 34...insulating paper, 40, 140, 240...wedge, 42...filler, 50, 150...core, 50C...cylindrical part, 50F...flange, 150C...cylindrical part, 150S...slit, 150SL...row of slits, 60...pressing jig, 60B...main body, 60P...protrusion, Da...axial direction, Dd...radial direction, Dc...circumferential direction.

Claims

1. A method for manufacturing a stator comprising: a stator core formed by laminating magnetic steel plates in an axial direction, with slots recessed from an inner peripheral surface toward an outer peripheral surface and extending in the axial direction; stator windings housed in the slots; and wedges formed by hardening a liquid resin and closing slot openings that connect the internal spaces of the slots with the internal spaces of the stator core, a stator winding installation step of installing the stator winding in the slot; a core inserting step of inserting a core into the internal space of the stator core; a resin filling step of filling the resin into the slot; a core removal step of removing the core from the internal space of the stator core after the resin has hardened; A method for manufacturing a stator having the above structure.

2. The core closes the inner circumferential side of the slot opening with its outer circumferential surface. The method for manufacturing the stator according to claim 1 .

3. The core has a circular outer circumferential surface that abuts against the inner circumferential surface of the stator core. The method for manufacturing the stator according to claim 2 .

4. At least the outer peripheral surface of the core is subjected to a release treatment. The method for manufacturing a stator according to claim 3 .

5. the core has a flange formed thereon that closes one side in the axial direction of a space surrounded by an inner surface of the slot, the stator winding, and the slot opening, In the resin filling step, the resin is filled into the slot from the other side in the axial direction of the space. The method for manufacturing the stator according to claim 1 .

6. a slit penetrating from the inside to the outside of the core is formed in the core at a position facing the slot when the core is inserted into the internal space of the stator core, the stator winding installation step; the core inserting step; a stator winding pushing step of moving the protrusions toward the outer periphery through the slits to push the stator winding toward the outer periphery; the resin filling step; a protrusion returning step of moving the protrusion to an inner peripheral side of the slit after the resin has hardened; The core removal step; The method for manufacturing a stator according to claim 1 , further comprising the steps of:

Images