JP6428558B2 - Manufacturing method of stator of rotating electric machine - Google Patents

Description

  The present invention relates to a method for manufacturing a stator of a rotating electrical machine, and more particularly to a method for fixing a coil.

  An electric motor that converts electrical energy into rotational kinetic energy, a generator that converts rotational kinetic energy into electrical energy, and an electric device that functions as both the motor and the generator are known. Hereinafter, these electric devices are referred to as rotating electric machines.

  The rotating electrical machine has two members that are arranged coaxially and relatively rotate. Normally, one is fixed and the other rotates. A coil is arranged on a fixed member (stator), and a rotating magnetic field is formed by supplying electric power to the coil. The other member (rotor) is rotated by the interaction with the magnetic field.

  Patent Document 1 below discloses a technique for fixing a constituent member of a stator with an impregnated and solidified varnish.

JP 2014-110740 A

  In order to fix the coil wound in a concentrated manner on each tooth of the stator, if the resin between the coils is impregnated and solidified, the amount of resin used increases.

  An object of this invention is to reduce the quantity of resin for fixing a coil.

  A method of manufacturing a stator for a rotating electrical machine according to the present invention includes a step of mounting an interphase insulator between adjacent coils on a coil / stator core assembly in which a coil is concentratedly wound on each tooth, and the coil / stator core assembly includes: And the step of injecting a liquid resin between adjacent coils from the resin injection hole provided in the interphase insulator. The interphase insulator has an inner wall portion facing a radially inner side surface of a portion located between adjacent teeth of the coil and a resin stopper extending radially outward from the inner wall portion when mounted on the coil / stator core assembly. Member. The inner wall portion is provided with a resin injection hole for injecting resin. In the state where the coil / stator core assembly is arranged so that the axis of the stator stands upright, the resin injection hole is positioned above the resin stopper member, and the distance between the resin injection hole and the resin stopper member is the dimension in the vertical direction of the coil. Shorter than. The resin injected between the adjacent coils from the resin injection hole is stopped by the resin stopper member, filled in the region above the resin stopper member, and solidified here.

  The resin filling member can limit the region where the resin is filled, and the amount of resin used can be suppressed.

It is a figure which shows the principal part structure of the stator of this embodiment, and is a figure which shows the cross section by the AA line in FIG. It is the figure which looked at the stator of this embodiment in the arrow B direction in FIG. It is a figure which shows an interphase insulator. It is a figure which shows an interphase insulator and a stator core.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1 and 2 are views showing the configuration of the main part of the stator 10 of the rotating electrical machine of the present embodiment. 1 is a cross-sectional view taken along line AA shown in FIG. 2, and FIG. 2 is a view showing a state of one slot viewed in the direction of arrow B shown in FIG.

  The stator 10 includes a stator core 12 and a coil 14 wound around the stator core 12, and has an annular shape or a cylindrical shape as a whole. Stator core 12 includes an annular or cylindrical yoke portion 16 and teeth 18 extending radially inward from the inner wall surface of yoke portion 16. The teeth 18 are arranged at intervals in the circumferential direction along the inner wall surface of the yoke portion 16, and the space between adjacent teeth 18 is called a slot. Hereinafter, the reference numeral 20 is attached to the slot. The coil 14 is formed by continuously and continuously winding a coil conductor 22 around one tooth 18. That is, the coil conductor wire 22 that has exited from one slot 20 enters the adjacent slot 20 and exits from the slot 20 and then enters the original slot 20 and is repeatedly wound around one tooth a predetermined number of times. This type of coil 14 is called concentrated winding. Further, as a method for forming the concentrated winding coil, a method may be employed in which the coil conductor 22 is wound separately from the stator core 12 and mounted on one tooth 18 instead of being directly wound around the teeth. A portion of the coil 14 protruding from the slot 20 is called a coil end. Hereinafter, reference numeral 24 is attached to the coil end.

  In the case where it is necessary to distinguish each of a plurality of elements such as the teeth 18, the slots 20, and the coil conductors 22, they will be described with suffixes “−1” and “−2”.

  The coil conductors 22 coming out of the slots 20 are distributed to the left and right at the coil end 24. In FIG. 1, the coil conductor 22-1 positioned on the right side in the slot 20-1 is bent toward the coil conductor 22-1 side of the slot 20-1, that is, on the teeth 18-1 side positioned on the right side. Wound around teeth 18-1. The coil conductor 22-2 located on the left side is bent toward the tooth 18-2 located on the left side of the slot 20-1, and is wound around the tooth 18-2. The coil conductor 22 exiting the slot 20-1 is distributed to the right side of the right coil conductor 22-1, and to the left side of the left coil conductor 22-2, so that the coil conductor 22-1, A valley is formed with the curved portion of 22-2 as the slope. The schematic shape of this valley is shown by a dashed-dotted triangle in FIG. A space between the coil conductors 22-1 and 22-2 forming the slope of the valley is hereinafter referred to as a “valley region 26”. The valley region 26 is formed in each of the two coil ends 24. When it is necessary to distinguish these two valley regions, in FIG. 2, the upper valley region 26 is referred to as an upper valley region 26A, and the lower valley region 26 is referred to as a lower valley region 26B. Also in the slot 20, a gap is formed between the right coil conductor 22-1 and the left coil conductor 22-2. This gap is referred to as an in-slot gap area 28.

  In the stator 10, an interphase insulator 30 is disposed between the right coil 14-1 and the left coil 14-2.

  3 and 4 are diagrams showing the interphase insulator 30. FIG. 3 shows a state viewed from the radially inner side when the interphase insulator 30 is mounted on the stator 10. FIG. 4 shows a state in which the interphase insulator 30 is viewed in the circumferential direction with the coil 14 removed.

  The interphase insulator 30 includes an inner wall portion 32 facing the radially inner side surface of the coil 14, and first and second resin stopper members 34 and 36 extending from the inner wall portion 32 toward the radially outer side. In FIG. 2, the inner wall portion 32 is omitted to clearly show the first and second resin stopper members 34 and 36.

  The first resin stopper 34 is disposed in the in-slot gap region 28 below the upper valley region 26 </ b> A, and the tip thereof reaches the bottom of the slot 20, that is, the vicinity of the yoke portion 16 or the yoke portion 16. The first resin stopper 34 has a thin plate shape with a rectangular cross section, and the longitudinal direction of the rectangular cross section coincides with the axial direction of the stator.

  The second resin stopper member 36 is disposed so as to face the end surface of the coil end 24 in the stator axial direction. The second resin stopper 36 also has a thin plate shape with a rectangular cross section, but the longitudinal direction of the rectangular cross section coincides with the direction orthogonal to the axis of the stator. The tip of the second resin stopper member 36 reaches a position corresponding to the bottom of the slot or the vicinity thereof. Alternatively, the second resin stopper member 36 may extend across the coil end 24 over the entire radial direction of the coil end 24.

  As shown in FIGS. 3 and 4, in the state where the interphase insulator 30 is disposed so that the first resin stopper member 34 is on the upper side and the second resin stopper member 36 is on the lower side, the inner wall portion 32 is above the first resin stopper member 34. The 1st resin injection hole 38 is provided in this. When a liquid resin such as an insulating varnish is injected from the first resin injection hole 38 in this state, the resin is stopped by the first resin stop member 34, stays in a space above this, and solidifies here. The solidified resin is indicated by reference numeral 42 in the slot 20 shown on the left and right in FIG. In the central slot 20 of FIG. 1, the solidified resin is omitted to show the first resin stopper member 34. FIG. 4 also shows a range where the solidified resin 42 exists. The resin is injected into the space between the first resin stopper 34 and the first resin injection hole 38. By arranging the first resin injection hole 38 near the upper end of the upper valley region 26A or at a higher position, the upper valley region 26A can be filled with the injected resin.

  A second resin injection hole 40 is provided above the second resin stopper member 36 of the inner wall portion 32. When a liquid resin such as an insulating varnish is injected from the second resin injection hole 40 in this state, the resin is stopped by the second resin stop member 36, stays in a space above this, and solidifies here. The existence range of the solidified resin 44 is shown in FIG. The resin is injected into the space between the second resin stopper member 36 and the second resin injection hole 40. By disposing the second resin injection hole 40 near the upper end of the lower valley region 26B or at a higher position, the lower valley region 26B can be filled with the injected resin.

  A manufacturing process of the stator 10 will be described. First, the stator core 12 is produced. The stator core 12 can be formed by stacking electromagnetic steel plates in the axial direction of the stator. The electromagnetic steel plate is a thin plate having the same shape as the cross section perpendicular to the axis of the stator core 12, and the stator core 12 can be formed by laminating them. The stator core 12 can also be formed by solidifying a magnetic material powder by applying one or both of pressing and heating. The coil 14 is formed by winding the coil conducting wire 22 around the stator core 12. The coil conductor 22 is wound by the concentrated winding described above. The intermediate in which the coil 14 is wound around the stator core 12 is referred to as a coil / stator core assembly.

  The interphase insulator 30 is attached to the coil / stator core assembly. The interphase insulator 30 is inserted into the slot 20 from the inside of the stator core 12. At this time, the first resin stopper member 34 is inserted into the in-slot gap region 28, and the second resin stopper member 36 is disposed so as to cover the end surface of the coil end 24.

  The coil / stator core assembly to which the interphase insulator 30 is mounted is arranged so that the axis of the stator stands, preferably in the vertical direction.

  Liquid resin is injected into the space between the adjacent coils 14 from the first and second resin injection holes 38 and 40 as indicated by an arrow J in FIG. The resin injected from the first resin injection hole 38 is directed downward according to gravity. However, when the resin reaches the first resin stopper member 34, the resin is stopped here and does not enter the in-slot gap region 28 below. The resin injected from the second resin injection hole 40 is directed downward according to gravity, but is stopped here when it reaches the second resin stopper member 36. When a predetermined amount of resin is injected, the injection is stopped.

  After injecting the resin, the resin is solidified by natural drying or heat treatment. The movement of the coil 14 is suppressed by the solidified resin.

  When only one of the set of the first resin injection hole 38 and the first resin stopper member 34 and the combination of the second resin injection hole 40 and the second resin stopper member 36 is provided, the direction of the stator axis of the resin injection hole and the resin stopper member Is shorter than the dimension in the same direction of the coil 14, the amount of resin used can be reduced as compared with the case where the resin is filled over the entire stator axial direction of the coil 14. When both the set of the first resin injection hole 38 and the first resin stop member 34 and the set of the second resin injection hole 40 and the second resin stop member 36 are provided, the first resin injection hole 38 and the first resin stop member 34, and the total distance between the second resin injection hole 40 and the second resin stopper member 36 is shorter than the dimension of the coil 14, so that the amount of resin used can be reduced over the entire stator axial direction of the coil 14. It can be reduced compared to the case of filling.

  The positions where the resin is filled and solidified are preferably two places separated vertically. The coil 14 can be reliably fixed by using two places. In particular, as described above, the upper and lower valley regions 26A and 26B can be filled.

  The first resin stopper member 34 can be disposed such that the upper surface thereof is located at the lower end of the upper valley region 26A. The second resin stopper member 36 can be disposed such that the upper surface thereof is located at the lower end of the lower valley region 26B.

Preferred embodiments of the stator of the rotating electrical machine according to the present invention will be described below.
A stator of a rotating electric machine,
A stator core in which teeth are arranged in the circumferential direction;
A coil concentrated around each tooth;
An interphase insulator disposed between adjacent coils;
Have
The interphase insulator has an inner wall portion provided with a resin injection hole facing a radially inner side surface of a portion located between adjacent teeth of the coil, and a resin stopper member extending from the inner wall portion toward the radially outer side. And the stator axial distance between the resin injection hole and the resin stopper is smaller than the stator axial dimension of the coil,
The stator further includes a resin that fills a region between a position between the adjacent coil and the position of the resin injection hole in the stator axial direction and the position of the resin stopper member.
A stator for rotating electrical machines.

  10 Stator, 12 Stator Core, 14 Coil, 16 Yoke, 18 Teeth, 20 Slot, 22 Coil Conductor, 24 Coil End, 26 Valley Area, 26A Upper Valley Area, 26B Lower Valley Area, 28 In-Slot Clearance Area, 30 Phases Insulator, 32 Inner wall portion, 34 First resin stopper member, 36 Second resin stopper member, 38 First resin injection hole, 40 Second resin injection hole, 42, 44 Solidified resin.

Claims (1)

A method of manufacturing a stator for a rotating electrical machine,
A step of attaching an interphase insulator between adjacent coils to a coil / stator core assembly in which coils are concentratedly wound around each tooth, and the interphase insulator is in a radial direction of a portion located between adjacent teeth of the coil in the attached state A step having an inner wall portion facing the inner side surface and provided with a resin injection hole, and a resin stopper member extending radially outward from the inner wall portion in a mounted state;
Arranging the coil / stator core assembly with the stator axis upright;
Injecting liquid resin between adjacent coils from the resin injection hole;
Have
When the coil / stator core assembly is placed with the stator axis upright, the resin injection hole is positioned above the resin stopper, and the distance between the resin injection hole and the resin stopper is based on the vertical dimension of the coil. Too short,
Stator manufacturing method.

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