Stator manufacturing equipment

Abstract

To provide a manufacturing device of a stator which can increase design freedom regarding a position of an extension line segment coil.SOLUTION: A manufacturing device of a stator comprises: a contact member constituted to form a bending starting point in an extension line segment coil among a plurality of segment coils inserted into a slot of a stator core and constituted to contact a side face of a projection projected from the slot of the extension line segment coil from the outside in a radial direction of the stator core to form the bending starting point; and an extension line holding part which holds the projection of the extension line segment coil and constituted to be movable along the radial direction and an axial direction of the stator core to the contact member.SELECTED DRAWING: Figure 7

Description

Technical Field

[0004] , , , , , , , , ,

[0005] , , , , ,

[0001] The technology disclosed in this specification relates to a manufacturing apparatus for manufacturing a stator, which is a component of a rotating electrical machine.

Background Art

[0002] The stator is formed by bending the protruding portions of a plurality of segment coils inserted into the slots of the stator core that protrude from the slots. The plurality of segment coils include a general wire segment coil that serves as a general wire and a lead wire segment coil that serves as a lead wire. After the protruding portion of the general wire segment coil is bent in the circumferential direction of the stator, it is joined to the protruding portion of another general wire segment coil. As a result, the general wire segment coils form a coil on the inner peripheral surface of the stator core. The protruding portion of the lead wire segment coil is bent in the radial direction and the axial direction of the stator core and then connected to a power line extending from a connection terminal.

[0003] Patent Document 1 discloses an example of a technique for bending the protruding portion of a lead wire segment coil. In this technique, a punch is used to bend the protruding portion of the lead wire segment coil in the radial direction of the stator core, and then a roller is used to bend the portion of the protruding portion that extends outside the stator core in the axial direction of the stator core.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The stator core is provided with ribs that protrude radially from its outer surface. These ribs have bolt holes formed in them for receiving bolts to fix the stator core to the housing. Bending using punches and rollers cannot be applied around the location of the ribs because the ribs and rollers interfere with each other. Thus, bending using punches and rollers results in a low degree of design freedom regarding the position of the lead wire segment coils. This specification provides a stator manufacturing apparatus that can increase the degree of design freedom regarding the position of the lead wire segment coils. [Means for solving the problem]

[0006] A stator manufacturing apparatus disclosed herein may include: a contact member configured to form a bending point in a lead wire segment coil among a plurality of segment coils inserted into a slot of a stator core, the contact member configured to abut the side surface of a protruding portion of the lead wire segment coil that protrudes from the slot from the radially outer side of the stator core to form the bending point; and a lead wire holding portion for holding the protruding portion of the lead wire segment coil, the lead wire holding portion configured to be movable relative to the contact member along the radial and axial directions of the stator core. According to this stator manufacturing apparatus, the protruding portion of the lead wire segment coil can be bent by moving the lead wire holding portion relative to the contact member. Therefore, the lead wire segment coil formed using this stator manufacturing apparatus can have a high degree of design freedom in terms of position.

[0007] The lead wire holding portion may be configured to be movable along the radial and axial directions of the stator core with respect to the contact member within the range of the stator core when viewed from the axial direction of the stator core. The protruding portion of the lead wire segment coil formed using this stator manufacturing apparatus is positioned inward from the outer circumferential surface of the stator core in the radial direction of the stator core. Therefore, the stator formed using this stator manufacturing apparatus can have a small size.

[0008] The lead wire holding portion may have a lead wire cap that includes a recess that covers the tip of the protruding portion of the lead wire segment coil. The lead wire cap may have a tapered surface on the opening edge of the recess that is located radially inward of the stator core, configured to widen the opening width of the recess. Such a lead wire cap can hold the protruding portion of the lead wire segment coil while separating it from the plurality of segment coils when covering the protruding portion of the lead wire segment coil.

[0009] The contact member is configured to form a bending point in the general wire segment coil among the plurality of segment coils, and may be configured to contact the side surface of the protruding portion of the general wire segment coil that protrudes from the slot from the circumferential direction of the stator core to form the bending point. In this stator manufacturing apparatus, the contact member can have the function of forming the bending point in both the lead wire segment coil and the general wire segment coil.

[0010] The stator manufacturing apparatus disclosed herein may further include a general wire holding portion for holding the protrusions of the general wire segment coil, which is configured to be movable along the circumferential direction of the stator core with respect to the contact member. In this case, the lead wire holding portion may have a lead wire cap including a recess that covers the protrusions of the lead wire segment coil. The lead wire cap and the general wire cap may have a common shape. With this stator manufacturing apparatus, the lead wire cap and the general wire cap can be used interchangeably, thus reducing the manufacturing cost of the stator. [Brief explanation of the drawing]

[0011] [Figure 1] This diagram schematically shows a perspective view of the stator. [Figure 2] This diagram schematically shows a perspective view of an intermediate product in the manufacturing process of a stator. [Figure 3] This diagram schematically shows a perspective view of an intermediate product in the manufacturing process of a stator. [Figure 4] This diagram illustrates a process of bending the protruding portion of a lead wire segment coil, and schematically shows a cross-sectional view of a stator core slot cut along the radial direction of the stator core. [Figure 5] This diagram illustrates a process of bending the protruding portion of a lead wire segment coil, and schematically shows a cross-sectional view of a stator core slot cut along the radial direction of the stator core. [Figure 6] This diagram schematically shows a perspective view of a part of a leader cap. [Figure 7] This diagram illustrates a process of bending the protruding portion of a lead wire segment coil, and schematically shows a cross-sectional view of a stator core slot cut along the radial direction of the stator core. [Figure 8] This diagram schematically shows the appearance of the contact member that abuts against the protruding portion of the lead wire segment coil. [Figure 9] This diagram schematically shows a perspective view of the contact member. [Modes for carrying out the invention]

[0012] The stator, a component of a rotating electric machine, will be described below with reference to the drawings. For the purpose of clarity in the illustrations, the shapes of common components may be shown differently in different drawings, but components with the same reference numerals represent the same component.

[0013] Figure 1 shows the finished stator 1, and Figures 2 and 3 show intermediate products in the manufacturing process of the stator 1. The stator 1 comprises a stator core 10 and a plurality of segment coils 20.

[0014] The stator core 10 is constructed by stacking multiple laminated steel plates, for example, made of a magnetic material, in the axial direction. The stator core 10 has an annular yoke portion 12, multiple teeth 14 extending radially inward from the inner circumferential surface of the yoke portion 12, and ribs 16 projecting radially outward from the outer circumferential surface of the yoke portion 12. A rotor (not shown) is inserted into the central hole of the yoke portion 12. Each of the multiple teeth 14 extends from one opening edge to the other opening edge of the yoke portion 12 along the axial direction of the stator core 10, and is spaced apart from each other along the circumferential direction of the stator core 10. The space between adjacent teeth 14 is called a slot 18. Bolt holes 19 are formed in the ribs 16, configured to receive bolts for fixing the stator core 10 to a housing (not shown).

[0015] Each of the plurality of segment coils 20 is inserted into a corresponding slot 18 among the plurality of slots 18 of the stator core 10. Each of the plurality of segment coils 20 is a flat wire formed by coating an insulator on the surface of a conductor. As shown in FIG. 2, each of the plurality of segment coils 20 is formed into a substantially U shape and then inserted into the slot 18 of the stator core 10 along the axial direction of the stator core 10. As shown in FIGS. 2 and 3, a portion of the two arms 22 of the segment coil 20 that protrudes from the slot 18 of the stator core 10 is referred to as a protrusion 24. The stator 1 is formed by bending the protrusion 24 of the segment coil 20 after inserting the substantially U-shaped segment coil 20 into the slot 18 of the stator core 10. Note that the tip of the protrusion 24 has a peeled portion where the insulator is removed and the conductor is exposed.

[0016] Here, as shown in FIG. 1, the plurality of segment coils 20 includes a plurality of general wire segment coils 20A and three lead wire segment coils 20B.

[0017] The general wire segment coil 20A is a segment coil for forming a coil on the inner peripheral surface of the stator core 10. The protrusion 24 of the general wire segment coil 20A is bent in the circumferential direction of the stator core 10. The plurality of bent general wire segment coils 20A are joined by welding the peeled portions formed at the tips between the corresponding general wire segment coils 20A. Thereby, the protrusions 24 of the plurality of general wire segment coils 20A form a coil on the inner peripheral surface of the stator core 10. In this example, the U-phase coil group, the V-phase coil group, and the W-phase coil group are formed by distributed winding on the inner peripheral surface of the stator core 10. Note that the plurality of general wire segment coils 20A also includes connection wire segment coils that connect coils of the same phase.

[0018] The lead wire segment coil 20B is a segment coil for providing lead wires corresponding to each of the U-phase coil group, V-phase coil group, and W-phase coil group. One arm portion 22 of the protruding portion 24 of the lead wire segment coil 20B is bent in the radial direction and axial direction of the stator core 10. In this example, three lead wires 22U, 22V, and 22W are provided by three lead wire segment coils 20B. The three lead wires 22U, 22V, and 22W are electrically connected to the corresponding power lines among the three power lines (U-phase power line, V-phase power line, and W-phase power line) extending from the three connection terminals. For example, a power conversion device is connected to the three connection terminals.

[0019] Next, a method of bending the protruding portion 24 of the lead wire segment coil 20B will be described. FIG. 4 shows a state in which a U-shaped segment coil 20 is inserted into the slot 18 of the stator core 10. Inside the slot 18 of the stator core 10, the lead wire segment coil 20B is inserted at the outermost side in the radial direction of the stator core 10, and in addition, a general wire segment coil 20A is inserted.

[0020] As shown in FIG. 5, the lead wire cap 32 of the lead wire holding portion 30 descends along the axial direction of the stator core 10 with respect to the lead wire segment coil 20B and holds the tip portion of the protruding portion 24 of the lead wire segment coil 20B so as to cover it. Here, referring to FIG. 6, the structure of the lead wire cap 32 of the lead wire holding portion 30 will be described.

[0021] The lead wire cap 32 has a fixed portion 33 and four wall portions 34, 35, 36, and 37 that rise from the fixed portion 33. The fixed portion 33 is a part that is fixed to a moving device (not shown) for example via fasteners. This allows the lead wire cap 32 to move in accordance with the movement of the moving device. The four wall portions 34, 35, 36, and 37 include a pair of thin wall portions 34 and 35 that are facing each other and a pair of thick wall portions 36 and 37 that are facing each other. The thickness of the thin wall portions 34 and 35 is less than the thickness of the thick wall portions 36 and 37. The height of the pair of thick wall portions 36 and 37 is greater than the height of the pair of thin wall portions 34 and 35. The recess 38 defined by the four wall portions 34, 35, 36, and 37 has a shape corresponding to the tip of the protruding portion 24 of the lead wire segment coil 20B. The depth of the recess 38 defined by the four wall portions 34, 35, 36, and 37 is greater than the length of the stripped portion of the protruding portion 24 of the lead wire segment coil 20B in which the conductor is exposed.

[0022] The pair of thin-walled portions 34 and 35 are portions that face each other along the radial direction of the stator core 10 when covering the tip of the protruding portion 24 of the lead wire segment coil 20B. Each of the pair of thin-walled portions 34 and 35 has tapered surfaces 34T and 35T configured to widen the opening width at the opening edge of the recess 38. The tapered surfaces 34T and 35T are not particularly limited, but may be composed of curved surfaces with a radius of curvature of approximately 1 mm, for example. Note that the tapered surface may be formed only on the thin-walled portion 34 located radially inward of the stator core 10 among the pair of thin-walled portions 34 and 35. The thickness of the thin-walled portions 34 and 35 is not particularly limited, but may be, for example, approximately 1.2 mm to approximately 2.4 mm. When the pair of thin-walled sections 34 and 35 have this shape, the lead wire cap 32 can cover the tip of the protruding section 24 of the lead wire segment coil 20B while expanding the space between it and the adjacent general wire segment coil 20A.

[0023] The pair of thick-walled portions 36 and 37 are opposing portions along the circumferential direction of the stator core 10 when they cover the tip of the protruding portion 24 of the lead wire segment coil 20B. Each of the pair of thick-walled portions 36 and 37 has tapered surfaces 36T and 37T configured to widen the opening width at the opening edge of the recess 38. The tapered surfaces 36T and 37T are not particularly limited, but may be composed of curved surfaces with a radius of curvature of approximately 3 mm, for example.

[0024] Next, as shown in Figures 7 and 8, a contact member 40 configured to form a bending point on the lead wire segment coil 20B is positioned to contact the side surface of the protruding portion 24 of the lead wire segment coil 20B. Note that in Figure 8, only one of the multiple segment coils 20, the lead wire segment coil 20B, is shown for clarity. Now, referring to Figure 9, the structure of the contact member 40 will be described.

[0025] The contact member 40 has a base portion 42 and a pair of branch portions 44 and 46 protruding from the base portion 42. When the contact member 40 contacts the lead wire segment coil 20B, the base portion 42 is located on the yoke portion 12 of the stator core 10, and the pair of branch portions 44 and 46 are located on the teeth 14 of the stator core 10. The base portion 42 of the contact member 40 contacts the side surface of the protruding portion 24 of the lead wire segment coil 20B from the radially outer side of the stator core 10. The pair of branch portions 44 and 46 of the contact member 40 contact the side surfaces of the respective protruding portions 24 of the general wire segment coil 20A and the lead wire segment coil 20B from the circumferential direction of the stator core 10.

[0026] As shown in Figure 7, after the contact member 40 contacts the side surface of the protrusion 24 of the lead wire segment coil 20B, the lead wire cap 32 moves relative to the contact member 40 while holding the lead wire segment coil 20B. The lead wire cap 32 moves radially outward from the stator core 10. Since the base 42 of the contact member 40 is in contact with the side surface of the protrusion 24 of the lead wire segment coil 20B, this contact point becomes the bending starting point, and the protrusion 24 of the lead wire segment coil 20B is bent radially from the stator core 10. The lead wire cap 32 also moves toward the stator core 10 along the axial direction of the stator core 10. The tip of the lead wire segment coil 20B covered by the lead wire cap 32 is bent in the axial direction of the stator core 10 while maintaining a state parallel to the axial direction of the stator core 10. In this way, by moving the lead wire cap 32 relative to the contact member 40, the protruding portion 24 of the lead wire segment coil 20B can be bent. This bending process can be applied even around the location where the rib 16 of the stator core 10 (see Figure 1, etc.) is located. Therefore, the lead wire segment coil 20B formed by this bending process can be placed in a desired position without being affected by the position of the rib 16, thus providing a high degree of design freedom in terms of position.

[0027] Furthermore, the lead wire cap 32 is configured to be movable along the radial and axial directions of the stator core 10 relative to the contact member 40 within the range where the stator core 10 exists, when viewed from the axial direction of the stator core 10. As a result, the protrusion 24 of the lead wire segment coil 20B formed by this bending process is bent so that it is positioned inward from the outer circumferential surface of the stator core 10 in the radial direction of the stator core 10. The length of the lead wire segment coil 20B can be optimized within the range where connection to the power lines is permitted, thus reducing the amount of coil used. In addition, the protrusion 24 of the bent lead wire segment coil 20B is covered with a thermosetting resin to ensure insulation. Since the protrusion 24 of the lead wire segment coil 20B is positioned inward from the outer circumferential surface of the stator core 10, the amount of resin used can be reduced.

[0028] In the above example, the protruding portion 24 of the lead wire segment coil 20B was bent in the radial and axial directions of the stator core 10. In addition, the support portion (not shown) that fixes and supports the stator core 10 may rotate around the stator core 10, causing the protruding portion 24 of the lead wire segment coil 20B to be bent in the circumferential direction of the stator core 10 as well. As a result, the lead wire segment coil 20B can be placed at any position within the stator 1, thus providing a high degree of design freedom regarding its position.

[0029] The above example describes a method for bending the protruding portion 24 of the lead wire segment coil 20B. In order to manufacture the stator 1, it is necessary to bend the protruding portion 24 of the general wire segment coil 20A in the circumferential direction of the stator core 10 to form a coil. To bend the general wire segment coil 20A, a general wire cap with a common shape with the lead wire cap 32 described above can be used. In this example, multiple general wire caps are arranged in the radial and circumferential directions of the stator core 10, and, similar to the lead wire cap 32, each of the multiple general wire caps holds the general wire segment coil 20A by covering the tip of the corresponding protruding portion 24 of the general wire segment coil 20A. After holding the general wire segment coil 20A, the general wire cap moves in the circumferential direction of the stator core 10, thereby bending the protruding portion 24 of the general wire segment coil 20A in the circumferential direction of the stator core. By making the lead wire cap 32 and the general wire cap a common shape, the lead wire cap 32 and the general wire cap can be used interchangeably. Therefore, the bending of the general wire segment coil 20A and the lead wire segment coil 20B can be carried out using common manufacturing equipment, thereby reducing the manufacturing cost of the stator 1. [Explanation of symbols]

[0030] 1: Stator, 10: Stator core, 12: Yoke section, 14: Teeth, 16: Rib, 18: Slot, 19: Bolt hole, 20: Segment coil, 20A: General wire segment coil, 20B: Lead wire segment coil, 24: Protrusion, 30: Lead wire holder, 32: Lead wire cap, 40: Contact member

Claims

1. A stator manufacturing apparatus, A contact member configured to form a bending point in a lead wire segment coil among a plurality of segment coils inserted into a slot of a stator core, wherein the contact member is configured to abut against the side surface of a protruding portion of the lead wire segment coil that protrudes from the slot from the radially outer side of the stator core to form the bending point, A stator manufacturing apparatus comprising: a lead wire holding portion for holding the protruding portion of the lead wire segment coil, the lead wire holding portion being configured to be movable along the radial and axial directions of the stator core with respect to the contact member.

2. The stator manufacturing apparatus according to claim 1, wherein the lead wire holding portion is configured to be movable with respect to the contact member along the radial and axial directions of the stator core within the range in which the stator core exists, when viewed from the axial direction of the stator core.

3. The lead wire holding portion has a lead wire cap that includes a recess that covers the tip of the protruding portion of the lead wire segment coil, The stator manufacturing apparatus according to claim 1, wherein the lead wire cap has a tapered surface configured to widen the opening width of the recess in the portion of the opening edge of the recess that is located radially inward of the stator core.

4. The contact member is configured to form a bending point in the general wire segment coil among the plurality of segment coils, and is configured to contact the side surface of the protruding portion of the general wire segment coil that protrudes from the slot from the circumferential direction of the stator core to form the bending point, as described in claim 1.

5. The general wire holding portion, which holds the protruding portion of the general wire segment coil, is further configured to be movable along the circumferential direction of the stator core with respect to the contact member, The lead wire holding portion has a lead wire cap that includes a recess that covers the tip of the protruding portion of the lead wire segment coil, The general wire holding portion has a general wire cap that includes a recess that covers the tip of the protruding portion of the general wire segment coil. The stator manufacturing apparatus according to claim 4, wherein the lead wire cap and the general wire cap have a common shape.

Images