JP7195064B2 - Method for manufacturing stator for rotating electric machine and method for manufacturing rotating electric machine - Google Patents

Description

The present invention relates to a method of manufacturing a stator for a rotating electric machine and a method of manufacturing a rotating electric machine .

A conventional method for manufacturing a coil of a rotary electric machine such as an electric motor or a generator is to cut off the insulating coating on a part of the conductor wire coated with the insulating coating with a cutting blade to form a pair of cut faces with a rectangular cross section facing each other. An insulating coating cutting step, and then cutting the insulating coating with a cutting blade to form another pair of opposing cut surfaces with a rectangular cross section, and one of the pair of opposing cut surfaces formed in the insulating coating cutting step. Pressing the surface of the conductor and offsetting it from the center of the conductor by the same amount as the thickness cut in the insulation coating cutting process, and after the cutting and pressure molding process, a square cross section of a part of the conductor A cutting step of cutting the part formed in the middle, a processing step of bending the cut conductor after the cutting step, and an insulating coating cutting step on the opposite side of the one surface after the processing step. and a joining step of welding and joining the formed cut surfaces (see, for example, Patent Document 1).

As a result, the coil can be produced by making the square cross-section portions of the conducting wire from which the insulation coating has been removed face each other without a gap, and welding the square cross-section portions together. Therefore, it is not necessary to press the square cross-section portions with a large force during welding. In addition, there is no possibility that springback will occur after joining, and the welded portion between the portions formed with square cross-sections will peel off. As a result, the joining work can be rationalized, and the reliability of the welded portion can be improved.

Japanese Patent No. 4654068

In Patent Document 1, in the insulating coating cutting step, a movable blade is moved in the width direction on a portion of the insulating coated conductor wire to cut the conductor portion together with the insulating coating, thereby forming a pair of opposed rectangular cross-section cut surfaces. was forming. At the time of cutting by the movable blade, a shear force causes a portion of the cut conductor wire to bend in the moving direction of the movable blade. As a result, depressions are formed in the surfaces forming the other pair of opposing resection surfaces of the rectangular cross section. Therefore, in the cutting and pressure forming process, when the movable blade is used to form another pair of opposing cutting surfaces with a rectangular cross section, the insulation coating in the recessed portion is not cut off, and the coating remains. For this reason, in the joining process, there has been a problem that poor welding due to the coating residue occurs. In addition, there is also the problem that the amount of conductor in the portion having a square cross section becomes smaller than the design value due to the coating residue, resulting in an increase in electrical resistance.

SUMMARY OF THE INVENTION The present invention has been made to solve such problems, and provides a rotary electric machine capable of suppressing the occurrence of coating residue at the coating peeling portion of a unit coil, and suppressing the occurrence of poor welding and an increase in electrical resistance. An object of the present invention is to obtain a method for manufacturing a stator and a method for manufacturing a rotating electric machine .

A method of manufacturing a stator for a rotating electric machine and a method of manufacturing a rotating electric machine according to the present invention each have a conductor portion and an insulating coating covering the conductor portion, and a plurality of stator cores are inserted into respective slots of the stator core. unit coils, each of the plurality of unit coils has, at an end protruding from the slot, a peeled coating portion having a rectangular cross section consisting only of the conductor portion; In the method for manufacturing a rotating electric machine, in which the target unit coils are joined by welding the peeled coating portions to each other, the plurality of unit coils having the conductor portion and the insulating coating coated on the conductor portion. a first cutting step of cutting at least the insulating coating on a pair of opposing side surfaces of a portion of a conductor wire having a rectangular cross section to form a pair of cut surfaces; One cut surface of the pair of cut surfaces is pressurized to plastically deform the conductor portion, and the other cut surface of the pair of cut surfaces is made into a flat surface continuous with the surface of the insulating coating, and the coating peeling portion and an offset step of forming a pair of opposing surfaces of the film stripped portion. and a second cutting step of forming a plane, wherein the offsetting step spreads the conductor wire in a direction orthogonal to both the direction of pressure applied to the one cut surface and the length direction of the conductor wire. , plastically deforming the conductor portion .

According to the present invention, since it has the above-described structure, it is possible to suppress the occurrence of coating residue at the coating peeling portion of the unit coil, thereby suppressing the occurrence of poor welding and the increase in electrical resistance. A method and method for manufacturing a rotating electric machine can be obtained.

1 is a longitudinal sectional view showing a rotating electric machine according to Embodiment 1 of the present invention; FIG. 1 is a transverse cross-sectional view showing a main part of a stator of a rotary electric machine according to Embodiment 1 of the present invention; FIG. 1 is a vertical cross-sectional view showing a main part of a stator of a rotary electric machine according to Embodiment 1 of the present invention; FIG. FIG. 2 is a side view of a main portion of the stator of the rotary electric machine according to Embodiment 1 of the present invention, viewed from the radially outer side; FIG. 2 is a perspective view showing a connection state between ends of unit coils in the stator of the rotary electric machine according to Embodiment 1 of the present invention; FIG. 4 is a cross-sectional view showing a conductor wire that is a material of a unit coil; FIG. 3 is a plan view of a conductor line viewed from the Y direction; FIG. 3 is a plan view of a conductor line viewed from the X direction; FIG. 11 is a plan view for explaining a first cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a first cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining an offset step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining an offset step in the manufacturing method of the unit coil of the comparative example; FIG. 10 is a plan view for explaining a cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 10 is a plan view for explaining a cutting step in the manufacturing method of the unit coil of the comparative example; It is a perspective view which shows a punch. It is a front view which shows a punch. FIG. 11 is a plan view for explaining a problem in the first cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a problem in the first cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a problem of the second cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 11 is a plan view for explaining a problem of the second cutting step in the manufacturing method of the unit coil of the comparative example; FIG. 4 is a plan view for explaining a first cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining a first cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining an offset step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining an offset step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 5 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 5 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining a cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining a cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a side view of a main part for explaining a unit coil mounting step in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention; FIG. 4 is a side view of a main part for explaining a first bending step of unit coils in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention; FIG. 5 is a side view of a main part explaining a second bending step of the unit coils in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention; FIG. 4 is a side view of a main part for explaining a welding step of unit coils in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention; FIG. 11 is a plan view for explaining a third cutting step in the method of manufacturing a unit coil according to Embodiment 2 of the present invention; FIG. 11 is a plan view for explaining a third cutting step in the method of manufacturing a unit coil according to Embodiment 2 of the present invention; FIG. 10 is a plan view for explaining an offset step in the method of manufacturing the unit coil according to Embodiment 2 of the present invention; FIG. 10 is a plan view for explaining an offset step in the method of manufacturing the unit coil according to Embodiment 2 of the present invention; FIG. 14 is a plan view for explaining a first cutting step in the method of manufacturing a unit coil according to Embodiment 3 of the present invention; FIG. 14 is a plan view for explaining a first cutting step in the method of manufacturing a unit coil according to Embodiment 3 of the present invention; FIG. 4 is a plan view for explaining an offset step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 4 is a plan view for explaining an offset step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 5 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 5 is a plan view for explaining a second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 7 is a plan view showing the periphery of the peeled-coating portion of the unit coil after the second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; FIG. 7 is a plan view showing the periphery of the peeled-coating portion of the unit coil after the second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention; It is a perspective view which shows a punch. It is a front view which shows a punch.

Embodiment 1.
1 is a longitudinal sectional view showing a controller-integrated dynamoelectric machine according to Embodiment 1 of the present invention. Note that the vertical cross-sectional view is a cross-sectional view showing a cross section including the axis of the rotating shaft. Further, in this specification, for the sake of convenience, the direction parallel to the axis of the rotating shaft is the axial direction, the direction perpendicular to the axis of the rotating shaft is the radial direction, and the direction perpendicular to the axis of the rotating shaft is the radial direction. Let the direction of rotation be the circumferential direction. In each figure, the arrow X indicates the radial direction, and the arrow Y indicates the circumferential direction.

In FIG. 1 , a controller-integrated rotating electrical machine 100 has a rotating electrical machine main body 101 and a control device 102 integrally attached to the rear side of the rotating electrical machine main body 101 .

A rotary electric machine main body 101 includes a housing 3 composed of a front bracket 1 and a rear bracket 2, a rotary shaft 6 rotatably supported by bearings 4 and 5 supported by the housing 3, and a rotary shaft 6 coaxially fixed to the rotary shaft 6. and a stator 10 fixed to the housing 3 so as to cover the outer circumference of the rotor 7 .

The rotor 7 includes a rotor core 8 fixed to the rotating shaft 6 passing through the axial position, and field coils 9 attached to the rotor core 8 .
The stator 10 includes an annular stator core 11 and stator windings 12 attached to the stator core 11 . In the stator 10, a stator core 11 arranged coaxially with the rotor core 8 and surrounding the rotor core 8 is sandwiched in a pressurized state by the front bracket 1 and the rear bracket 2 from both sides in the axial direction. and is held in the housing 3 .

A pulley 13 is attached to the protruding end of the rotor 7 from the front bracket 1 . A pair of slip rings 14 are attached to the protruding end of the rotating shaft 6 from the rear bracket 2 . A pair of brushes 15 are accommodated in a brush holder 16 and arranged so as to be in contact with a pair of slip rings 14 . A resolver 17 that detects the magnetic pole position of the rotor 7 is arranged on a sensor fixing portion 18 on the outer side of the rear bracket 2 in the axial direction.

The control device 102 includes a power circuit module 20 having a switching element for turning ON/OFF the current supplied to the stator 10, a field circuit module 21 having a switching element for turning ON/OFF the current supplied to the rotor 7, a power circuit, and a power circuit. A control board 22 having a control circuit unit (not shown) for outputting control signals for switching elements of the module 20 and the field circuit module 21 is provided. The power circuit module 20 , the field circuit module 21 , and the control board 22 are arranged axially outside the rear bracket 2 . A rear cover 23 is attached to the rear bracket 2 so as to cover the brush holder 16, the power circuit module 20, the field circuit module 21, the control board 22, and the like.

Next, the configuration of the stator 10 will be explained. FIG. 2 is a cross-sectional view showing a main portion of the stator of the rotating electric machine according to Embodiment 1 of the present invention, and FIG. 3 shows a main portion of the stator of the rotating electric machine according to Embodiment 1 of the present invention. FIG. 4 is a longitudinal cross-sectional view, and FIG. 4 is a side view of a main part of the stator of the rotating electrical machine according to Embodiment 1 of the present invention, viewed from the radially outer side. Note that the cross-sectional view is a cross-sectional view showing a cross section perpendicular to the axis of the rotating shaft.

Here, for convenience of explanation, it is assumed that the number of slots per phase per pole is 2, and the stator winding is a three-phase winding. Also, the housing positions of the unit coils in the slot are defined as the first layer, the second layer, the third layer, and the fourth layer from the inner diameter side. The upper side in FIG. 4 is the one axial end side of the stator core 11 , and the lower side in FIG. 4 is the other axial end side of the stator core 11 .

The stator 10 includes an annular stator core 11 and stator windings 12 attached to the stator core 11, as shown in FIGS. The stator core 11 is produced by laminating and integrating magnetic thin plates such as electromagnetic steel plates, and includes an annular core back 31 and each of the core backs 31 protruding radially inward from the inner peripheral wall surface of the core back 31 and extending in the circumferential direction. and a plurality of teeth 32 arranged at an angular pitch. Spaces formed between teeth 32 adjacent in the circumferential direction serve as slots 33 . Insulators 34 are mounted in the slots 33 to ensure electrical insulation between the stator core 11 and the stator windings 12 . The insulator 34 is made of paper, resin, or a composite material thereof. Here, it is made into a sheet by sandwiching a polyimide film between meta-aramid fibers.

The stator winding 12 is configured by connecting a plurality of unit coils 35 inserted into slots 33 . The unit coil 35 is linearly formed of a conductor having a rectangular cross section, such as copper or aluminum, coated with an insulating coating such as enamel resin. Each slot 33 accommodates four unit coils 35 arranged in a row in the radial direction.

At one end in the axial direction of the stator core 11, the unit coils 35 housed in the first and third layers in the slots 33 are inclined leftward in FIG. is bent into The projecting portions of the unit coils 35 housed in the second and fourth layers in the slot 33 from the slot 33 are bent rightward in FIG.

Here, one end of the unit coil 35 housed in the first layer of one slot 33 and one end of the unit coil 35 housed in the second layer of the slot 33 six slots away from the one slot 33 in the left direction in FIG. and one end of the unit coil 35 overlap in the radial direction. One end of the unit coil 35 housed in the third layer of one slot 33 and the unit coil 35 housed in the fourth layer of the slot 33 six slots away from the one slot 33 in the left direction in FIG. and one end of the radially overlapping.

One end portions of the unit coils 35 housed in the first layer and the second layer of the pair of slots 33 separated by six slots are welded and connected. One end portions of the unit coils 35 housed in the third and fourth layers of the pair of slots 33 separated by six slots are welded and connected. The pair of slots 33 separated by 6 slots is a pair of slots 33 positioned on both sides of six teeth 32 that are continuous in the circumferential direction. A joint portion 36 is a joint portion formed by welding tip portions of the unit coils 35 to each other.

At the other end in the axial direction of the stator core 11, the projecting portions of the unit coils 35 housed in the first and third layers in the slots 33 from the slots 33 are inclined rightward in FIG. It is bent like The projecting portions of the unit coils 35 housed in the second and fourth layers in the slot 33 from the slot 33 are bent leftward in FIG.

Here, the other end of the unit coil 35 housed in the first layer of one slot 33 and the second layer of the slot 33 six slots away from the one slot 33 in the right direction in FIG. The other end portion of the unit coil 35 located there overlaps in the radial direction. The other end of the unit coil 35 housed in the third layer of one slot 33 and the unit coil housed in the fourth layer of the slot 33 six slots away from the one slot 33 in the right direction in FIG. 35 overlaps in the radial direction.

The other ends of the unit coils 35 housed in the first and second layers of the pair of slots 33 separated by six slots are welded and connected. The other ends of the unit coils 35 housed in the third and fourth layers of the pair of slots 33 separated by six slots are welded and connected.

As a result, two one-turn coils are formed by connecting in series the unit coils 35 housed in the first and second layers of the group of slots 33 arranged at intervals of 6 slots. there is Further, two one-turn coils are formed by connecting in series the unit coils 35 housed in the third and fourth layers of the group of slots 33 arranged at intervals of 6 slots. . The 6-slot interval is the interval between the slots 33 positioned on both sides of the six teeth 32 that are continuous in the circumferential direction.

Here, the connection structure of the unit coils 35 will be described with reference to FIG. FIG. 5 is a perspective view showing the state of connection between the ends of the unit coils in the stator of the rotary electric machine according to Embodiment 1 of the present invention.

The unit coil 35 includes a conductor portion 351 having a rectangular cross section and an insulating coating 352 covering the conductor portion 351 . The insulating coating 352 at both ends of the unit coil 35 is removed. A region where the insulating coating is removed is referred to as a coating stripped portion 353 . A region covered with the insulating coating 352 is referred to as a coating portion 354 . The film peeling portion 353 connects a thick portion 353a on the root side having a large radial thickness, a thin portion 353b on the tip side having a thin radial thickness, and the thick portion 353a and the thin portion 353b. and an inclined portion 353c whose thickness gradually decreases from the thick portion 353a toward the thin portion 353b. The step in the radial direction between the thick portion 353a and the thin portion 353b is t. The circumferential width of the film peeling portion 353 is constant.

A surface of one of the unit coils 35 to be connected, which is positioned on one side in the radial direction of the coating stripped portion 353 , is a flat surface 358 that is substantially level with the coating portion 354 . The surface of the other unit coil 35 to be connected, which is located on the other side in the radial direction of the film peeling portion 353 , is a flat surface 358 that is substantially level with the film portion 354 . As a result, the tip portions of the unit coils 35 face each other without a gap and overlap in the radial direction. Here, the surfaces located on both sides in the radial direction of the film peeling portion 353 are a pair of opposed surfaces, and the surfaces located on both sides in the circumferential direction are another pair of opposed surfaces.

As a result, the front ends of the unit coils 35 can be welded while facing each other without a gap. Therefore, it is not necessary to press the tip portions against each other with a large force during welding. In addition, there is no fear that springback will occur after welding and the joint 36 will peel off. As a result, the joining work can be rationalized, and the reliability of the joining portion 36 can be improved. Furthermore, the portion to which the unit coil 35 is welded is formed into a thin portion 353b having a small radial thickness, and has a small cross-sectional area. As a result, the amount of heat input during welding can be reduced, and more effective heating becomes possible.

Next, a method for manufacturing a unit coil of a comparative example will be described. 6 is a cross-sectional view showing a conductor wire that is a material of a unit coil, FIG. 7 is a plan view of the conductor wire viewed from the Y direction, FIG. 8 is a plan view of the conductor wire viewed from the X direction, FIGS. 10 is a plan view for explaining the first cutting step in the manufacturing method of the unit coil of the comparative example, and FIGS. 11 and 12 are respectively for explaining the second cutting step in the manufacturing method of the unit coil of the comparative example. 13 and 14 are plan views for explaining the offset process in the manufacturing method of the unit coil of the comparative example, and FIGS. 15 and 16 are respectively the cutting process in the manufacturing method of the unit coil of the comparative example. 17 is a perspective view showing the punch, and FIG. 18 is a front view showing the punch. 9, 11, 13 and 15 are plan views of the periphery of the processed portion of the conductor wire viewed from the Y direction. 10, 12, 14 and 16 are plan views of the periphery of the processed portion of the conductor wire viewed from the X direction.

The conductor wire 350 is, as shown in FIG. 6, a continuous conductor wire in which an insulating film 352 is coated with a conductor portion 351 of copper, aluminum, or the like. As shown in FIGS. 7 and 8, the conductor wire 350 is a continuous conductor wire having a rectangular cross section with four flat surfaces. The side faces A positioned on both sides in the radial direction of the conductor wire 350 are a pair of facing sides, and the side faces B positioned on both sides in the circumferential direction are another pair of facing faces. In the manufacturing method of the unit coil of the comparative example, although not shown, the first cut portion, the second cut portion, the offset portion, and the cut portion are arranged in a row at intervals of the length of the unit coil 35. ing.

First, the conductor wire 350 is conveyed to the first cutting portion. In the first cutting portion, as shown in FIGS. 9 and 10, a pair of punches P1 having blade portions are moved in the direction of arrow C1 on both sides of the conductor wire 350 in the X direction (first cutting step). As a result, the conductor portion 351 and the insulating coating 352 on both sides of the conductor wire 350 in the X direction are cut off by the blade portion of the punch P1. Therefore, the cut surfaces on both sides of the conductor wire 350 in the X direction are formed into a surface shape that matches the shape of the blade portion of the punch P1. As a result, the cut surfaces on both sides of the conductor wire 350 in the X direction are a pair of first flat surfaces 355a, a second flat surface 355b located between the pair of first flat surfaces 355a, and a pair of first flat surfaces 355a. and a pair of inclined surfaces 355c connecting the second flat surface 355b.

The conductor wire 350 is then conveyed to the second cutting section. In the second cutting portion, as shown in FIGS. 11 and 12, a pair of punches P2 having blade portions are moved in the direction of arrow C2 on both sides of the conductor wire 350 in the Y direction (second cutting step). As a result, the conductor portion 351 and the insulating coating 352 on both sides of the conductor wire 350 in the Y direction are cut off by the blade portion of the punch P2. Therefore, the cut surfaces on both sides of the conductor wire 350 in the Y direction are formed into a surface shape that matches the shape of the blade portion of the punch P2. The cut surfaces on both sides of the conductor line 350 in the Y direction are the third flat surfaces 355d.

The conductor wire 350 is then transported to the offset section. In the offset portion, as shown in FIGS. 13 and 14, a punch P3 is applied to the cut surface on one side of the conductor wire 350 in the X direction and moved in the direction of arrow C2 (offset step). Here, as shown in FIGS. 17 and 18, the punch P3 has a pair of first flat pressure surfaces P3a, a second flat pressure surface P3b positioned between the pair of first flat pressure surfaces P3a, and a pair of flat pressure surfaces P3b. It has a convex pressing surface S1 consisting of a pair of inclined pressing surfaces P3c connecting the first flat pressing surface P3a and the second flat pressing surface P3b. A step d1 between the first flat pressing surface P3a and the second flat pressing surface P3b is equal to the radial step t between the thick portion 353a and the thin portion 353b. The width U1 of the punch P3 is sufficiently larger than the Y-direction width of the cut portion of the conductor line 350 cut in the second cutting step. The width U2 of the punch P3 is greater than the lengthwise width of the cut portion of the conductor line 350 cut in the second cutting step. As a result, both sides of the cutting portion of the conductor wire 350 are pressed on both sides of the pressing surface of the punch P3 in the length direction, thereby suppressing the occurrence of floating and shifting in the longitudinal direction of the conductor wire 350 during cutting.

In the offset process, the conductor portion 351 of the conductor wire 350 is plastically deformed, and the cut surface on the other side of the conductor wire 350 in the X direction becomes a flat surface 358 with substantially no level difference with the insulating coating 352 . That is, the cut surface on the other side in the X direction becomes a flat surface 358 that is substantially continuous with the surface of the insulating coating 352 . The surface shape of the pressing surface S1 of the punch P3 is transferred to the cut surface on one side of the conductor wire 350 in the X direction. As a result, one side surface of the conductor wire 350 in the X direction is composed of a pair of first flat surfaces 355a, a second flat surface 355b positioned between the pair of first flat surfaces 355a, and a second flat surface 355b. It is formed in a stepped surface shape including a pair of inclined surfaces 355c connecting the flat surface 355b.

The conductor wire 350 is then transported to the cutting section. At the cut portion, the cut portion of the conductor wire 350 is cut at the central portion in the length direction of the conductor wire 350 . The conductor wire 350 is transported in its length direction with the length of the unit coil 35 as the transport pitch, and the first cutting step, the second cutting step, the offsetting step and the cutting step are performed. As a result, as shown in FIGS. 15 and 16, the unit coil 35 is manufactured, in which film-peeling portions 353 each having a thick portion 353a, an inclined portion 353c and a thin portion 353b are formed at both ends. A pair of circumferential side surfaces of the film peeling portion 353 are third flat surfaces 355d. The other side surface in the radial direction of the peeled coating portion 353 is a flat surface 358 that is substantially level with the insulating coating 352 .

Next, the problem of the manufacturing method of the unit coil of the comparative example will be explained. 19 and 20 are plan views for explaining problems in the first excision step in the manufacturing method of the unit coil of the comparative example, respectively, and FIGS. It is a top view explaining the problem of 2 excision processes. 19 and 21 are plan views of the periphery of the processed portion of the conductor wire viewed from the Y direction. 20 and 22 are plan views of the periphery of the processed portion of the conductor wire viewed from the X direction.

In the first cutting step, as shown in FIGS. 19 and 20, a pair of punches P1 having blades are moved in the direction of arrow C1 on both sides of the conductor wire 350 in the X direction. At this time, the width between the second flat surfaces 355b on both sides in the X direction is narrower than the width between the first flat surfaces 355a on both sides in the X direction. Therefore, the intensity of the area between the second flat surfaces 355b is smaller than the intensity of the area between the first flat surfaces 355a. On the other hand, the amount of removal for forming the second flat surface 355b is larger than the amount of removal for forming the first flat surface 355a. Therefore, of the pair of side surfaces in the direction of the arrow C1 of the cut portion of the conductor wire 350, the rear side in the direction of the arrow C1 is deformed as shown in FIG. , deforms into a concave shape, and a depression F is formed.

Next, in the second cutting step, as shown in FIGS. 21 and 22, a pair of punches P2 having blades are moved in the direction of arrow C2 on both sides of the conductor wire 350 in the Y direction. At this time, of the pair of side surfaces in the direction of the arrow C1 of the cut portion of the conductor wire 350, since the recess F is formed in the rear side surface in the direction of the arrow C1 (upper side in FIG. 22), it cannot be cut out by the punch P2. part can be done. As a result, as shown in FIGS. 21 and 22, of the pair of side surfaces in the Y direction of the cut portion of the conductor wire 350, the region D of the side surface (upper side surface in FIG. 22) where the depression F was formed. , the insulating coating 332 remains. Furthermore, the width between the third flat surfaces 355d on both sides in the Y direction of the region where the second flat surfaces 355b are formed is narrower than the designed value. The width between the third flat surfaces 355d on both sides in the Y direction of the region where the coating residue and the second flat surface 355b are formed does not change in the offset process and the cutting process.

Therefore, in the welding process, defective welding occurs due to the coating residue. In addition, since the width between the pair of second flat surfaces 355b is narrower than the designed value, the cross-sectional area of the peeled film portion 353 is reduced from the designed value, and the coil resistance increases.

Next, a method of manufacturing a unit coil in the method of manufacturing a stator according to Embodiment 1 will be described. 23 and 24 are respectively plan views for explaining the first cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention, and FIGS. 25 and 26 are respectively Embodiment 1 of the present invention. 27 and 28 are plan views for explaining the second cutting step in the method for manufacturing a unit coil according to Embodiment 1 of the present invention; 29 and 30 are plan views explaining the cutting step in the method of manufacturing the unit coil according to Embodiment 1 of the present invention, respectively. 23, 25, 27 and 29 are plan views of the periphery of the processed portion of the conductor wire viewed from the Y direction. 24, 26, 28 and 30 are plan views of the periphery of the processed portion of the conductor wire viewed from the X direction.

Also in Embodiment 1, the unit coil 35 is manufactured using the conductor wire 350 . In the manufacturing method of the unit coil according to Embodiment 1, although not shown, the first cut portion, the offset portion, the second cut portion, and the cut portion are arranged in a line at intervals of the length of the unit coil 35. is set up.

First, the conductor wire 350 is conveyed to the first cutting section. In the first cutting portion, as shown in FIGS. 23 and 24, a pair of punches P4 having blade portions are moved in the direction of arrow C1 on both sides of the conductor wire 350 in the X direction (first cutting step). As a result, both sides of the conductor wire 350 in the X direction, that is, the conductor portion 351 and the insulating coating 352 on the pair of opposing side surfaces are cut off by the blade portion of the punch P4. Therefore, a pair of cut surfaces having a surface shape that matches the shape of the blade portion of the punch P4 is formed on a pair of opposed side surfaces of the conductor wire 350 . A pair of opposed cut surfaces of the conductor wire 350 becomes a first flat surface 355a.

The conductor wire 350 is then transported to the offset section. In the offset portion, as shown in FIGS. 25 and 26, a punch P3 is applied to one of the pair of cut surfaces of the conductor wire 350 and moved in the direction of arrow C2 (offset step). As a result, the conductor portion 351 of the conductor wire 350 is plastically deformed, and the other cut surface of the pair of cut surfaces of the conductor wire 350 becomes a flat surface 358 with substantially no level difference with the insulating coating 352 . The surface shape of the pressing surface S1 of the punch P3 is transferred to one of the pair of cut surfaces of the conductor wire 350 . Therefore, one cut surface of the conductor wire 350 is composed of a pair of first flat surfaces 355a, a second flat surface 355b located between the pair of first flat surfaces 355a, and a pair of first flat surfaces 355a and a second flat surface. It is formed in a stepped surface shape having a pair of inclined surfaces 355c connecting with the surface 355b.

At this time, one cut surface of the conductor wire 350 is pressed by the pressing surface S1 of the punch P3. As a result, as shown in FIGS. 25 and 26, the region E of the cut portion of the conductor line 350 is plastically deformed so as to become thin in the X direction and widen in the Y direction.

The conductor wire 350 is then conveyed to the second cutting section. In the second cutting portion, as shown in FIGS. 27 and 28, a pair of punches P2 having blade portions are moved in the direction of arrow C2 on both sides of the conductor wire 350 in the Y direction (second cutting step). As a result, both sides of the conductor wire 350 in the Y direction, that is, the conductor portion 351 and the insulating coating 352 on the other pair of opposing side surfaces are cut off by the blade portion of the punch P2. Another pair of opposing side surfaces of the conductor wire 350 are formed with cut surfaces having a surface shape that matches the shape of the blade portion of the punch P2. The cut surfaces formed on the other pair of opposing side surfaces of the conductor wire 350 are the third flat surfaces 355d. Here, the Y-direction spacing of the punches P2 is equal to the Y-direction width of the coating stripped portion 353 of the unit coil 35 .

The conductor wire 350 is then transported to the cutting section. At the cutting portion, as shown in FIGS. 29 and 30, the cut portion of the conductor wire 350 is cut at the central portion in the length direction of the conductor wire 350 (cutting step). The conductor wire 350 is transported in its length direction with the length of the unit coil 35 as the transport pitch, and the first cutting step, the second cutting step, the offsetting step and the cutting step are performed. As a result, the unit coil 35 having the coating stripped portions 353 formed at both ends is manufactured. Here, one cut surface of the conductor wire 350 to which the surface shape of the pressing surface S1 of the punch P3 is transferred, a coated portion 352, and the other cut surface formed on a flat surface 358 with no step difference are formed into a coated peeled portion 353. becomes a pair of faces facing each other. The cut surfaces formed on the other pair of opposing side surfaces of the conductor wire 350 become the other pair of opposing surfaces of the coating stripped portion 353 .

In Embodiment 1, the offset process is performed following the first cutting process of forming the first flat surfaces 355a on both sides in the X direction of the cut portion of the conductor line 350 . In the offset step, the side surface on the other side in the X direction of the cut portion of the conductor wire 350 is formed into a flat surface 358 that is substantially level with the insulating coating 352, and the side surface on the one side in the X direction of the cut portion of the conductor wire 350 is formed. , a pair of first flat surfaces 355a, a second flat surface 355b located between the pair of first flat surfaces 355a, and a pair of inclined surfaces 355c connecting the pair of first flat surfaces 355a and the second flat surfaces 355b. and is formed in a stepped surface shape. Then, following the offset step, a second cutting step is performed to form third flat surfaces 355d on both side surfaces in the Y direction of the cut portion of the conductor line 350 . As a result, the widened portion in the Y direction of the removed portion of the conductor line 350 generated in the offset step is removed by the punch P2 in the second removing step.

As a result, the insulating coating 352 on each surface of the cut portion of the conductor wire 350 is reliably removed. Furthermore, the width between the third flat surfaces 355d on both sides in the Y direction of the region where the second flat surface 355b is formed is the design value. Therefore, in the welding process, the occurrence of poor welding due to the coating residue is suppressed. Also, since the width between the third flat surfaces 355d on both sides in the Y direction is the design value, the cross-sectional area of the film peeling portion 353 is the design value, and the coil resistance is the design value.

Next, a method for manufacturing a stator according to Embodiment 1 will be described. FIG. 31 is a side view of a main part for explaining a unit coil mounting step in the manufacturing method of the stator for the rotating electric machine according to Embodiment 1 of the present invention, and FIG. FIG. 33 is a side view of a main part for explaining the first bending step of the unit coils in the stator manufacturing method, and FIG. 33 is the second bending step of the unit coils in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention. FIG. 34 is a side view of the main part for explaining the welding process of the unit coils in the manufacturing method of the stator for the rotary electric machine according to Embodiment 1 of the present invention. Note that the side views of FIGS. 31 to 34 are side views of the stator as seen from radially outward.

First, insulators 34 are attached to respective slots 33 of stator core 11 . Next, as shown in FIG. 31, four unit coils 35 manufactured in this manner are mounted in each slot 33 from one end in the axial direction (unit coil mounting step). At this time, both ends of each unit coil 35 protrude from the slot 33 . The unit coils 35 mounted on the first layer and the third layer of the slot 33 have a flat surface 358 that is substantially flush with the insulating coating 352 of the coating peeling portion 353 and faces radially outward. The unit coils 35 mounted on the second layer and the fourth layer of the slot 33 have a flat surface 358 that is substantially flush with the insulating coating 352 of the coating stripped portion 353 and faces radially inward.

Next, as shown in FIG. 32, the portion of the unit coil 35 protruding from each slot 33 toward one end in the axial direction is bent in the circumferential direction (first bending step). At this time, the projecting portion of the unit coil 35 projecting from the first layer and the third layer of the slot 33 toward one end in the axial direction is bent leftward in FIG. A protruding portion of the unit coil 35 protruding from the second layer and the fourth layer of the slot 33 toward one end in the axial direction is bent rightward in FIG. Further, the region including the film peeling portion 353 on the one axial end side of each unit coil 35 is bent so as to extend axially outward.

As a result, an area including the peeled film portion 353 on the one end side in the axial direction of the unit coil 35 housed in the first layer of one slot 33 and a slot six slots away from the one slot 33 in the left direction in FIG. 33 overlaps in the radial direction with the area including the peeled coating portion 353 on the one axial end side of the unit coil 35 housed in the second layer of 33 . In addition, the area including the film peeling portion 353 on the one end side in the axial direction of the unit coil 35 housed in the third layer of one slot 33 and the slot 33 six slots away from the one slot 33 in the left direction in FIG. and a region including the film peeling portion 353 on the one axial end side of the unit coil 35 housed in the fourth layer overlaps in the radial direction.

Next, as shown in FIG. 33, the portion of the unit coil 35 protruding from each slot 33 toward the other end in the axial direction is bent in the circumferential direction (second bending step). At this time, the projecting portion of the unit coil 35 projecting from the first layer and the third layer of the slot 33 toward the other end in the axial direction is bent rightward in FIG. A projecting portion of the unit coil 35 projecting from the second layer and the fourth layer of the slot 33 toward the other end in the axial direction is bent leftward in FIG. Furthermore, the region including the film peeling portion 353 on the other axial end side of each unit coil 35 is bent so as to extend axially outward.

As a result, the area including the film peeling portion 353 on the other axial end side of the unit coil 35 housed in the first layer of the one slot 33 and the one slot 33 are separated from the one slot 33 in the right direction in FIG. 33 by six slots. A region including the film peeling portion 353 on the other axial end side of the unit coil 35 housed in the second layer of the slot 33 overlaps in the radial direction. In addition, a region including the film peeling portion 353 on the other axial end side of the unit coil 35 housed in the third layer of one slot 33 and a slot six slots away from the one slot 33 in the left direction in FIG. 33 overlaps in the radial direction with a region including the peeled film portion 353 on the other axial end side of the unit coil 35 housed in the fourth layer of 33 .

Next, as shown in FIG. 34, the thin portions 353b of the film peeling portions 353 overlapping in the radial direction are welded together at both axial ends of the stator core 11 (welding step). As a result, the unit coils 35 to be connected are connected by the joints 36, and the stator 10 is manufactured. At this time, since the facing surface of the film peeling portion 353 to be welded is a flat surface 358 that is substantially level with the insulating film, the film peeling portions 353 face each other without a gap and overlap in the radial direction. Welded.

In the stator manufacturing method according to the first embodiment, the coating stripped portions 353 of the unit coils 35 to be connected face each other without a gap and are welded in a state of overlapping in the radial direction. Therefore, it is not necessary to press the peeled coating portions 353 against each other with a large force during welding. In addition, there is no possibility that springback will occur after bonding and the bonding portion 36 will peel off. As a result, the joining work can be rationalized, and the reliability of the joining portion 36 can be improved. Further, the film peeling portion 353 has a stepped shape, and the tip portion of the film peeling portion 353 is formed as a thin portion 353b to reduce the cross-sectional area. As a result, the amount of heat input during welding can be reduced, and more effective heating becomes possible.

Since the unit coil 35 is inserted into the slot 33 after the insulator 34 is mounted in the slot 33, damage to the insulating coating 352 when inserting the unit coil 35 into the slot 33 is suppressed. Thereby, the insulation performance of the stator winding 12 is improved.

In Embodiment 1, the unit coils are mounted one by one in the slots of the stator core. Annular unit coil assemblies may be assembled by arranging them in the same number as the slots, and the unit coil assemblies may be mounted in the slots of the stator core.

Embodiment 2.
35 and 36 are respectively plan views for explaining the third cutting step in the manufacturing method of the unit coil according to the second embodiment of the invention, and FIGS. 37 and 38 are respectively the second embodiment of the invention. 2 is a plan view for explaining an offset step in the manufacturing method of the unit coil according to FIG. 35 and 37 are plan views of the periphery of the processed portion of the conductor wire viewed from the Y direction. 36 and 38 are plan views of the periphery of the processed portion of the conductor wire viewed from the X direction.

Embodiment 2 is configured in the same manner as Embodiment 1 above, except that in the manufacturing method of the unit coil, the third cutting step is performed after the first cutting step and prior to the offset step. there is

In the second embodiment, following the first cutting step, as shown in FIGS. 35 and 36, a pair of punches P5 having blades are moved in the direction of arrow C2 on both sides of conductor wire 350 in the Y direction. (third cutting step). As a result, both sides of the conductor wire 350 in the Y direction, that is, the conductor portion 351 and the insulating coating 352 on the other pair of opposing side surfaces are cut off by the blade portion of the punch P5. Therefore, another pair of cut surfaces having a surface shape matching the shape of the blade portion of the punch P5 is formed and cut on the other pair of opposing side surfaces of the conductor wire 350 . That is, the other pair of cut surfaces of the conductor wire 350 becomes the fourth flat surface 355e. Next, the conductor wire 350 having the other pair of cut surfaces of the conductor wire 350 formed on the fourth flat surface 355e is conveyed to the offset section.

In the offset portion, as shown in FIGS. 37 and 38, a punch P3 is applied to one of the pair of cut surfaces of the conductor wire 350 and moved in the direction of arrow C2 (offset step). As a result, the conductor portion 351 of the conductor wire 350 is plastically deformed, and the other cut surface of the pair of cut surfaces of the conductor wire 350 becomes a flat surface 358 with substantially no level difference with the insulating coating 352 . The surface shape of the pressing surface S1 of the punch P3 is transferred to one of the pair of cut surfaces of the conductor wire 350 . Therefore, one cut surface of the conductor wire 350 is composed of a pair of first flat surfaces 355a, a second flat surface 355b located between the pair of first flat surfaces 355a, and a pair of first flat surfaces 355a and a second flat surface. It is formed in a stepped surface shape having a pair of inclined surfaces 355c connecting with the surface 355b.

At this time, one of the pair of cut surfaces of the conductor wire 350 is pressed by the pressure surface S1 of the punch P3. As a result, as shown in FIGS. 37 and 38, the region E of the cut portion of the conductor line 350 is plastically deformed so as to become thin in the X direction and widen in the Y direction.

The conductor wire 350 is then conveyed to the second cutting section. In the second cut portion, although not shown, both sides of the conductor wire 350 in the Y direction, that is, the conductor portions 351 on the other pair of opposing side surfaces are cut by the blade portion of the punch P2. Another pair of opposing side surfaces of the conductor wire 350 are formed with cut surfaces having a surface shape that matches the shape of the blade portion of the punch P2. The cut surfaces formed on the other pair of opposing side surfaces of the conductor wire 350 are the third flat surfaces 355d.

Also in the second embodiment, the Y-direction edge of the cut portion of the conductor wire 350 widened in the offset process is cut in the second cutting process, so that the same effect as in the first embodiment can be obtained.
According to the second embodiment, the third cutting step is performed prior to the offsetting step, and the insulating coating 352 on the Y-direction edge of the cut portion of the conductor wire 350 is cut. Therefore, in the second cutting step after the offset step, the remaining coating is reliably prevented from occurring. In addition, since the Y-direction width of the removed portion of the conductor wire 350 is narrowed by the amount of the insulating film 352 being removed, the removed portion of the conductor wire 350 is likely to be plastically deformed in the offset process. deformation is suppressed.

Here, the Y-direction spacing of the punches P5 may be less than or equal to the spacing that allows the insulation coating 352 on both sides of the conductor wire 350 in the Y-direction to be removed. In addition, the Y-direction spacing of the punches P2 is equal to the Y-direction width of the coating stripped portion 353 of the unit coil 35 .

Embodiment 3.
39 and 40 are respectively plan views for explaining the first cutting step in the manufacturing method of the unit coil according to Embodiment 3 of the present invention, and FIGS. 41 and 42 are respectively Embodiment 1 of the present invention. 43 and 44 are plan views for explaining the second cutting step in the method for manufacturing a unit coil according to Embodiment 1 of the present invention; FIGS. 45 and 46 are plan views showing the surroundings of the peeled film portion of the unit coil after the second cutting step in the manufacturing method of the unit coil according to Embodiment 1 of the present invention, and FIG. 47 shows a punch P7. A perspective view and FIG. 48 are front views showing the punch P8. 39, 41, 43 and 45 are plan views of the periphery of the processed portion of the conductor wire viewed from the Y direction. 40, 42, 44 and 46 are plan views of the periphery of the processed portion of the conductor wire viewed from the X direction.

In Embodiment 3, the conductor wire 350 is cut to produce a conductor wire 356 having the same length as the unit coil 35 . Next, as shown in FIGS. 39 and 40, a pair of punches P6 having blades are moved in the direction of arrow C1 on both sides of the cut portion of the conductor wire 356 in the X direction (first cutting step). As a result, both sides of the cut portion of the conductor wire 356 in the X direction, that is, the conductor portion 351 and the insulating coating 352 on the pair of opposing side surfaces are cut by the blade portion of the punch P6. Therefore, a pair of cut surfaces having a surface shape that matches the shape of the blade portion of the punch P6 is formed on a pair of opposing side surfaces of the conductor wire 356 . A pair of opposed cut surfaces of the conductor wire 356 becomes a first flat surface 357a.

A conductor line 356 is then transported to the offset section. In the offset portion, as shown in FIGS. 41 and 42, a punch P7 is applied to one of the pair of cut surfaces of the conductor wire 356 and moved in the direction of arrow C2 (offset step). 47 and 48, the punch P7 connects the first flat pressure surface P7a, the second flat pressure surface P7b, and the first flat pressure surface P7a and the second flat pressure surface P7b. and a convex pressurizing surface S2 consisting of an inclined pressurizing surface P7c. A step d2 between the first flat pressing surface P7a and the second flat pressing surface P7b is equal to a radial step t between the thick portion 353a and the thin portion 353b. The width U3 of the punch P7 is sufficiently larger than the Y-direction width of the cut portion of the conductor line 356 cut in the first cutting step. The width U4 of the punch P7 is larger than the lengthwise width of the cut portion of the conductor line 356 cut in the first cutting step. As a result, the root side of the cut portion of the conductor wire 356 is pressed on the opposite side of the first flat pressurizing surface P7a of the pressurizing surface S2 of the punch P7 from the inclined pressurizing surface P7c. occurrence of deviation is suppressed.

As a result, the conductor portion 351 of the conductor wire 356 is plastically deformed, and the other cut surface of the pair of cut surfaces of the conductor wire 356 becomes a flat surface 358 with substantially no level difference with the insulating coating 352 . The surface shape of the pressure surface S2 of the punch P7 is transferred to one of the pair of cut surfaces of the conductor wire 356 . Therefore, one cut surface of the conductor wire 356 includes a first flat surface 357a, a second flat surface 357b located on the tip side of the first flat surface 357a, and the first flat surface 357a and the second flat surface 357b. It is formed in a stepped surface shape having a connecting inclined surface 357c.

At this time, one cut surface of the conductor wire 356 is pressed by the pressing surface S2 of the punch P7. As a result, as shown in FIGS. 41 and 42, the region G of the cut portion of the conductor line 356 is plastically deformed so that it becomes thinner in the X direction and widens in the Y direction and the length direction.

The conductor wire 356 is then conveyed to the second cutout. In the second cutting portion, as shown in FIGS. 43 and 44, a punch P8 having a blade portion is moved in the direction of arrow C2 along both sides of the cutting portion of the conductor wire 356 in the Y direction and the leading end edge (second cutting portion). 2 resection step). As a result, both sides of the conductor wire 356 in the Y direction, that is, the conductor portion 351 and the insulating coating 352 on the other pair of opposing side surfaces and the tip edge portion are cut off by the blade portion of the punch P8. Another pair of opposing side surfaces of the conductor wire 356 are formed with cut surfaces having a surface shape that matches the shape of the blade portion of the punch P8. The cut surfaces formed on the other pair of opposing side surfaces of the conductor wire 356 are the third flat surfaces 357d. The interval in the Y direction between the blade portions of the punch P8 is equal to the width in the Y direction of the film peeling portion 353 of the unit coil 35 . As a result, as shown in FIGS. 45 and 46, the unit coil 35 having the coating stripped portion 353 is manufactured.

In the third embodiment as well, both edges in the Y direction and the leading end edge in the longitudinal direction of the cut portion of the conductor wire 356 widened in the offset step are cut in the second cutting step. A similar effect can be obtained.

Here, also in the third embodiment, as in the second embodiment, prior to the offset step, the conductor portions 351 and the insulating coating 352 on both sides of the cut portion of the conductor wire 356 in the X direction are cut. steps may be performed.

In each of the above-described embodiments, four unit coils are arranged in one row in the slot, but the number of unit coils arranged in one row in the slot is not limited to four. A book is fine.
In each of the above-described embodiments, linear unit coils are used, but the unit coils are not limited to linear unit coils. For example, U-shaped unit coils and spirally wound unit coils can be used.
In each of the above-described embodiments, the tip portions of the unit coils are joined by welding. can be used.

Further, in each of the embodiments described above, the number of slots is formed at a ratio of 2 per pole per phase, but the number of slots per pole per phase is not limited to 2, and may be 1, for example. When the number of slots is 1 per phase per pole, unit coils separated by 3 slots are connected to each other.
In each of the first embodiments described above, the stator winding is composed of three phase windings, but the number of phases of the stator winding is not limited to three, and may be five or seven.

11 stator core, 33 slot, 35 unit coil, 350, 356 conductor wire, 351 conductor portion, 352 insulating coating, 353 coating peeling portion, 353a thick portion, 353b thin portion, 358 flat surface.

Claims (7)

A plurality of unit coils each having a conductor portion and an insulating coating coated on the conductor portion and inserted into each slot of the stator core,
Each of the plurality of unit coils has, at an end protruding from the slot, a film peeling portion having a rectangular cross section and consisting only of the conductor portion,
In a method for manufacturing a stator for a rotary electric machine, wherein the unit coils to be connected among the plurality of unit coils are joined by welding the peeled coating portions to each other,
At least the insulating coating on a pair of opposing side surfaces is removed from a portion of a conductor wire having a rectangular cross section and forming the plurality of unit coils, the conductor portion and the insulating coating covering the conductor portion. , a first cutting step of forming a pair of cut surfaces;
One cut surface of the pair of cut surfaces formed in the first cutting step is pressurized to plastically deform the conductor portion so that the other cut surface of the pair of cut surfaces is continuous with the surface of the insulating coating. an offset step of forming a pair of opposing surfaces of the film peeling portion as flat surfaces to be
After the offset step, a second cutting step of cutting another pair of opposing side surfaces of a portion of the conductor wire to form another pair of opposing surfaces of the film peeling portion;
with
In the offset step, the conductor portion is plastically deformed so that the conductor wire spreads in a direction perpendicular to both the direction of pressure applied to the one cut surface and the length direction of the conductor wire ,
The method of manufacturing a stator for a rotary electric machine, wherein, in the second cutting step, the portion where the conductor wire is widened in the offset step is cut . A plurality of unit coils each having a conductor portion and an insulating coating coated on the conductor portion and inserted into each slot of the stator core,
Each of the plurality of unit coils has, at an end protruding from the slot, a film peeling portion having a rectangular cross section and consisting only of the conductor portion,
In a method for manufacturing a stator for a rotary electric machine, wherein the unit coils to be connected among the plurality of unit coils are joined by welding the peeled coating portions to each other,
At least the insulating coating on a pair of opposing side surfaces is removed from a portion of a conductor wire having a rectangular cross section and forming the plurality of unit coils, the conductor portion and the insulating coating covering the conductor portion. , a first cutting step of forming a pair of cut surfaces;
One cut surface of the pair of cut surfaces formed in the first cutting step is pressurized to plastically deform the conductor portion so that the other cut surface of the pair of cut surfaces is continuous with the surface of the insulating coating. an offset step of forming a pair of opposing surfaces of the film peeling portion as flat surfaces to be
After the offset step, a second cutting step of cutting another pair of opposing side surfaces of a portion of the conductor wire to form another pair of opposing surfaces of the film peeling portion;
with
After the first cutting step and prior to the offset step, the insulating coating on the other pair of side surfaces and the conductor portion are cut from a portion of the conductor wire to form another pair of cut surfaces. A method of manufacturing a stator for a rotary electric machine, further comprising a third cutting step. The part of the conductor wire is part of an intermediate portion in the length direction of the conductor wire,
3. The fixing of a rotating electric machine according to claim 1, further comprising a cutting step of cutting a portion of the conductor wire at a central position in the length direction to fabricate the unit coil after the second cutting step. Child production method. 4. The method according to claim 3 , wherein in the offset step, the one cut surface is formed into a stepped surface shape having thick portions at both ends in the longitudinal direction between the pair of cut surfaces and a thin portion at the central portion. A method for manufacturing a stator for a rotating electric machine. The conductor wire has a length of the unit coil,
part of the conductor wire is an end portion of the conductor wire,
3. The unit coil according to claim 1, wherein in the second cutting step, a tip end portion of a portion of the conductor wire is cut to simultaneously form a tip end surface of the film-peeled portion, thereby fabricating the unit coil. A method for manufacturing a stator for a rotating electric machine. 6. The rotary electric machine according to claim 5 , wherein in the offset step, the one cut surface is formed into a stepped surface shape having a thick portion on the root side between the pair of cut surfaces and a thin portion on the tip side. A stator manufacturing method. A rotating electrical machine manufacturing method for manufacturing a rotating electrical machine comprising a rotating electrical machine stator manufactured using the rotating electrical machine stator manufacturing method according to any one of claims 1 to 6 .

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