Stator manufacturing method, stator jig

Abstract

To provide a manufacturing method of a stator capable of accurately inserting a segment coil while suppressing positional displacement of insulation paper, and a stator jig.SOLUTION: A manufacturing method of a stator includes: an insulation paper insertion step of inserting insulation paper into a slot in such a manner that a front end of the insulation paper protrudes from the slot; a guide part arrangement step of arranging, on teeth, guide parts which are movable in a radial direction of a stator core, while forming a cap by opposing them to each other in a circumferential direction of the stator core; an insulation paper expansion step of expanding an opening of the insulation paper by inserting a convex-shaped insertion tool, which is movable in a radial direction in the gap, into the opening of the front end of the insulation paper; and a segment coil insertion step of moving the insertion tool to the outside in the radial direction of the stator core toward an outer peripheral edge of the slot and inserting the segment coil into the slot while guiding the segment coil by the guide parts and the insertion tool.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a stator and a stator jig.

Background Art

[0002] In recent years, a technique has been developed in which an opening at the tip of insulating paper inserted into a slot of a stator core is expanded, and a segment coil is inserted into the slot while suppressing displacement of the insulating paper.

[0003] For example, Patent Document 1 discloses a method for manufacturing a stator in which an opening at the tip of insulating paper is expanded by moving a pair of guide portions in the circumferential direction of a stator core while abutting the guide portions against the inside of the opening at the tip of the insulating paper, and a segment coil is inserted into the slot.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the method for manufacturing a stator disclosed in Patent Document 1 described above, a segment coil is guided between guide surfaces of a pair of guide portions in the circumferential direction of a stator core, but there is a risk that the insertion of the segment coil in the radial direction may be displaced and contact the stator core.

[0006] The present disclosure has been made in view of such circumstances, and provides a method for manufacturing a stator and a stator jig that can accurately insert a segment coil while suppressing displacement of insulating paper.

Means for Solving the Problems

[0007] The method for manufacturing a stator according to the present disclosure is Stator core and A segment coil is inserted into a slot formed between the teeth of the stator core, An insulating paper provided between the slot and the segment coil, A method for manufacturing a stator having, An insulating paper insertion step of inserting the insulating paper into the slot such that the leading edge of the insulating paper protrudes from the slot, A guide portion arrangement step involves arranging guide portions that are radially movable on the stator core on the teeth while forming a gap by arranging them facing each other in the circumferential direction of the stator core, An insulating paper expansion step involves expanding the opening of the insulating paper by inserting a radially movable convex-shaped insertion tool into the opening at the tip of the insulating paper, A segment coil insertion step involves moving the insertion tool radially outward of the stator core toward the outer edge of the slot, and inserting the segment coil into the slot while guiding the segment coil with the guide portion and the insertion tool. It is equipped with.

[0008] The stator manufacturing method according to this disclosure expands the opening at the leading edge of the insulating paper, allowing the segment coil to be guided into the slot by the guide portion and insertion tool. Therefore, it is possible to manufacture a stator in which the segment coil is accurately inserted into the slot while suppressing misalignment of the insulating paper.

[0009] The insertion tool may be inserted into the opening at the tip of the insulating paper such that the depth to which the insertion tool is inserted into the tip of the insulating paper is less than or equal to the length to which the tip of the insulating paper protrudes from the slot, and the length of the opening in the insulating paper in the circumferential direction of the stator core after expansion is greater than or equal to the length of the gap in the circumferential direction of the stator core. With this configuration, the opening at the tip of the insulating paper is appropriately expanded so that the segment coil can be inserted while suppressing displacement of the insulating paper. As a result, a stator in which the segment coil is accurately inserted into the slot can be manufactured.

[0010] The stator fixture relating to this disclosure is A guide portion that is movable in the radial direction of the stator core, An insertion tool with a convex shape is provided between the slots formed between the teeth of the stator core and the segment coil inserted into the slots, and its tip protrudes from the slots for insertion into insulating paper, A stator fixture equipped with, The guide portions are arranged on the teeth while forming a gap between them by arranging them opposite each other in the circumferential direction of the stator core. By inserting a radially movable convex-shaped insertion tool into the opening at the tip of the insulating paper, the opening of the insulating paper is expanded. The insertion tool is moved radially outward from the stator core so as to face the outer edge of the slot, and the segment coil is inserted into the slot while being guided by the guide portion and the insertion tool.

[0011] The stator jig according to this disclosure expands the opening at the leading edge of the insulating paper, allowing the segment coil to be guided into the slot by the guide portion and insertion tool. Therefore, the segment coil can be accurately inserted into the slot while suppressing misalignment of the insulating paper.

[0012] The insertion tool has a convex shape such that the length in the circumferential direction of the stator core at the opening of the insulating paper after expansion is not less than the length in the circumferential direction of the stator core of the gap, and the depth at which the insertion tool is inserted into the tip of the insulating paper may be not more than the length protruding from the slot at the tip of the insulating paper. With such a configuration, while suppressing the displacement of the insulating paper, the opening at the tip of the insulating paper is appropriately expanded so that the segment coil can be inserted. Therefore, the segment coil can be accurately inserted into the slot.

Advantages of the Invention

[0013] According to the present disclosure, it is possible to provide a method for manufacturing a stator and a stator jig that can accurately insert a segment coil while suppressing displacement of the insulating paper.

Brief Description of the Drawings

[0014] [Figure 1] It is a perspective view of a stator manufactured by the stator jig and the stator manufacturing method according to Embodiment 1. [Figure 2] It is a drawing showing the configuration of the stator jig according to Embodiment 1. [Figure 3] It is a drawing showing the configuration of the stator jig according to Embodiment 1. [Figure 4] It is a drawing showing the configuration of the stator jig according to Embodiment 1. [Figure 5] It is a drawing showing a state where the insertion tool is inserted into the opening at the tip of the insulating paper. [Figure 6] It is a flowchart illustrating the manufacturing method of the stator according to Embodiment 1.

Modes for Carrying Out the Invention

[0015] Hereinafter, the present disclosure will be described through embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. Also, not all of the configurations described in the embodiments are essential as means for solving the problems. For clarity of explanation, the following description and drawings have been appropriately omitted and simplified. In each drawing, the same reference numerals are assigned to the same elements, and duplicate explanations are omitted as necessary. Of course, the right-handed xyz orthogonal coordinates shown in the drawings are for convenience in explaining the positional relationship of the components. Usually, the positive direction of the z-axis is vertically upward, and the xy plane is the horizontal plane.

[0016] (Embodiment 1) <Stator> First, the stator will be described with reference to FIG. 1. FIG. 1 is a perspective view of a stator manufactured by the stator jig and the stator manufacturing method according to Embodiment 1. The stator 10 shown in FIG. 1 is a stator after inserting the segment coil 12 and twisting and forming the coil end portion 15 by the stator jig and the stator manufacturing method according to Embodiment 1.

[0017] As shown in FIG. 1, the stator 10, which is the stator of a rotating electrical machine, has a stator core 11 and a plurality of segment coils 12. The stator core 11 is formed by laminating substantially cylindrical electromagnetic steel sheets in the axial direction of the stator 10 (the z-axis direction in FIG. 1), and teeth 16 protruding toward the inner peripheral side and slots 13 are provided.

[0018] The slots 13 are formed between adjacent teeth 16. The slots 13 are recesses provided with a predetermined thickness from the inner peripheral surface to the outer surface of the stator 10. In the stator core 11, the teeth 16 and the slots 13 are alternately formed in the circumferential direction of the stator core 11. Hereinafter, the circumferential direction refers to the circumferential direction of the stator core 11, which is the direction indicated by the arrow in FIG. 1. Also, the radial direction is the direction from the outer periphery of the stator core 11 toward the center of the stator core 11, which is the direction indicated by the arrow in FIG. 1.

[0019] In the example shown in Figure 1, two different segment coils 12 are joined at the coil joint 14 at the tip of the conductor. Multiple coil joints 14 are arranged circumferentially at the coil end portion 15 of the segment coil 12.

[0020] In Figure 1, the coil end portions 15 are arranged in four rows in the radial direction, but it is preferable to arrange the segment coils 12 to match the radial length of the slot 13. The coil joint portions 14 are in a state where the insulating coating has been removed in order to join the segment coils 12 together, and the metal base material is exposed.

[0021] <Configuration of the stator jig> Next, the configuration of the stator jig will be described with reference to Figures 2 to 4. Figures 2 to 4 are diagrams showing the configuration of the stator jig according to Embodiment 1. In each diagram, the upper section shows a plan view (xy plan view) of the stator jig and stator core, and the lower section shows a cross-sectional view (xz cross-sectional view) of the stator jig and stator core. The stator jig is a jig for expanding the opening at the leading edge of the insulating paper.

[0022] First, let's explain the insulating paper. As shown in Figures 2 to 4, the insulating paper P1 is placed between the slot and the segment coil. As shown in the lower part of Figures 2 to 4, the leading edge of the insulating paper P1 is positioned to protrude from the slot 13. Details of the dimensions of the insulating paper P1 will be described later.

[0023] The insulating paper P1 is, for example, a sheet-like insulating member that can come into contact with the slot 13. The insulating paper P1 is intended to ensure insulation between the segment coil 12 inserted into the slot 13 and the slot 13 (stator core 11). Preferably, the insulating paper P1 contains an adhesive, such as a foamed adhesive resin, in its surface or internal layer for fixing the segment coil 12, but it may also not contain an adhesive.

[0024] In the upper section of Figures 2 to 4, the insulating paper P1 is represented by a dotted line. Figure 2 shows the state before the opening at the tip of the insulating paper is expanded. Figure 3 shows the state after the opening at the tip of the insulating paper has been expanded. Figure 4 shows the state in which the segment coil 12 is inserted into the insulating paper with the expanded opening at the tip.

[0025] Next, the configuration of the stator jig will be described. As shown in the upper part of Figure 2, the stator jig consists of a guide section 21 and an insertion tool 22. The guide section 21 is movable in the radial direction of the stator core 11. Similarly, the insertion tool 22 is also movable in the radial direction of the stator core 11. The guide section 21 and the insertion tool 22 are independently movable in the radial direction.

[0026] Furthermore, the guide section 21 and the insertion tool 22 do not move up or down in the z-axis direction, but rather move radially at a predetermined height. Figures 2 to 4 show the insertion tool 22 being moved radially, illustrating the different positions of the insertion tool 22.

[0027] The insertion tool 22 will now be described in detail. The insertion tool 22 consists of a straight section 32 and a protruding section 42. When the protruding section 42 is inserted into the opening at the leading edge of the insulating paper, the opening of the insulating paper is expanded. Details of the dimensions of the insertion tool 22 will be described later.

[0028] As shown in the upper part of Figures 2-4, a gap SP1 is formed by arranging the guide portions 21 opposite each other in the circumferential direction of the stator core. The insertion tool 22 moves radially within the gap SP1 formed between the guide portions 21. The upper part of Figure 2 shows the insertion tool 22 positioned radially outward. The upper part of Figure 3 shows the insertion tool 22 moved radially inward from the state shown in the upper part of Figure 2. The upper part of Figure 4 shows the insertion tool 22 moved radially outward toward the outer edge of the slot 13 from the state shown in the upper part of Figure 3.

[0029] As shown in the upper part of Figure 4, the insertion tool 22 is positioned radially outward of the stator core so as to face the outer edge of the slot 13, thereby guiding the segment coil 12 into the slot without any radial misalignment.

[0030] The guide portion 21 will now be described in detail. As shown in the lower part of Figure 3, the guide portion 21 has a recess 31 formed therein so that the insulating paper P1 and the insertion tool 22 do not interfere with each other. The pair of guide portions 21 are formed so as to cover the insulating paper P1 and the insertion tool 22 by the recess 31. The guide portion 21 is not limited to the shapes shown in Figures 2 to 4, and can be any shape as long as the recess 31 is formed. Alternatively, the guide portions 21 may be arranged opposite each other via the straight portion 32 of the insertion tool 22 without forming a recess 31 and without covering the insulating paper P1 and the insertion tool 22.

[0031] As shown in the upper part of Figure 4, the guide portion 21 is moved and positioned on the teeth 16 so that the segment coil 12 can be guided into the gap SP1 and slot 13. In other words, the guide portion 21 guides the segment coil 12 into the slot so that its circumferential direction does not shift.

[0032] Specifically, as shown in the upper part of Figure 4, the guide section 21 guides the segment coil so that it does not shift in the circumferential direction, and the insertion tool 22 guides the segment coil so that it does not shift in the radial direction. This allows the segment coil 12 to be accurately inserted into the slot 13.

[0033] The guide section 21 and insertion tool 22 have, for example, a cam mechanism (not shown), and by rotating the cam ring, radial movement is possible. The stator core 11 can also move up and down in the axial direction (z-axis direction). Naturally, the guide section 21 and insertion tool 22 and the stator core 11 can move independently.

[0034] <Operation of the stator jig> The operation of the stator jig will be explained with reference to Figures 2 to 4. First, as shown in the lower part of Figure 2, the insulating paper P1 is inserted into the slot 13 so that the leading edge of the insulating paper P1 protrudes from the slot 13. For example, by inserting a blade (not shown) from the negative z-axis direction into the inside of the insulating paper P1, the insulating paper P1 is pushed up within the slot 13, and the leading edge of the insulating paper P1 protrudes from the slot 13.

[0035] Next, as shown in the upper part of Figure 2, the guide portions 21 are positioned on the teeth 16, forming a gap SP1 by arranging them opposite each other in the circumferential direction of the stator core 11. Also, as shown in the upper part of Figure 2, the insertion tool 22 is positioned radially outward from the stator core 11. More specifically, as shown in the upper part of Figure 2, the insertion tool 22 is located on the stator core 11.

[0036] Next, as shown in the upper part of Figure 3, the insertion tool 22 is moved and positioned radially inward of the stator core 11 from the state shown in the upper part of Figure 2. More specifically, as shown in the upper part of Figure 3, the insertion tool 22 is positioned on the slot 13.

[0037] Here, as shown in the lower part of Figure 3, the stator core 11 is raised in the positive z-axis direction. This allows the insertion tool 22 to be inserted into the opening at the leading edge of the insulating paper P1. More specifically, the convex portion 42 of the insertion tool 22 contacts the opening at the leading edge of the insulating paper P1, expanding the opening in the insulating paper. This expands the opening at the leading edge of the insulating paper P1 in the circumferential direction.

[0038] Next, as shown in the upper part of Figure 4, the insertion tool 22 is moved and positioned radially outward from the stator core so as to face the outer edge of the slot 13. More specifically, while maintaining the expanded state of the opening of the insulating paper (lower part of Figure 3), the insertion tool 22 is moved to the outer edge of the slot 13. This expands the opening at the leading edge of the insulating paper P1 in the radial direction. With this configuration, the opening at the leading edge of the insulating paper P1 is expanded in both the circumferential and radial directions, becoming mortar-shaped. Then, as shown in the lower part of Figure 4, the segment coil 12 is inserted into the slot 13.

[0039] As shown in the lower part of Figure 4, when inserting the segment coil 12 by moving the insertion tool 22 to the outer edge of the slot 13, interference between the insertion tool 22 and the segment coil 12 can be suppressed. In addition, although a force is generated at the opening of the insulating paper P1 that returns it to its pre-expansion state, the insertion tool 22 holds down the opening of the insulating paper P1 at the outer edge of the slot 13, thus suppressing it from returning to its pre-expansion state.

[0040] Furthermore, since the insertion tool 22 holds down the opening of the insulating paper P1 at the outer edge of the slot 13 while inserting the segment coil into the slot 13, it is possible to suppress misalignment of the insulating paper and a decrease in insulation performance due to damage to the insulating paper.

[0041] Thus, the stator jig according to Embodiment 1 expands the opening at the leading edge of the insulating paper, allowing the segment coil to be guided into the slot by the guide portion and insertion tool. Therefore, the segment coil can be accurately inserted into the slot while suppressing misalignment of the insulating paper relative to the slot.

[0042] Furthermore, in the stator jig according to Embodiment 1, since the guide section 21 and the insertion tool 22 can move radially independently, the same stator jig can be used even for stators where the slot position has shifted due to a change in the diameter of the stator core. Moreover, since only the guide section 21 and the insertion tool 22 need to be prepared, equipment costs can be reduced.

[0043] <Dimensions related to the stator jig> Next, the dimensions of the stator jig and insulating paper will be explained with reference to Figure 5. Figure 5 shows the insertion tool inserted into the opening at the tip of the insulating paper.

[0044] The depth H1 to which the insertion tool is inserted into the leading edge of the insulating paper is described below. The depth H1 is less than or equal to the length H2 to which the leading edge of the insulating paper P1 protrudes from the slot. More specifically, the amount of rise of the stator core 11 is controlled so that the depth H1 becomes length H2.

[0045] Next, we will explain the length W3 in the circumferential direction of the stator core at the opening of the expanded insulating paper. The length W3 is greater than or equal to the length W4 in the circumferential direction of the stator core at the gap SP1. Since the width of the segment coil is less than the length W4, if the length W3 is greater than or equal to the length W4, the segment coil can be inserted into the slot 13.

[0046] In this way, when the insertion tool 22 is inserted into the opening of the insulating paper P1 such that the depth H1 is less than or equal to the length H2 and the length W3 is greater than or equal to the length W4, the opening at the leading edge of the insulating paper is appropriately expanded so that the segment coil can be inserted while suppressing displacement of the insulating paper.

[0047] Even if the thickness and shape of the segment coils 12 inserted into the slot 13 differ, the length W3 at the opening of the insulating paper P1 can be adjusted according to the shape of the segment coils 12 by controlling the depth H1, i.e., the amount of rise of the stator core 11. In other words, the stator manufacturing method according to Embodiment 1 makes it possible to manufacture a stator in which the segment coils 12 are accurately inserted into the slot 13 while suppressing misalignment of the insulating paper P1, even if the shape of the inserted segment coils 12 differs.

[0048] Here, the insertion width W1 will be explained. The insertion width W1 is the circumferential length of the end face on the insulating paper side of the protrusion 42 of the insertion tool 22. In order to insert the insertion tool 22 into the opening of the insulating paper P1, the insertion width W1 must be smaller than the width of the insulating paper P1 before expansion, i.e., the width W2. Also, in the example shown in Figure 5, the circumferential length of the straight section 32 is the same as the insertion width W1, but this is not limited to this, and the circumferential length of the straight section 32 may be larger or smaller than the insertion width. However, since the insertion tool 22 is movable in the radial direction of the gap SP1, the circumferential length of the straight section 32 is smaller than the length W4.

[0049] Here, a configuration has been described in which the stator core 11 rises, and the insertion tool 22 is inserted into the insulating paper, without the guide section 21 and the insertion tool 22 rising or falling in the z-axis direction. However, the system is not limited to this configuration, and the insertion tool 22 may be inserted into the insulating paper by the guide section 21 and the insertion tool 22 rising or falling in the z-axis direction, without the stator core 11 rising or falling in the z-axis direction. In this case, the stroke of the insertion tool 22 is controlled to adjust the depth H1 and length W3.

[0050] <Stator Manufacturing Method> Next, the method for manufacturing a stator according to Embodiment 1 will be described with reference to Figure 6. Figure 6 is a flowchart illustrating the method for manufacturing a stator according to Embodiment 1. Figures 2 to 4 will be referenced as appropriate during the explanation.

[0051] First, insert the insulating paper into the slot (step ST1). More specifically, as shown in the lower part of Figure 2, insert the insulating paper P1 into the slot 13 so that the leading edge of the insulating paper P1 protrudes from the slot 13. Step ST1 is referred to as the insulating paper insertion step.

[0052] Next, the guide portion is positioned on the teeth (step ST2). More specifically, as shown in the lower part of Figure 2, guide portions 21 that are movable in the radial direction of the stator core 11 are positioned on the teeth 16 while forming a gap SP1 by arranging them opposite each other in the circumferential direction of the stator core 11. Step ST2 is referred to as the guide portion positioning step.

[0053] Next, the opening of the insulating paper is expanded (step ST3). More specifically, as shown in the lower part of Figure 3, the opening of the insulating paper P1 is expanded by inserting the insertion tool 22 into the opening at the leading edge of the insulating paper P1. Step ST3 is referred to as the insulating paper expansion step.

[0054] Next, the segment coil is inserted into the slot (step ST4). More specifically, as shown in the lower part of Figure 4, the stator core 11 is moved radially outward toward the outer edge of the slot 13, and the segment coil 12 is inserted into the slot 13 while being guided by the guide portion 21 and the insertion tool 22. Step ST4 is referred to as the segment coil insertion step.

[0055] After inserting the segment coil 12 in step ST4, the stator 10 shown in Figure 1 can be manufactured by twisting the coil end portion 15 of the segment coil 12.

[0056] Thus, the stator manufacturing method according to Embodiment 1 expands the opening at the leading edge of the insulating paper, allowing the segment coil to be guided into the slot by the guide portion and insertion tool. Therefore, it is possible to manufacture a stator in which the segment coil is accurately inserted into the slot while suppressing misalignment of the insulating paper.

[0057] This disclosure is not limited to the embodiments described above, and may be modified as appropriate without departing from its intent. [Explanation of symbols]

[0058] 10 staters 11 Stator Core 12-segment coil 13 slots 14. Coil joint 15. Coil end section 16 teeth 21 Guide Section 22 Insertion Tools 31 Recess 32 Straight section 42 Convex part H1 Depth H2, W3, W4 Length P1 Insulating paper SP1 Gap W1 Insertion width W2 width

Claims

1. Stator core and A segment coil is inserted into a slot formed between the teeth of the stator core, An insulating paper provided between the slot and the segment coil, A method for manufacturing a stator having, An insulating paper insertion step of inserting the insulating paper into the slot such that the leading edge of the insulating paper protrudes from the slot, A guide portion arrangement step involves arranging a pair of guide portions that are movable in the radial direction of the stator core on the teeth while forming a gap by arranging them facing each other in the circumferential direction of the stator core, An insulating paper expansion step involves expanding the opening in the insulating paper by inserting a radially movable convex-shaped insertion tool into the opening at the tip of the insulating paper, A segment coil insertion step involves moving the insertion tool radially outward of the stator core toward the outer edge of the slot, and inserting the segment coil into the slot while guiding the segment coil with the pair of guides and the insertion tool. A method for manufacturing a stator, comprising the following:

2. In the insulating paper expansion step, The depth to which the insertion tool is inserted into the leading edge of the insulating paper is less than or equal to the length to which the leading edge of the insulating paper protrudes from the slot. The length of the opening in the insulating paper after expansion in the circumferential direction of the stator core is greater than or equal to the length of the gap in the circumferential direction of the stator core. Insert the insertion tool into the opening at the tip of the insulating paper. A method for manufacturing a stator according to claim 1.

3. A pair of guide sections that are movable in the radial direction of the stator core, An insertion tool with a convex shape is provided between the slots formed between the teeth of the stator core and the segment coil inserted into the slots, and its tip protrudes from the slots for insertion into insulating paper, A stator fixture equipped with, The pair of guide portions are arranged on the teeth while forming a gap between them by arranging them facing each other in the circumferential direction of the stator core. By inserting a radially movable convex-shaped insertion tool into the opening at the tip of the insulating paper, the opening of the insulating paper is expanded. The insertion tool is moved radially outward from the stator core toward the outer edge of the slot, and the segment coil is inserted into the slot while being guided by the pair of guides and the insertion tool. Stator jig.

4. The aforementioned insertion tool is The opening in the insulating paper after expansion has a convex shape such that the length in the circumferential direction of the stator core is greater than or equal to the length of the gap in the circumferential direction of the stator core. The depth to which the insertion tool is inserted into the leading edge of the insulating paper is set to be less than or equal to the length that protrudes from the slot at the leading edge of the insulating paper. The stator jig according to claim 3.

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