Stator manufacturing method, motor manufacturing method, and stator manufacturing device

Abstract

A stator manufacturing method according to the present invention comprises: a positioning step in which positioning jigs (41, 42) are brought into contact with a pair of inclined parts (13a) to position the same in the radial direction of a stator (10) such that leading end portions of a pair of segment coils (13) adjacent to each other in the radial direction of the stator (10) are in contact with each other; a molding step in which, in the state in which the pair of inclined parts (13a) have been positioned, a pair of linear parts (13b) that are continuous with the pair of inclined parts (13a) are plastically deformed; and a welding step in which the plastically deformed pair of linear parts (13b) are welded.

Description

Stator manufacturing method, motor manufacturing method, and stator manufacturing device

[0001] The present invention relates to a stator manufacturing method, a motor manufacturing method, and a stator manufacturing apparatus.

[0002] JP2016-131453A discloses a method for manufacturing a stator that includes a correction process for correcting the relative positions of the tips of different segment coils that are welded in a welding process.

[0003] In the straightening process, a die is brought into contact with the tip end portion of an adjacent pair that is located on the inner side from the inner circumferential side, and the tip end portion located on the inner circumferential side is plastically deformed in the direction of the tip end portion located on the outer circumferential side. Next, the die is moved, and the die is brought into contact with the tip end portion of an adjacent pair that is located on the outer circumferential side from the outer circumferential side, and the tip end portion located on the outer circumferential side is plastically deformed in the direction of the tip end portion located on the inner circumferential side.

[0004] In the above manufacturing method, when the tip of the segment coil is pressed with a mold, the force transmitted from the mold deforms the parts other than the tip, resulting in the problem that the deformed segment coil interferes with other segment coils, causing the tip positions of the other segment coils to shift.

[0005] The present invention has been made in consideration of these technical challenges, and aims to prevent segment coils that are plastically deformed from interfering with other segment coils.

[0006] According to one aspect of the present invention, there is provided a method for manufacturing a stator in which a plurality of segment coils are arranged on a stator core, wherein the plurality of segment coils each have an inclined portion that inclines circumferentially around the stator based on the axial direction of the stator, and a straight portion that is located at the tip of the segment coil and extends in the axial direction of the stator continuously from the inclined portion, and the method for manufacturing the stator includes a positioning step in which a positioning jig is abutted against a pair of the inclined portions to position them in the radial direction of the stator so that the tip ends of a pair of adjacent segment coils in the radial direction of the stator abut each other; a forming step in which, with the pair of inclined portions positioned, a pair of straight portions that are continuous with the pair of inclined portions are plastically deformed; and a welding step in which the pair of plastically deformed straight portions are welded together.

[0007] In the above-described embodiment, the pair of linear portions connected to the pair of inclined portions are plastically deformed while the pair of inclined portions is positioned. Therefore, when the pair of linear portions are plastically deformed, deformation of portions other than the pair of linear portions can be suppressed. Therefore, interference between the segment coil to be plastically deformed and other segment coils can be suppressed.

[0008] FIG. 1 is a cross-sectional view showing a schematic configuration of a motor having a stator manufactured by a stator manufacturing method according to an embodiment of the present invention. FIG. 2 is a flowchart showing an example of a stator manufacturing method. FIG. 3 is a perspective view of a stator after a twisting process. FIG. 4 is a schematic diagram for explaining the arrangement of a plurality of segment coils after the twisting process. FIG. 5 is a schematic diagram showing a schematic configuration of an example of a stator manufacturing apparatus. FIG. 6 is a perspective view of a first positioning jig. FIG. 7 is a schematic diagram for explaining the positioning process. FIG. 8 is a view taken along arrow VIII in FIG. 7. FIG. 9 is a schematic diagram for explaining a state in which a pair of inclined portions are positioned. FIG. 10 is a perspective view of a forming jig. FIG. 11 is a schematic diagram for explaining the forming process. FIG. 12 is a perspective view of a first positioning jig according to a modified example. FIG. 13 is a schematic diagram showing a state in which abutting portions abut against the forming jig. FIG. 14 is a perspective view of a first positioning jig according to another modified example. FIG. 15 is a plan view of a second positioning jig according to another modified example.

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0010] FIG. 1 is a cross-sectional view showing a schematic configuration of a motor 100 having a stator 10 manufactured by a stator manufacturing method according to an embodiment of the present invention.

[0011] The motor 100 includes a stator 10, a rotor 20 arranged coaxially with the stator 10, and a case 30 that houses the stator 10 and the rotor 20. The stator 10 and the rotor 20 have a generally annular shape, and the stator 10 is arranged to surround the outer periphery of the rotor 20. A rotating shaft 21 is attached to the center of the rotor 20, and the rotating shaft 21 is rotatably supported by the case 30 via bearings 22 and 23.

[0012] The motor 100 is mounted, for example, on a vehicle (not shown). The motor 100 can operate as an electric motor that receives power from a battery (not shown) to drive the motor. When the rotor 20 receives rotational energy from a drive wheel (not shown), the motor 100 functions as a generator and can charge the battery. The motor 100 may be used as either an electric motor or a generator. The motor 100 can also be mounted on various devices other than vehicles.

[0013] Vehicles in which the motor 100 is mounted include, for example, a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), and the like.

[0014] The stator 10 is fixed to the inner peripheral surface of the cylindrical portion of the case 30. The stator 10 includes a substantially annular stator core 11 and a coil 12 disposed on the inner peripheral portion of the stator core 11. The coil 12 is composed of a plurality of segment coils 13 (see FIG. 3).

[0015] The rotor 20 has a plurality of permanent magnets 14 arranged at equal intervals in the circumferential direction. The rotor 20 rotates around a rotation axis 21 due to a reaction force of the permanent magnets 14 generated by a rotating magnetic flux applied from the coil 12 of the stator 10.

[0016] Next, a description will be given of a method for manufacturing the stator 10. Fig. 2 is a flowchart showing an example of a method for manufacturing the stator 10.

[0017] As shown in Fig. 2, the manufacturing method of the stator 10 of this embodiment includes the following steps (1) to (6): (1) an insertion step of inserting the segment coils 13 into the slots 11a (see Fig. 3) of the stator core 11; (2) an expansion step of expanding the ends of the segment coils 13 from the inner periphery side to the outer periphery side of the stator 10; (3) a twisting step of twisting the ends of the segment coils 13 on odd-numbered turns (odd-numbered) and the ends of the segment coils 13 on even-numbered turns (even-numbered) counting from the inner periphery side of the stator 10 in different directions in the circumferential direction of the stator 10; (4) a positioning step of positioning a pair of inclined portions 13a (see Fig. 3) of a pair of segment coils 13 to be welded in a subsequent step; (5) a forming step of plastically deforming a pair of straight portions 13b (see Fig. 3) continuous with the pair of inclined portions 13a while the pair of inclined portions 13a is positioned; and (6) a welding step of welding the pair of plastically deformed straight portions 13b.

[0018] The insertion process, expansion process, twisting process, and welding process are well known, so their explanation will be omitted, and the positioning process and molding process will be explained in detail below with reference to Figures 3 to 11. Note that the coordinate axes in Figures 4, 5, 7 to 9, and 11 correspond to each other.

[0019] FIG. 3 is a perspective view of the stator 10 after the twisting process.

[0020] 3, the stator core 11 has a plurality of slots 11a formed at predetermined intervals in the circumferential direction. A plurality of segment coils 13 are arranged in each of the plurality of slots 11a.

[0021] In FIG. 3, the odd-numbered segment coils 13 counting from the inner periphery of the stator 10 are twisted clockwise, and the even-numbered segment coils 13 are twisted counterclockwise.

[0022] After the twisting process, the multiple segment coils 13 each have an inclined portion 13a that inclines in the circumferential direction of the stator 10 based on the axial direction of the stator 10 (the direction of the center axis CL shown in Figure 1), and a straight portion 13b that is located at the tip of the segment coil 13 and extends in the axial direction of the stator 10 continuously from the inclined portion 13a.

[0023] 4 is a schematic diagram for explaining the arrangement of the plurality of segment coils 13 after the twisting process. As an example, FIG. 4 shows segment coils 131 to 138 as the plurality of segment coils 13 as viewed from the axial direction (Z-axis direction) of the stator 10.

[0024] As shown in Figure 4, there are gaps between the second segment coil 132 and the third segment coil 133, between the fourth segment coil 134 and the fifth segment coil 135, and between the sixth segment coil 136 and the seventh segment coil 137, counting from the inner side of the stator 10.

[0025] In this embodiment, in the welding process, the straight portion 13b of segment coil 132 is welded to the straight portion 13b of segment coil 133, the straight portion 13b of segment coil 134 is welded to the straight portion 13b of segment coil 135, and the straight portion 13b of segment coil 136 is welded to the straight portion 13b of segment coil 137. Therefore, in this embodiment, the positioning process and the forming process are performed using a manufacturing device 200 for the stator 10 shown in Figure 5, so that the pair of straight portions 13b to be welded in the welding process are aligned.

[0026] Specifically, in this embodiment, by performing the positioning process and the molding process, the straight portion 13b of segment coil 132 is aligned with the straight portion 13b of segment coil 133, the straight portion 13b of segment coil 134 is aligned with the straight portion 13b of segment coil 135, and the straight portion 13b of segment coil 136 is aligned with the straight portion 13b of segment coil 137. Before the welding process, a cutting process may be performed to align the lengths of the straight portions 13b.

[0027] FIG. 5 is a schematic diagram illustrating an example of a manufacturing apparatus 200 for the stator 10. As shown in FIG.

[0028] As shown in Figure 5, the manufacturing apparatus 200 includes a housing 210, a positioning mechanism 220 that positions a pair of inclined portions 13a of a pair of segment coils 13 to be welded in a subsequent process, a forming mechanism 230 that plastically deforms and aligns a pair of straight portions 13b that are continuous with the positioned pair of inclined portions 13a, and a controller 240 that controls the positioning mechanism 220 and the forming mechanism 230.

[0029] The controller 240 is configured, for example, by a microcomputer equipped with a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), an input / output interface, etc. The controller 240 performs various processes by having the CPU read and execute various programs stored in the ROM. The controller 240 can also be configured by multiple microcomputers. The various programs may be stored on a non-transitory recording medium such as a CD-ROM.

[0030] The housing 210 comprises a first base 211 on whose upper surface the stator 10 is attached, a second base 212 on whose upper surface the positioning mechanism 220 and the molding mechanism 230 are attached, and a plurality of pillars 213 connecting the first base 211 and the second base 212.

[0031] The stator 10 is attached to the first base 211 so that the ends (inclined portions 13a and straight portions 13b) of the segment coils 13 are exposed on the underside through the holes 211a. The first base 211 has a mechanism for rotating the stator 10 around its axis.

[0032] The positioning mechanism 220 has a first positioning jig 41 and a second positioning jig 42. The positioning mechanism 220 can move the first positioning jig 41 and the second positioning jig 42 in the X-axis direction, the Y-axis direction, and the Z-axis direction, respectively.

[0033] 6 is a perspective view of the first positioning jig 41. Since the second positioning jig 42 has a symmetrical shape to the first positioning jig 41, the second positioning jig 42 is indicated by the corresponding reference numeral and a description thereof will be omitted.

[0034] As shown in Figure 6, the first positioning jig 41 (42) has a linear main body 41a (42a) and protrusions 41b (42b) that protrude laterally from the main body 41a (42a) and abut against the inclined portions 13a of the segment coil 13. In the example of Figure 6, three protrusions 41b (42b) are provided. The number of protrusions 41b (42b) may be one or more. If multiple protrusions 41b (42b) are provided, multiple pairs of inclined portions 13a can be positioned at once.

[0035] 7 is a schematic diagram for explaining the positioning step, and FIG. 8 is a view taken along the arrow VIII in FIG.

[0036] In the positioning step, the controller 240 controls the positioning mechanism 220 to place the first positioning jig 41 and the second positioning jig 42 at the positions shown in FIGS.

[0037] Specifically, as shown in Figure 7, the first positioning jig 41 has protrusions 41b located on the inner periphery of segment coil 132, the inner periphery of segment coil 134, and the inner periphery of segment coil 136 when viewed in the axial direction (Z-axis direction) of the stator 10, and as shown in Figure 8, when viewed in the radial direction (X-axis direction) of the stator 10, the protrusions 41b are positioned so as to overlap with the inclined portions 13a.

[0038] Furthermore, as shown in Figure 7, when viewed in the axial direction (Z-axis direction) of the stator 10, the second positioning jig 42 has protrusions 42b located on the outer periphery of segment coil 133, the outer periphery of segment coil 135, and the outer periphery of segment coil 137, and as shown in Figure 8, when viewed in the radial direction (X-axis direction) of the stator 10, the protrusions 42b are positioned so as to overlap with the inclined portions 13a.

[0039] Next, the controller 240 controls the positioning mechanism 220 to move the first positioning jig 41 from the inner periphery of the stator 10 toward the outer periphery of the stator 10 in the radial direction (X-axis direction) of the stator 10, as shown by arrows A and B in Figure 7, and to move the second positioning jig 42 from the outer periphery of the stator 10 toward the inner periphery of the stator 10 in the radial direction (X-axis direction) of the stator 10.

[0040] As a result, the positioning jigs 41, 42 abut against a pair of inclined portions 13a so that the tip ends of a pair of adjacent segment coils 13 in the radial direction (X-axis direction) of the stator 10 abut against each other, positioning them in the radial direction (X-axis direction) of the stator 10.

[0041] FIG. 9 is a schematic diagram for explaining a state in which the pair of inclined portions 13a are positioned.

[0042] Specifically, in this embodiment, as shown in Figure 9, the inclined portion 13a of segment coil 132 and the inclined portion 13a of segment coil 133 are positioned so that segment coil 132 and segment coil 133 abut, the inclined portion 13a of segment coil 134 and the inclined portion 13a of segment coil 135 are positioned so that segment coil 134 and segment coil 135 abut, and the inclined portion 13a of segment coil 136 and the inclined portion 13a of segment coil 137 are positioned so that segment coil 136 and segment coil 137 abut.

[0043] The forming mechanism 230 has a forming jig 43. The forming mechanism 230 can move the forming jig 43 in the X-axis direction and the Y-axis direction.

[0044] FIG. 10 is a perspective view of the molding jig 43. As shown in FIG.

[0045] As shown in FIG. 10, the forming jig 43 has three insertion holes 43a.

[0046] FIG. 11 is a schematic diagram for explaining the molding process.

[0047] In the molding process, the controller 240 controls the molding mechanism 230 to position the molding jig 43 in a position where a pair of straight portions 13b are inserted into the insertion holes 43a of the molding jig 43, as shown in Figure 11.

[0048] Specifically, in this embodiment, as shown in Figure 11, the straight portion 13b of segment coil 132 and the straight portion 13b of segment coil 133 are inserted into the first insertion hole 43a counting from the inner side of the stator 10, the straight portion 13b of segment coil 134 and the straight portion 13b of segment coil 135 are inserted into the second insertion hole 43a, and the straight portion 13b of segment coil 136 and the straight portion 13b of segment coil 137 are inserted into the third insertion hole 43a.

[0049] Next, the controller 240 controls the forming mechanism 230 to reciprocate the forming jig 43 in the radial direction (X-axis direction) of the stator 10 as shown by arrow C in FIG.

[0050] This allows the pair of straight portions 13b inserted into one insertion hole 43a to be plastically deformed. In this embodiment, the forming jig 43 has multiple (three) insertion holes 43a, so multiple (three) pairs of straight portions 13b can be formed at one time. The number of insertion holes 43a may be one or more.

[0051] The amount of reciprocating movement of the forming jig 43 is determined taking into consideration the springback of the straight portions 13b. The pair of straight portions 13b formed in the forming process maintains the positional accuracy required for the subsequent welding process even after the forming jig 43 is removed. In this embodiment, the pair of straight portions 13b are aligned in abutting contact with each other.

[0052] Furthermore, in this embodiment, the pair of straight portions 13b are inserted into the insertion holes 43a of the molding jig 43 while the pair of inclined portions 13a are positioned, thereby reducing the occurrence of defects in which the pair of straight portions 13b come off the molding jig 43 during molding.

[0053] However, when the straight portion 13b of the segment coil 13 is plastically deformed by the forming jig 43, if the force is transmitted from the forming jig 43 to portions other than the straight portion 13b, the portions other than the straight portion 13b will also be deformed. In this case, the deformed segment coil 13 may interfere with other segment coils 13, causing the straight portion 13b of the other segment coils 13 to become misaligned.

[0054] In contrast, in this embodiment, the pair of inclined portions 13a are positioned, and then the pair of straight portions 13b connected to the pair of inclined portions 13a are plastically deformed. Therefore, when the pair of straight portions 13b are plastically deformed, deformation of portions other than the pair of straight portions 13b can be suppressed. Therefore, interference between the segment coil 13 to be plastically deformed and other segment coils 13 can be suppressed.

[0055] When the forming is completed, the controller 240 controls the positioning mechanism 220 and the forming mechanism 230 to move the first positioning jig 41 , the second positioning jig 42 , and the forming jig 43 to positions away from the coil 12 .

[0056] The controller 240 controls the first base 211 to rotate the stator 10 around its axis, and executes the positioning process and the forming process for all the segment coils 13 to be formed.

[0057] Hereinafter, the main effects of the method for manufacturing the stator 10, the method for manufacturing the motor 100, and the manufacturing apparatus 200 for the stator 10 according to the embodiments of the present invention will be described together.

[0058] In a manufacturing method of a stator 10 in which a plurality of segment coils 13 are arranged on a stator core 11, the plurality of segment coils 13 each have an inclined portion 13a that inclines in the circumferential direction of the stator 10 based on the axial direction of the stator 10, and a straight portion 13b that is located at the tip of the segment coil 13 and extends axially of the stator 10 continuously from the inclined portion 13a, and the manufacturing method of the stator 10 includes a positioning process in which positioning jigs 41, 42 are abutted against the pair of inclined portions 13a to position them radially of the stator 10 so that the tip portions of a pair of radially adjacent segment coils 13 abut each other, a molding process in which, with the pair of inclined portions 13a positioned, a pair of straight portions 13b that are continuous with the pair of inclined portions 13a are plastically deformed, and a welding process in which the pair of plastically deformed straight portions 13b are welded together.

[0059] With this, while the pair of inclined portions 13a is positioned, the pair of straight portions 13b connected to the pair of inclined portions 13a are plastically deformed. Therefore, when the pair of straight portions 13b are plastically deformed, deformation of portions other than the pair of straight portions 13b can be suppressed. Therefore, interference between the segment coil 13 to be plastically deformed and other segment coils 13 can be suppressed.

[0060] In the positioning process, a first positioning jig 41 that abuts against the inclined portion 13a of the segment coil 13 located on the inner side of the stator 10 is moved in the radial direction of the stator 10 from the inner side of the stator 10 toward the outer side of the stator 10, and a second positioning jig 42 that abuts against the inclined portion 13a of the segment coil 13 located on the outer side of the stator 10 is moved in the radial direction of the stator 10 from the outer side of the stator 10 toward the inner side of the stator 10, thereby positioning the pair of inclined portions 13a.

[0061] According to this, by using the first positioning jig 41 and the second positioning jig 42, the pair of inclined portions 13a can be easily positioned.

[0062] In the molding process, the pair of straight portions 13b are inserted into insertion holes 43a provided in the molding jig 43, and the molding jig 43 is moved back and forth in the radial direction of the stator 10, thereby plastically deforming the pair of straight portions 13b.

[0063] According to this, the pair of linear portions 13b can be easily plastically deformed by using the forming jig 43. Furthermore, since the pair of linear portions 13b are inserted into the insertion holes 43a of the forming jig 43, it is possible to reduce the occurrence of defects in which the pair of linear portions 13b come off the forming jig 43 during forming.

[0064] The first positioning jig 41 and the second positioning jig 42 each have a linear main body portion 41a, 42a and a protrusion portion 41b, 42b that protrudes laterally from the main body portion 41a, 42a and abuts the inclined portion 13a of the segment coil 13.

[0065] This allows the protrusions 41b, 42b to be easily inserted between the segment coil 13 to be positioned and another segment coil 13 adjacent to that segment coil 13.

[0066] In a method for manufacturing a motor 100 having a stator 10 in which a plurality of segment coils 13 are arranged on a stator core 11, the stator 10 is manufactured using a manufacturing method for a stator 10.

[0067] This prevents the segment coils 13 to be plastically deformed from interfering with other segment coils 13 when manufacturing the stator 10, thereby improving the quality and yield of the motor 100.

[0068] In a manufacturing apparatus 200 for a stator 10 in which a plurality of segment coils 13 are arranged on a stator core 11, the plurality of segment coils 13 each have an inclined portion 13a that inclines in the circumferential direction of the stator 10 based on the axial direction of the stator 10, and a straight portion 13b that is located at the tip of the segment coil 13 and extends axially of the stator 10 continuously from the inclined portion 13a, and the manufacturing apparatus 200 for the stator 10 positions the pair of inclined portions 13a in the radial direction of the stator 10 by abutting positioning jigs 41, 42 against the pair of inclined portions 13a so that the tip portions of a pair of adjacent segment coils 13 in the radial direction of the stator 10 abut each other, and with the pair of inclined portions 13a positioned, plastically deforms a pair of straight portions 13b that are continuous with the pair of inclined portions 13a.

[0069] With this, while the pair of inclined portions 13a is positioned, the pair of straight portions 13b connected to the pair of inclined portions 13a are plastically deformed. Therefore, when the pair of straight portions 13b are plastically deformed, deformation of portions other than the pair of straight portions 13b can be suppressed. Therefore, interference between the segment coil 13 to be plastically deformed and other segment coils 13 can be suppressed.

[0070] Although an embodiment of the present invention has been described above, the above embodiment merely shows one application example of the present invention, and is not intended to limit the technical scope of the present invention to the specific configuration of the above embodiment.

[0071] For example, in the above embodiment, the positioning mechanism 220 has the first positioning jig 41 and the second positioning jig 42. However, the positioning mechanism 220 may have a first positioning jig 44 and a second positioning jig 45 shown in FIG.

[0072] 12 is a perspective view of the first positioning jig 44. Since the second positioning jig 45 has a symmetrical shape to the first positioning jig 44, the second positioning jig 45 is indicated by the corresponding reference numeral and a description thereof will be omitted.

[0073] As shown in Figure 12, the first positioning jig 44 (45) has a linear main body portion 44a (45a), a protrusion portion 44b (45b) that protrudes laterally from the main body portion 44a (45a) and abuts against the inclined portion 13a of the segment coil 13, and an abutment portion 44c (45c) that abuts against the forming jig 43.

[0074] 13 is a schematic diagram showing a state in which the contact portions 44c and 45c are in contact with the forming jig 43. FIG. 13 corresponds to the arrow VIII in FIG.

[0075] 13, when the first positioning jig 44 and the second positioning jig 45 are used, the position of the forming jig 43 in the Z-axis direction is determined at the position where the forming jig 43 abuts against the abutment portions 44c and 45c. This makes it easy to position the forming jig 43 in the Z-axis direction.

[0076] Furthermore, the positioning mechanism 220 may have a first positioning jig 46 shown in Fig. 14 and a second positioning jig 47 shown in Fig. 15 instead of the first positioning jig 41 and the second positioning jig 42. The first positioning jig 46 and the second positioning jig 47 are an example of a case where the shapes of the first positioning jig and the second positioning jig 47 are not symmetrical to each other.

[0077] Fig. 14 is a perspective view of the first positioning jig 46. Fig. 15 is a plan view of the second positioning jig 47. The coordinate axes in Figs. 14 and 15 correspond to the coordinate axes in Figs. 4, 5, etc.

[0078] As shown in Figure 14, the first positioning jig 46 has a linear main body portion 46a, a protrusion portion 46b that protrudes laterally from the main body portion 46a and abuts the inclined portion 13a of the segment coil 13, and an extension portion 46c that extends toward the outer periphery of the stator 10 beyond the protrusion portion 46b.

[0079] The first positioning jig 46 moves in the direction of the arrow in Figure 14 and abuts against the inclined portion 13a of the segment coil 13 located on the inner side of the stator 10 from the inner side of the stator 10.

[0080] The protruding portion 46b has a flat surface perpendicular to the X-axis, and this flat surface abuts against the inclined portion 13a from the inner circumferential side of the stator 10. This allows the inclined portion 13a to be positioned more stably.

[0081] The extensions 46c press the inclined portions 13a of the segment coils 13 on the outermost side of the stator 10. This allows the segment coils 13 on the outermost side of the stator 10 to be aligned.

[0082] As shown in Figure 15, the second positioning jig 47 has a linear main body portion 47a and a protrusion portion 47b that protrudes laterally from the main body portion 47a and abuts the inclined portion 13a of the segment coil 13.

[0083] The second positioning jig 47 moves in the direction of the arrow in Figure 15 and abuts against the inclined portion 13a of the segment coil 13 located on the outer periphery of the stator 10 from the outer periphery of the pair of segment coils 13.

[0084] The protruding portion 47b has a flat surface perpendicular to the X-axis, and this flat surface abuts against the inclined portion 13a from the outer periphery side of the stator 10. This allows the inclined portion 13a to be positioned more stably.

[0085] In the above embodiment, the manufacturing apparatus 200 has been described as including the positioning mechanism 220 and the forming mechanism 230. However, the manufacturing apparatus 200 may further include a welding mechanism that welds the pair of plastically deformed straight portions 13b.

[0086] In the above embodiment, a case has been described in which a plurality of insertion holes 43a are provided in one forming jig 43. However, the forming jig 43 may be configured by combining a plurality of jigs, each having a single insertion hole.

[0087] This application claims priority based on Japanese Patent Application No. 2024-125590, filed with the Japan Patent Office on August 1, 2024, the entire contents of which are incorporated herein by reference.

Claims

1. A method for manufacturing a stator having a plurality of segment coils arranged on a stator core, wherein each of the plurality of segment coils has an inclined portion that is inclined circumferentially of the stator with respect to the axial direction of the stator, and a straight portion that is located at the tip of the segment coil and continues from the inclined portion and extends in the axial direction of the stator, the method for manufacturing the stator comprising: a positioning step of abutting a pair of the inclined portions with a positioning jig and positioning them in the radial direction of the stator so that the tip ends of a pair of the segment coils that are adjacent in the radial direction of the stator abut each other; a forming step of plastically deforming a pair of the straight portions that are continuous with the pair of inclined portions while the pair of inclined portions is positioned; and a welding step of welding the pair of straight portions that have been plastically deformed.

2. A method for manufacturing a stator as described in claim 1, wherein in the positioning step, a first positioning jig that abuts against the inclined portion of one of the pair of segment coils located on the inner side of the stator is moved in the radial direction of the stator from the inner side of the stator toward the outer side of the stator, and a second positioning jig that abuts against the inclined portion of one of the pair of segment coils located on the outer side of the stator is moved in the radial direction of the stator from the outer side of the stator toward the inner side of the stator, thereby positioning the pair of inclined portions.

3. A method for manufacturing a stator according to claim 1 or 2, wherein in the forming step, the pair of straight portions are inserted into insertion holes provided in a forming jig, and the forming jig is reciprocated in the radial direction of the stator, thereby plastically deforming the pair of straight portions.

4. A method for manufacturing a stator as described in claim 2, wherein the first positioning jig and the second positioning jig each have a linear main body portion and a protrusion portion that protrudes laterally from the main body portion and abuts the inclined portion of the segment coil.

5. A method for manufacturing a motor having a stator in which a plurality of segment coils are arranged on a stator core, wherein the stator is manufactured using a stator manufacturing method according to any one of claims 1 to 4.

6. A manufacturing device for a stator in which a plurality of segment coils are arranged on a stator core, wherein each of the plurality of segment coils has an inclined portion that is inclined in the circumferential direction of the stator with respect to the axial direction of the stator, and a straight portion that is located at the tip of the segment coil and continues from the inclined portion and extends in the axial direction of the stator, the manufacturing device for a stator comprising: a positioning jig abutting the pair of inclined portions to position them in the radial direction of the stator so that the tip ends of a pair of adjacent segment coils in the radial direction of the stator abut each other; and with the pair of inclined portions positioned, plastically deforming the pair of straight portions that are continuous with the pair of inclined portions.

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