Stator of a rotating electric machine, method for manufacturing a stator of a rotating electric machine

Abstract

This stator of a dynamo-electric machine includes a first coil that extends out along an axial direction from an end surface of the core, and a second coil that extends out from the end surface of the core and is inclined in the circumferential direction relative to the axial direction. The coil end section of the first coil is provided with two first radial-direction surfaces and two first circumferential-direction surfaces. The coil end section of the second coil is provided with two second radial-direction surfaces, two inclined surfaces, and a second circumferential-direction surface that is adjacent to the second radial-direction surfaces and to the second inclined surface facing toward the core. The coil end section of the second coil has curved sections that are curved toward respective radial-direction exteriors at positions between the first coils.

Description

Technical Field

[0001] The present invention relates to a stator of a rotating electrical machine and a method for manufacturing the stator of a rotating electrical machine.

Background Art

[0002] In a stator of a rotating electrical machine, it is necessary to suppress the height of a coil (segment conductor) to be inserted and also to suppress a decrease in coil insulation. It is necessary to achieve both of the above suppressions simultaneously while simplifying the manufacture of the stator. For example, Patent Document 1 below discloses a method for manufacturing a stator of a rotating electrical machine in which a joint portion of a leg portion of a segment conductor is sealed with an insulating resin to improve the insulation of a coil end.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Conventionally, among the coils inserted into the core, a coil extending axially from the slot of the stator and a coil inclined with respect to the axial direction are brought close to each other by a chuck and welded at their respective ends. However, at that time, since they may contact each other at portions other than the joint portion between the axially extending coil and the inclined coil, there is a problem that the enamel layer of the coil is rubbed and the insulation performance is deteriorated. In view of this, an object of the present invention is to provide a stator of a rotating electrical machine and a method for manufacturing the stator of a rotating electrical machine that can be welded without deteriorating the insulation performance.

Means for Solving the Problems

[0005] The stator of a rotating electric machine comprises an annular core having a plurality of slots in the circumferential direction, a plurality of coils having a plurality of straight sections provided along the radial direction of the plurality of slots, and coil end sections formed extending from both ends of the straight sections to the outside of the core, wherein the plurality of coils include a first coil extending axially from the end face of the core, and a second coil extending from the end face of the core and inclined in the circumferential direction with respect to the axial direction, and the coil end section of the first coil The first coil comprises two first radial surfaces facing each other in the radial direction and two first circumferential surfaces facing each other in the circumferential direction, and the coil end portion of the second coil comprises two second radial surfaces facing each other in the radial direction, two inclined surfaces facing each other between the two second radial surfaces, and a second circumferential surface adjacent to the inner inclined surface of the two inclined surfaces that faces the core side and the two second radial surfaces, and the coil end portion of the second coil has a bent portion that bends radially outward at a position between the plurality of first coils. Furthermore, as a method for manufacturing the stator of a rotating electric machine, a plurality of coils are inserted into an annular core having a plurality of slots in the circumferential direction, and the plurality of inserted coils include a first coil extending axially from the end face of the core and a second coil extending from the end face of the core and inclined circumferentially with respect to the axial direction, and when welding the coil end portion of the first coil and the coil end portion of the second coil to each other, a method is employed in which the two first circumferential surfaces that face each other in the circumferential direction at the coil end portion of the first coil and the two inclined surfaces that face each other between the two second radial surfaces that face each other in the radial direction at the coil end portion of the second coil, the outer inclined surface that does not face the core side and the second circumferential surface that is adjacent to the inner inclined surface that faces the outer inclined surface and the two second radial surfaces is gripped by a jig. [Effects of the Invention]

[0006] This invention provides a stator for a rotating electric machine that can be welded without degrading its insulation performance, and a method for manufacturing a stator for a rotating electric machine. [Brief explanation of the drawing]

[0007] [Figure 1] Overall view of the stator of a rotating electric machine [Figure 2] Diagram illustrating the problems with the coil end section. [Figure 3] Diagram illustrating the configuration of a coil in one embodiment of the present invention. [Figure 4] Figure 3 is an explanatory diagram of the coil's bend and the connection between coils. [Figure 5] Diagrams illustrating the surfaces of each coil end. [Figure 6] Diagram illustrating a gripping jig used for joining coils.

[0008] Embodiments of the present invention will be described below with reference to the drawings. The following description and drawings are illustrative for illustrating the present invention, and have been omitted and simplified as appropriate for clarity of explanation. The present invention can also be carried out in various other forms. Unless otherwise specified, each component may be singular or plural.

[0009] The positions, sizes, shapes, and ranges of the components shown in the drawings may not represent their actual positions, sizes, shapes, and ranges in order to facilitate understanding of the invention. Therefore, the present invention is not necessarily limited to the positions, sizes, shapes, and ranges disclosed in the drawings.

[0010] (An embodiment of the present invention and the overall configuration of the apparatus) (Figure 1) The stator 10 of a rotating electric machine has a plurality of coils 1 and a stator core 2 (hereinafter referred to as core 2). The plurality of coils 1 are inserted into the core 2 to function as the stator 10. The plurality of coils 1 are inserted into the stator 10 at predetermined intervals in the circumferential direction from each other. The coils 1 are, for example, conductive segment conductors with an enamel layer coated on their surface.

[0011] (Figure 2) In the stator 10, the annular core 2 is provided with multiple slots 2a into which multiple coils 1 are inserted in the circumferential direction. Multiple coils 1 are inserted into the slots 2a along the radial direction of the stator 10. In the coil 1, the portion inserted into the slots 2a is called the straight portion, and the portions extending from both ends of the straight portion to the outside of the core 2 are called the coil end portions.

[0012] The multiple coils 1 include straight coils 3 extending axially from the end face of the core 2 and diagonal coils 4 extending from the end face of the core 2 and inclined circumferentially with respect to the axial direction. Here, the straight coils 3 are defined as the first coil 3, and the diagonal coils 4 are defined as the second coil 4.

[0013] When the coil ends of the first coil 3 and the second coil 4 are joined at their ends, they are coil-chucked radially 1b, and at this time, coil contact 1a occurs between them. When such coil contact 1a occurs, the enamel layers of the coils rub against each other, resulting in a decrease in insulation performance.

[0014] (Figures 3 and 4) Figure 3(a) is an explanatory diagram of the coil configuration according to one embodiment of the present invention, and Figure 3(b) is a view of Figure 3(a) from the circumferential direction. Furthermore, Figure 4(a) is an explanatory diagram of the bent portion of the coil in Figure 3, and Figure 4(b) is an explanatory diagram of the joining of coils.

[0015] To solve the above-mentioned problems as shown in Figure 2, the coil end portion of the second coil 4 has a bent portion 5 that bends radially outward at a position between the multiple first coils 3. This not only suppresses friction of the enamel layer due to the coil contact 1a (Figure 2) between the coils mentioned above, but also brings the ends of the coil end portions of the first coil 3 and the second coil 4 closer together by the bent portion 5, thus simplifying the radial coil chuck 1b (Figure 2) process and enabling welding. By welding the ends of the coil end portions of the first coil 3 and the second coil 4 together, a welded joint 6 is formed.

[0016] (Fig. 5) In the welded joint of the present invention, it is necessary to position the coil end portion of the first coil 3 and the coil end portion of the second coil 4. Therefore, for the coil end portions of each coil, the surfaces to be fixed for positioning are determined as follows.

[0017] The coil end portion of the first coil 3 includes two first radial surfaces 3c facing each other in the radial direction and two first circumferential surfaces 3a facing each other in the circumferential direction. Further, the coil end portion of the second coil 4 includes two second radial surfaces 4c facing each other in the radial direction, two inclined surfaces 4D, 4d facing each other between the two second radial surfaces 4c, an inner inclined surface 4d facing the core 2 side among the two inclined surfaces 4D, 4d, and a second circumferential surface 4a adjacent to the two second radial surfaces 4c.

[0018] Also, the coil end portion of the first coil 3 includes a first axial surface 3b adjacent to the two first radial surfaces 3c and the two first circumferential surfaces 3a. Further, the coil end portion of the second coil 4 includes a second axial surface 4b adjacent to the two second radial surfaces 4c, an outer inclined surface 4D facing the inner inclined surface 4d, and the second circumferential surface 4a. Thus, since the first coil 3 and the second coil 4 define the directions of the surfaces of the coil end portions in the axial direction, radial direction, and circumferential direction, the positioning of the welded joint can be clarified.

[0019] (Manufacturing method) [[ID=十七]](Fig. 6) Although the process of the coil chuck 1b (Fig. 2) is not required for the first coil 3 and the second coil 4, as described above, a gripping jig 7 for position fixing is required for the welded joint of the coils. Therefore, for the surfaces and processes to be gripped in each of the coils described in Fig. 5, the following is done.

[0020] First, multiple coils 1 are inserted into an annular core 2 which has multiple slots 2a in the circumferential direction. The inserted coils 1 include a first coil 3 that extends axially from the end face of the core 2 and a second coil 4 that extends from the end face of the core 2 and is inclined circumferentially with respect to the axial direction.

[0021] Then, when welding the coil end portion of the first coil 3 and the coil end portion of the second coil 4 to each other, the gripping jig 7 grips the two first circumferential surfaces 3a that face each other in the circumferential direction at the coil end portion of the first coil 3, and the two inclined surfaces 4D and 4d that face each other between the two second radial surfaces 4c that face each other in the radial direction at the coil end portion of the second coil 4, specifically the outer inclined surface 4D that does not face the core 2 side, the inner inclined surface 4d that faces the outer inclined surface 4D, and the second circumferential surface adjacent to the two second radial surfaces 4c.

[0022] This enables welding of coils having the features of the present invention. Furthermore, it suppresses the reduction in coil insulation by avoiding contact between coils and eliminates the need for the coil chuck 1b in the manufacturing process. Additionally, it eliminates the need for a twisting process after inserting the coil 1 into the core 2, significantly reducing production costs.

[0023] According to the embodiment of the present invention described above, the following effects are achieved.

[0024] (1) The stator 10 of the rotating electric machine comprises an annular core 2 having a plurality of slots 2a in the circumferential direction, and a plurality of coils 1 having a plurality of straight sections provided along the radial direction of the plurality of slots 2a, and coil end sections formed extending from both ends of the straight sections to the outside of the core 2. The plurality of coils 1 include a first coil 3 extending axially from the end face of the core 2, and a second coil 4 extending from the end face of the core 2 and inclined circumferentially with respect to the axial direction. The coil end section of the first coil 3 comprises two first radial surfaces 3c facing each other in the radial direction, and two first circumferential surfaces 3a facing each other in the circumferential direction. The coil end portion of the second coil 4 includes two radially opposing second radial surfaces 4c, two inclined surfaces 4D and 4d facing each other between the two second radial surfaces 4c, and a second circumferential surface 4a adjacent to the inner inclined surface 4d facing the core 2 and the two second radial surfaces 4c. The coil end portion of the second coil 4 has a bent portion 5 that bends radially outward at a position between the multiple first coils 3. This makes it possible to provide a stator for a rotating electric machine that can be welded without degrading insulation performance.

[0025] (2) The coil end portion of the first coil 3 has two first radial surfaces 3c and two first circumferential surfaces 3a, and a first axial surface 3b adjacent to them. The coil end portion of the second coil 4 has two second radial surfaces 4c and an external inclined surface 4D facing the internal inclined surface 4d and a second circumferential surface 4a, and a second axial surface 4b adjacent to it. In this way, the axial surface for welding the coils together can be determined.

[0026] (3) Multiple coils 1 are inserted into an annular core 2 having multiple slots 2a in the circumferential direction. The inserted coils 1 include a first coil 3 extending axially from the end face of the core 2 and a second coil 4 extending from the end face of the core 2 and inclined circumferentially with respect to the axial direction. When welding the coil end portions of the first coil 3 and the coil end portions of the second coil 4 to each other, the jig 7 grips the two first circumferential surfaces 3a of the coil end portion of the first coil 3 that are facing each other in the circumferential direction, and the two inclined surfaces 4D and 4d of the second coil 4 that are facing each other between the two second radial surfaces 4c, specifically the outer inclined surface 4D that is not facing the core 2 side, and the second circumferential surface 4a that is adjacent to the inner inclined surface 4d that faces the outer inclined surface 4D and the two second radial surfaces 4c. By adopting this manufacturing method, it is possible to manufacture a stator for a rotating electric machine that can be welded without degrading the insulation performance.

[0027] It should be noted that the present invention is not limited to the embodiments described above, and various modifications and combinations of other configurations can be made without departing from the spirit of the invention. Furthermore, the present invention is not limited to having all the configurations described in the embodiments described above, and may also include configurations in which some of those configurations are omitted. [Explanation of Symbols]

[0028] 1 coil 1a Coil contact 1b Coil Chuck 2 Stator Cores 2a slot 3. Straight coil (first coil) 3a First circumferential surface 3b 1st axis direction plane 3c First radial plane 4. Diagonal coil (second coil) 4a Second circumferential surface 4b 2nd axis direction plane 4c Second radial plane 4D external slope 4d internal slope 5. Flexed section 6. Welded section 7 Gripping jig 10 Stator of a rotating electric machine

Claims

1. Multiple coils are inserted into an annular core having multiple slots in the circumferential direction. The inserted coils include a first coil extending axially from the end face of the core and a second coil extending from the end face of the core and inclined circumferentially with respect to the axial direction, When welding the coil end portion of the first coil and the coil end portion of the second coil to each other, the following are gripped by a jig: two first circumferential surfaces facing each other in the circumferential direction at the coil end portion of the first coil, and two inclined surfaces facing each other between two second radial surfaces facing each other in the second coil, specifically the outer inclined surface that does not face the core, and the inner inclined surface facing the outer inclined surface and the second circumferential surface adjacent to the two second radial surfaces. A method for manufacturing a stator for a rotating electric machine.

2. The coil end portion of the first coil is provided with two first radial surfaces facing each other in the radial direction, The aforementioned internal inclined surface faces the core side, The coil end portion of the second coil has a bent portion that bends radially outward at a position between the plurality of first coils. A method for manufacturing a stator of a rotating electric machine according to claim 1.

3. The coil end portion of the first coil comprises two first radial surfaces and two first circumferential surfaces, and a first axial surface adjacent thereto. The coil end portion of the second coil comprises two second radial surfaces, an external inclined surface facing the internal inclined surface, a second circumferential surface, and a second axial surface adjacent to them. A method for manufacturing a stator of a rotating electric machine according to claim 2.

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