JP2002330572A - Unit coil for winding for slot-less stator, and its manufacturing method - Google Patents
Unit coil for winding for slot-less stator, and its manufacturing methodInfo
- Publication number
- JP2002330572A JP2002330572A JP2001136347A JP2001136347A JP2002330572A JP 2002330572 A JP2002330572 A JP 2002330572A JP 2001136347 A JP2001136347 A JP 2001136347A JP 2001136347 A JP2001136347 A JP 2001136347A JP 2002330572 A JP2002330572 A JP 2002330572A
- Authority
- JP
- Japan
- Prior art keywords
- coil
- stator winding
- unit
- jig
- stator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Iron Core Of Rotating Electric Machines (AREA)
- Windings For Motors And Generators (AREA)
- Insulation, Fastening Of Motor, Generator Windings (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、モータや発電機等
の回転電気機械のスロットレス型ステータに用いられる
２層円筒状のステータ巻線を構成する単位コイル及びそ
の製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a unit coil constituting a two-layer cylindrical stator winding used for a slotless stator of a rotating electric machine such as a motor or a generator, and a method of manufacturing the unit coil.
【０００２】[0002]
【従来の技術】従来、スロットレス型ステータは、スロ
ットを有しない円筒状のステータコアの内周にその軸方
向から円筒状のステータ巻線を挿入して製造している
（特許第２８４７８００号公報、特許第２９７２４１３
号公報等参照）。2. Description of the Related Art Conventionally, a slotless type stator is manufactured by inserting a cylindrical stator winding from an axial direction into an inner periphery of a cylindrical stator core having no slot (Japanese Patent No. 2847800; Patent No. 2972413
Reference).
【０００３】ところで、ステータ巻線が２層の円筒状で
あって、ステータ巻線を構成する単位コイルが、ステー
タ巻線の径方向外層部に周方向に並べて配置する複数の
外層コイル辺と、ステータ巻線の径方向内層部に周方向
に並べて配置する複数の内層コイル辺と、これら外層コ
イル辺と内層コイル辺とを橋渡しする複数のコイル端と
を有するものである場合、単位コイルのコイル辺間ピッ
チ、即ち、外層コイル辺と内層コイル辺との間のピッチ
を大きく設定すると、複数の単位コイルのコイル端が多
数重なり合って、ステータ巻線のコイル端部分の外径が
大きくなり、このままではステータ巻線をステータコア
に挿入できない。そのため、コイル端を径方向内側に曲
げた状態でステータコアにステータ巻線を挿入した後、
コイル端を径方向外側に曲げることが必要になり、コイ
ル端の曲げに手間がかかって、生産性の向上を図ること
が困難になっている。[0003] By the way, the stator winding has a two-layer cylindrical shape, and a unit coil constituting the stator winding has a plurality of outer layer coil sides arranged circumferentially on a radially outer layer portion of the stator winding; When the stator coil has a plurality of inner layer coil sides arranged in the circumferential direction on a radial inner layer portion of the stator winding and a plurality of coil ends bridging the outer layer coil side and the inner layer coil side, the coil of the unit coil is used. If the pitch between sides, that is, the pitch between the outer layer coil side and the inner layer coil side is set large, a large number of coil ends of a plurality of unit coils overlap, and the outer diameter of the coil end portion of the stator winding becomes large. Therefore, the stator winding cannot be inserted into the stator core. Therefore, after inserting the stator winding into the stator core with the coil end bent inward in the radial direction,
It is necessary to bend the coil end radially outward, and it takes time and effort to bend the coil end, making it difficult to improve productivity.
【０００４】[0004]
【発明が解決しようとする課題】上記不具合を解消する
ため、ステータコアを周方向に分割された複数の分割コ
アで構成し、ステータ巻線の外周においてこれら分割コ
アを互に結合してステータコアを組立てることが考えら
れる。これによれば、ステータ巻線のコイル端部分の外
径がステータコアの内径以上になっても、コイル端を内
側に曲げずにステータ巻線をステータコアの内周に装着
できる。In order to solve the above problem, the stator core is constituted by a plurality of divided cores divided in the circumferential direction, and these divided cores are connected to each other on the outer periphery of the stator winding to assemble the stator core. It is possible. According to this, even if the outer diameter of the coil end portion of the stator winding is equal to or larger than the inner diameter of the stator core, the stator winding can be mounted on the inner periphery of the stator core without bending the coil end inward.
【０００５】然し、このものでも、ステータ巻線の外周
においてステータコアを組立てた後、コイル端がロータ
に接続しないように、コイル端全体を径方向外側に曲げ
ることが必要になる。この場合、複数の単位コイルのコ
イル端同士が軸方向に重なり、特に、多数の電線を束ね
たワイヤ状のコイル素材で単位コイルを形成すると、コ
イル端を小さな曲率半径で曲げることができないため、
コイル端を含むステータ全体の軸長が増加し、ステータ
が大形化する。また、複数の単位コイルを円筒状に並べ
て配設してステータ巻線を組立てる際、各単位コイルの
コイル端と隣接する単位コイルのコイル端とが干渉し、
ステータ巻線の組立作業が面倒になる。However, even in this case, after assembling the stator core around the outer periphery of the stator winding, it is necessary to bend the entire coil end radially outward so that the coil end is not connected to the rotor. In this case, the coil ends of the plurality of unit coils overlap in the axial direction. In particular, if the unit coil is formed of a wire-shaped coil material in which a large number of electric wires are bundled, the coil ends cannot be bent with a small radius of curvature.
The axial length of the entire stator including the coil ends increases, and the size of the stator increases. Also, when assembling a stator winding by arranging a plurality of unit coils in a cylindrical shape, the coil ends of each unit coil and the coil ends of adjacent unit coils interfere with each other,
The assembly work of the stator winding becomes complicated.
【０００６】ところで、上記の如くステータ巻線の外周
において複数の分割コアを結合してステータコアを組立
てる場合には、単位コイルのコイル端を予め所望の形状
に成形しておくことができる。When the stator core is assembled by combining a plurality of divided cores on the outer periphery of the stator winding as described above, the coil ends of the unit coils can be formed in a desired shape in advance.
【０００７】本発明は、この点に着目し、ステータ巻線
の組立作業を容易にすると共に、コイル端の軸方向張り
出し長さも短縮し得るようにしたスロットレス型ステー
タ用巻線の単位コイル及びその製造方法を提供すること
を課題としている。The present invention, which focuses on this point, is intended to facilitate the assembly work of the stator winding and to reduce the axially extending length of the coil end in the unit coil of the slotless type stator winding. It is an object to provide a manufacturing method thereof.
【０００８】[0008]
【課題を解決するための手段】上記課題を解決すべく、
周方向に分割された複数の分割コアで構成される、スロ
ットを有しない円筒状のステータコアの内周に装着する
２層円筒状のステータ巻線を構成する単位コイルであっ
て、ステータ巻線の径方向外層部に周方向に並べて配置
する複数の外層コイル辺と、ステータ巻線の径方向内層
部に周方向に並べて配置する複数の内層コイル辺と、こ
れら外層コイル辺と内層コイル辺とを橋渡しする複数の
コイル端とを有するものにおいて、本発明は、単位コイ
ルのコイル端が、内層コイル辺の配置部におけるステー
タ巻線の接線方向に屈曲した内層コイル辺側の接線方向
屈曲部と、ステータ巻線の径方向外側に屈曲した外層コ
イル辺側の径方向屈曲部と、接線方向屈曲部から径方向
屈曲部に向ってステータ巻線の軸方向内方への傾斜角を
持って螺旋状にのびる螺旋部とを有する形状に成形され
ている、ことを特徴とする。Means for Solving the Problems In order to solve the above problems,
A unit coil, which is composed of a plurality of divided cores divided in a circumferential direction and constitutes a two-layer cylindrical stator winding mounted on the inner periphery of a cylindrical stator core having no slot, A plurality of outer coil sides arranged side by side in the radial direction on the radial outer layer part, a plurality of inner layer sides arranged circumferentially on the radial inner layer part of the stator winding, and these outer coil sides and the inner layer coil side In those having a plurality of bridging coil ends, the present invention provides a coil end of a unit coil, a tangential bending portion on an inner layer coil side side bent in a tangential direction of a stator winding in an arrangement portion of an inner layer coil side, A helical shape having a radially bent portion on the side of the outer layer coil bent toward the radially outward side of the stator winding and an axially inclining angle of the stator winding from the tangentially bent portion toward the radially bent portion. In That is molded into a shape having a spiral portion, characterized in that.
【０００９】また、本発明による上記単位コイルの製造
方法は、多数の自己融着電線を束ねたワイヤ状のコイル
素材で形成した重ね巻コイルの各コイル辺を加圧加熱し
て、自己融着電線同士の融着により各コイル辺を所定の
断面形状に成形する工程と、外周面に、ステータ巻線の
径方向外層部の内径と等径の外層コイル辺装着部と、ス
テータ巻線の径方向内層部の内径と等径の内層コイル辺
装着部とを単位コイルのコイル辺間ピッチと等ピッチで
形成すると共に、単位コイルのコイル端の螺旋部の内周
形状に合致する突部を両コイル辺装着部間の軸方向外方
部分に突設した第１治具に、外層コイル辺装着部と内層
コイル辺装着部とに夫々重ね巻コイルの対応するコイル
辺が装着されるように重ね巻コイルをセットする工程
と、第１治具の周囲に、重ね巻コイルの各コイル辺を第
１治具との間に挟み込むと共に、軸方向端面に単位コイ
ルのコイル端の接線方向屈曲部、径方向屈曲部及び螺旋
部の軸方向内側面に合致する形状の成形面を形成して成
る第２治具をセットする工程と、軸方向端面に単位コイ
ルのコイル端の少なくとも径方向屈曲部及び螺旋部の軸
方向外側面に合致する形状の成形面を形成して成る押型
により重ね巻コイルのコイル端を第２治具との間で加圧
加熱して、自己融着電線同士の融着によりコイル端を成
形する工程とから成る。Further, in the method of manufacturing a unit coil according to the present invention, each coil side of a lap-wound coil formed of a wire-shaped coil material in which a large number of self-fusing electric wires are bundled is heated and self-fused. A step of forming each coil side into a predetermined cross-sectional shape by fusing wires together; and, on the outer peripheral surface, an outer layer coil side mounting portion having the same diameter as the inner diameter of the radially outer layer portion of the stator winding, The inner-layer coil side mounting portion having the same inner diameter as the inner-layer portion is formed at the same pitch as the pitch between the coil sides of the unit coil, and both the protrusions matching the inner peripheral shape of the spiral portion at the coil end of the unit coil are formed. The outer coil side mounting portion and the inner layer coil side mounting portion are overlapped on the first jig protruding from the axially outer portion between the coil side mounting portions so that the corresponding coil sides of the superposed coil are mounted on the outer coil side mounting portion and the inner layer coil side mounting portion, respectively. A step of setting a wound coil and the periphery of the first jig , Each coil side of the lap wound coil is sandwiched between the first jig and the axial end face is aligned with the tangential bent portion, the radial bent portion, and the axial inner surface of the spiral portion of the coil end of the unit coil. Setting a second jig having a molded surface having a shape, and forming a molded surface having a shape conforming to at least the radially bent portion and the axially outer surface of the spiral portion of the coil end of the unit coil on the axial end surface. Forming a coil end by applying pressure and heating between the second jig and the coil end of the lap-wound coil by the formed die, and fusing the self-fused electric wires to each other.
【００１０】本発明の単位コイルによれば、コイル端が
他の単位コイルのコイル端と干渉せず、ステータ巻線の
組立作業が容易になる。また、コイル端が単位コイル毎
に予め成形されているため、ステータコアの内周にステ
ータ巻線を装着してからコイル端全体を径方向外側に曲
げる場合に比し、コイル端の軸方向張り出し長さを必要
最小限に抑えることができ、コイル端を含むステータ全
体の軸長を短縮できる。According to the unit coil of the present invention, the coil end does not interfere with the coil ends of the other unit coils, and the assembly work of the stator winding is facilitated. Also, since the coil ends are preformed for each unit coil, the axial extension of the coil ends in the axial direction is smaller than when the entire coil ends are bent radially outward after the stator winding is mounted on the inner periphery of the stator core. Can be minimized, and the axial length of the entire stator including the coil ends can be reduced.
【００１１】また、本発明の単位コイルの製造方法によ
れば、コイル端を接線方向屈曲部と径方向屈曲部と螺旋
部とを有する所要の形状に正確に、且つ、能率良く成形
できる。According to the method of manufacturing a unit coil of the present invention, the coil end can be accurately and efficiently formed into a required shape having a tangentially bent portion, a radially bent portion and a spiral portion.
【００１２】[0012]
【発明の実施の形態】図１及び図２を参照して、１は回
転電気機械たる三相交流発電機のステータを示してい
る。このステータ１は、スロットを有しない円筒状のス
テータコア２の内周に円筒状のステータ巻線３を固定し
て成るスロットレス型のものに構成されている。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 1 and 2, reference numeral 1 denotes a stator of a three-phase AC generator as a rotating electric machine. This stator 1 is configured as a slotless type stator in which a cylindrical stator winding 3 is fixed to the inner periphery of a cylindrical stator core 2 having no slot.
【００１３】ステータ巻線３は、Ｕ，Ｖ，Ｗの３相のコ
イルを図２（Ｂ）に示す如く星形結線して成るもので、
各相のコイルを出力端側の第１単位コイル４Ｕ，４Ｖ，
４Ｗとこれに直列の中点（Ｎ点）側の第２単位コイル４
Ｕ′，４Ｖ′，４Ｗ′とで構成している。これら第１と
第２の各単位コイルはコイル辺間ピッチを略１８０°と
した３．５ターンのコイルで構成されている。図２
（Ａ）には、Ｕ，Ｖ，Ｗの各相の第１単位コイル４Ｕ，
４Ｖ，４Ｗの出力端から数えて１番目のコイル辺がＵ
１，Ｖ１，Ｗ１、２番目のコイル辺がＵ２，Ｖ２，Ｗ
２、３番目のコイル辺がＵ３，Ｖ３，Ｗ３、４番目のコ
イル辺がＵ４，Ｖ４，Ｗ４、５番目のコイル辺がＵ５，
Ｖ５，Ｗ５、６番目のコイル辺がＵ６，Ｖ６，Ｗ６、７
番目のコイル辺がＵ７，Ｖ７，Ｗ７で示されており、各
相の第２単位コイル４Ｕ′，４Ｖ′，４Ｗ′の第１単位
コイル４Ｕ，４Ｖ，４Ｗとの接続端から数えて１番目の
コイル辺がＵ１′，Ｖ１′，Ｗ１′、２番目のコイル辺
がＵ２′，Ｖ２′，Ｗ２′、３番目のコイル辺がＵ
３′，Ｖ３′，Ｗ３′、４番目のコイル辺がＵ４′，Ｖ
４′，Ｗ４′、５番目のコイル辺がＵ５′，Ｖ５′，Ｗ
５′、６番目のコイル辺がＵ６′，Ｖ６′，Ｗ６′、７
番目のコイル辺がＵ７′，Ｖ７′，Ｗ７′で示されてい
る。第１と第２の各単位コイルの奇数番目のコイル辺は
径方向外層部、偶数番目のコイル辺は径方向内層部に配
置されており、かくて、ステータ巻線３は全体として２
層の円筒状になる。The stator winding 3 is formed by connecting three-phase coils of U, V and W in a star shape as shown in FIG. 2 (B).
The coils of each phase are connected to the first unit coils 4U, 4V,
4W and the second unit coil 4 in series with the middle point (N point) side
U ', 4V', and 4W '. Each of the first and second unit coils is constituted by a 3.5-turn coil having a pitch between coil sides of approximately 180 °. FIG.
(A) shows a first unit coil 4U of each phase of U, V, and W,
The first coil side counted from the output terminals of 4V and 4W is U
1, V1, W1, the second coil side is U2, V2, W
The second and third coil sides are U3, V3, W3, the fourth coil side is U4, V4, W4, and the fifth coil side is U5.
V5, W5, the sixth coil side is U6, V6, W6, 7
The third coil side is indicated by U7, V7, W7, and the first coil side is counted from the connection end of the second unit coils 4U ', 4V', 4W 'of each phase with the first unit coils 4U, 4V, 4W. Are U1 ', V1', W1 ', the second coil side is U2', V2 ', W2', and the third coil side is U
3 ', V3', W3 ', the fourth coil side is U4', V
4 ', W4', 5th coil side is U5 ', V5', W
5 'and 6th coil sides are U6', V6 ', W6', 7
The third coil side is indicated by U7 ', V7', W7 '. The odd-numbered coil sides of the first and second unit coils are arranged in the radially outer layer portion, and the even-numbered coil sides are arranged in the radially inner layer portion.
The layers become cylindrical.
【００１４】ステータ１の軸方向一端側（図１の右側）
には、図３に示す如く、各相の第１単位コイル４Ｕ，４
Ｖ，４Ｗの１番目のコイル辺Ｕ１，Ｖ１，Ｗ１から一体
にのびる出力導体５Ｕ，５Ｖ，５Ｗと、各相の第２単位
コイル４Ｕ′，４Ｖ′，４Ｗ′の７番目のコイル辺Ｕ
７′，Ｖ７′，Ｗ７′の端末を接続金具６ａを介してま
とめて接続した中点用導体６とが配設されている。ま
た、図３には、各相の第１単位コイル４Ｕ，４Ｖ，４Ｗ
の２番目のコイル辺Ｕ２，Ｖ２，Ｗ２と３番目のコイル
辺Ｕ３，Ｖ３，Ｗ３とを一端側で橋渡しするコイル端が
Ｕ２３，Ｖ２３，Ｗ２３、４番目のコイル辺Ｕ４，Ｖ
４，Ｗ４と５番目のコイル辺Ｕ５，Ｖ５，Ｗ５とを一端
側で橋渡しするコイル端がＵ４５，Ｖ４５，Ｗ４５、６
番目のコイル辺Ｕ６，Ｖ６，Ｗ６と７番目のコイル辺Ｕ
７，Ｖ７，Ｗ７とを一端側で橋渡しするコイル端がＵ６
７，Ｖ６７，Ｗ６７で示されており、各相の第２単位コ
イル４Ｕ′，４Ｖ′，４Ｗ′の１番目のコイル辺Ｕ
１′，Ｖ１′，Ｗ１′と２番目のコイル辺Ｕ２′，Ｖ
２′，Ｗ２′とを一端側で橋渡しするコイル端がＵ１′
２′，Ｖ１′２′，Ｗ１′２′、３番目のコイル辺Ｕ
３′，Ｖ３′，Ｗ３′と４番目のコイル辺Ｕ４′，Ｖ
４′，Ｗ４′とを一端側で橋渡しするコイル端がＵ３′
４′，Ｖ３′４′，Ｗ３′４′、５番目のコイル辺Ｕ
５′，Ｖ５′，Ｗ５′と６番目のコイル辺Ｕ６′，Ｖ
６′，Ｗ６′とを一端側で橋渡しするコイル端がＵ５′
６′，Ｖ５′６′，Ｗ５′６′で示されている。更に図
４には、各相の第１単位コイル４Ｕ，４Ｖ，４Ｗの１番
目のコイル辺Ｕ１，Ｖ１，Ｗ１と２番目のコイル辺Ｕ
２，Ｖ２，Ｗ２とを他端側で橋渡しするコイル端がＵ１
２，Ｖ１２，Ｗ１２、３番目のコイル辺Ｕ３，Ｖ３，Ｗ
３と４番目のコイル辺Ｕ４，Ｖ４，Ｗ４とを他端側で橋
渡しするコイル端がＵ３４，Ｖ３４，Ｗ３４、５番目の
コイル辺Ｕ５，Ｖ５，Ｗ５と６番目のコイル辺Ｕ６，Ｖ
６，Ｗ６とを他端側で橋渡しするコイル端がＵ５６，Ｖ
５６，Ｗ５６で示されており、各相の第２単位コイル４
Ｕ′，４Ｖ′，４Ｗ′の２番目のコイル辺Ｕ２′，Ｖ
２′，Ｗ２′と３番目のコイル辺Ｕ３′，Ｖ３′，Ｗ
３′とを他端側で橋渡しするコイル端がＵ２′３′，Ｖ
２′３′，Ｗ２′３′、４番目のコイル辺Ｕ４′，Ｖ
４′，Ｗ４′と５番目のコイル辺Ｕ５′，Ｖ５′，Ｗ
５′とを他端側で橋渡しするコイル端がＵ４′５′，Ｖ
４′５′，Ｗ４′５′、６番目のコイル辺Ｕ６′，Ｖ
６′，Ｗ６′と７番目のコイル辺Ｕ７′，Ｖ７′，Ｗ
７′とを他端側で橋渡しするコイル端がＵ６′７′，Ｖ
６′７′，Ｗ６′７′で示されている。また、ステータ
１の他端側において、各相の第１単位コイル４Ｕ，４
Ｖ，４Ｗの７番目のコイル辺Ｕ７，Ｖ７，Ｗ７の端末と
第２単位コイル４Ｕ′，４Ｖ′，４Ｗ′の１番目のコイ
ル辺Ｕ１′，Ｖ１′，Ｗ１′の端末とを夫々接続金具７
Ｕ，７Ｖ，７Ｗを介して接続している。One axial end of the stator 1 (right side in FIG. 1)
As shown in FIG. 3, the first unit coils 4U, 4
Output conductors 5U, 5V, 5W extending integrally from the first coil sides U1, V1, W1 of V, 4W, and the seventh coil side U of the second unit coils 4U ', 4V', 4W 'of each phase.
A midpoint conductor 6 is provided in which terminals 7 ', V7', and W7 'are connected together via a connection fitting 6a. FIG. 3 shows the first unit coils 4U, 4V, 4W of each phase.
The coil ends bridging the second coil sides U2, V2, W2 and the third coil sides U3, V3, W3 at one end are U23, V23, W23, and the fourth coil sides U4, V
The coil ends bridging the fourth and fourth coil sides U5, V5 and W5 at one end are U45, V45, W45 and 6
The sixth coil side U6, V6, W6 and the seventh coil side U
The coil end bridging 7, V7 and W7 at one end is U6
7, V67, W67, and the first coil side U of the second unit coils 4U ', 4V', 4W 'of each phase.
1 ', V1', W1 'and the second coil side U2', V
The coil end bridging 2 'and W2' at one end is U1 '
2 ', V1'2', W1'2 ', third coil side U
3 ', V3', W3 'and the fourth coil side U4', V
The coil end bridging 4 'and W4' at one end is U3 '
4 ', V3'4', W3'4 ', fifth coil side U
5 ', V5', W5 'and the sixth coil side U6', V
The coil end bridging 6 'and W6' at one end is U5 '
6 ', V5'6' and W5'6 '. Further, FIG. 4 shows the first coil sides U1, V1, W1 and the second coil sides U of the first unit coils 4U, 4V, 4W of each phase.
2, V2 and W2 are bridged at the other end by U1
2, V12, W12, third coil side U3, V3, W
The coil ends bridging the third and fourth coil sides U4, V4, W4 at the other end are U34, V34, W34, the fifth coil sides U5, V5, W5 and the sixth coil sides U6, V
Coil ends bridging the other end with U56, V6
56, W56, the second unit coil 4 of each phase
U ', 4V', 4W ', the second coil side U2', V
2 ', W2' and third coil sides U3 ', V3', W
3 'is bridged at the other end by U2'3', V
2'3 ', W2'3', fourth coil side U4 ', V
4 ', W4' and the fifth coil side U5 ', V5', W
The coil end bridging 5 'with the other end is U4'5', V
4'5 ', W4'5', sixth coil side U6 ', V
6 ', W6' and the seventh coil side U7 ', V7', W
And the coil end bridging the other end with U6'7 ', V
6'7 'and W6'7'. Further, on the other end side of the stator 1, the first unit coils 4U, 4
Connection terminals for the terminals of the seventh coil sides U7, V7, W7 of V, 4W and the terminals of the first coil sides U1 ', V1', W1 'of the second unit coils 4U', 4V ', 4W', respectively. 7
U, 7V, 7W.
【００１５】ステータコアは、周方向に２分割された半
円筒状の２個の分割コア２ａ，２ａで構成されている。
そして、各分割コア２ａの周方向一側縁に溝部２ｂを形
成すると共に、各分割コア２ａの周方向他側縁に突部２
ｃを形成し、各分割コア２ａの突部２ｃを相手方の分割
コア２ａの溝部２ｂに周方向から圧入することで両分割
コア２ａ，２ａが互いに結合されるようにしている。こ
こで、突部２ｃの基端及び溝部２ｂの開口端は若干くび
れており、突部２ｃを溝部２ｂに一旦圧入すると、両分
割コア２ａ，２ａは強固に結合される。尚、ステータコ
ア２を３個以上の分割コアで構成することも可能であ
る。The stator core is constituted by two semi-cylindrical divided cores 2a, 2a divided into two in the circumferential direction.
A groove 2b is formed on one circumferential edge of each split core 2a, and a protrusion 2b is formed on the other circumferential edge of each split core 2a.
c is formed, and the projections 2c of each of the divided cores 2a are pressed into the grooves 2b of the other divided core 2a from the circumferential direction so that the two divided cores 2a, 2a are connected to each other. Here, the base end of the protrusion 2c and the opening end of the groove 2b are slightly constricted, and once the protrusion 2c is press-fitted into the groove 2b, the two split cores 2a, 2a are firmly connected. Incidentally, the stator core 2 may be constituted by three or more divided cores.
【００１６】ステータ１の製造に際しては、図５（Ａ）
（Ｂ）に示す円柱状の内径治具１０を用い、内径治具１
０の外周にＵ，Ｖ，Ｗの３相の第１単位コイル４Ｕ，４
Ｖ，４Ｗと第２単位コイル４Ｕ′，４Ｖ′，４Ｗ′とを
配置して、図６（Ａ）に示す如く、２層の円筒状のステ
ータ巻線３を組立てる。ここで、内径治具１０は、内周
面にテーパーを付けた周方向複数のセグメント１０ｂに
分割された外筒１０ａと、外筒１０ａに挿入されるテー
パーロッド１０ｃとで構成されている。外筒１０ａを構
成する複数のセグメント１０ｂは両端のＯリング１０
ｄ，１０ｄで弾力的に締め付けられており、外筒１０ａ
の先端に当接する当板１０ｅを通してテーパーロッド１
０ｃに調整ボルト１０ｆを螺合させ、調整ボルト１０ｆ
によりテーパーロッド１０ｃを進退させて、外筒１０
ａ、即ち、内径治具１０を拡径、縮径自在としている。
外筒１０ａの尾端とテーパーロッド１０ｃの尾端のフラ
ンジ１０ｇとの間にはスペーサ１０ｈが介設されてお
り、スペーサ１０ｈにより外筒１０ｃに対するテーパー
ロッド１０ｃの最大挿入位置を規制し、この最大挿入位
置で内径治具１０の外径がステータ巻線３の径方向内層
部の内径に等しくなるようにし、この状態で上記の如く
ステータ巻線３を組立てる。When manufacturing the stator 1, FIG.
Using the cylindrical inner jig 10 shown in FIG.
0, U, V, W three-phase first unit coils 4U, 4
V, 4W and the second unit coils 4U ', 4V', 4W 'are arranged to assemble a two-layer cylindrical stator winding 3 as shown in FIG. Here, the inner diameter jig 10 includes an outer cylinder 10a divided into a plurality of segments 10b in the circumferential direction with an inner peripheral surface tapered, and a tapered rod 10c inserted into the outer cylinder 10a. The plurality of segments 10b constituting the outer cylinder 10a are O-rings 10 at both ends.
d, 10d elastically tightened, the outer cylinder 10a
Taper rod 1 through the contact plate 10e which contacts the tip of
0c, the adjusting bolt 10f is screwed into the adjusting bolt 10f.
Causes the tapered rod 10c to move forward and backward,
a, that is, the inner diameter jig 10 can be freely expanded and reduced in diameter.
A spacer 10h is interposed between the tail end of the outer cylinder 10a and the flange 10g at the tail end of the tapered rod 10c. The spacer 10h regulates the maximum insertion position of the tapered rod 10c with respect to the outer cylinder 10c. At the insertion position, the outer diameter of the inner diameter jig 10 is made equal to the inner diameter of the radially inner layer portion of the stator winding 3, and in this state, the stator winding 3 is assembled as described above.
【００１７】次に、図６（Ｂ）に示す如く、周方向に分
割された複数のセグメント１１ａで構成される、内径が
ステータコア２の内径より僅かに大きな外径治具１１で
内径治具１０の外周のステータ巻線３を囲い、内径治具
１０と外径治具１１との間に樹脂またはワニスを充填
し、或いは、各単位コイルが多数の自己融着電線を束ね
たワイヤ状のコイル素材で形成されているときは、加熱
により自己融着電線を融着させ、これにより単位コイル
同士を固着してステータ巻線３を一体化する。Next, as shown in FIG. 6 (B), an outer diameter jig 11 composed of a plurality of segments 11a divided in the circumferential direction and having an inner diameter slightly larger than the inner diameter of the stator core 2 is used. And a resin or varnish is filled between the inner diameter jig 10 and the outer diameter jig 11 or a wire-shaped coil in which each unit coil bundles a number of self-fused electric wires. When formed of a material, the self-fused electric wires are fused by heating, thereby fixing the unit coils and integrating the stator winding 3.
【００１８】次に、図６（Ｃ）に示す如く、１対の分割
コア２ａ，２ａをプレス装置等により内径治具１０の外
周のステータ巻線３を周方向両側から挟み込むように接
近させ、両分割コア２ａ，２ａを溝部２ｂと突部２ｃと
で互いに結合させて、ステータコア２を組立てる。この
際、ステータ巻線３は両分割コア２ａ，２ａ間で挟圧さ
れて、ステータコア２の内周に締め付け固定される。
尚、外径治具１１を用いてのステータ巻線３の一体化処
理を省略し、ステータコア２を組立てた後に、ステータ
コア２と内径治具１０との間に樹脂を充填する等して、
ステータ巻線３の一体化とステータコア２へのステータ
巻線３の固着とを行うようにしても良い。Next, as shown in FIG. 6 (C), the pair of split cores 2a, 2a are approached by a pressing device or the like so as to sandwich the stator winding 3 on the outer periphery of the inner diameter jig 10 from both sides in the circumferential direction. The stator core 2 is assembled by connecting the two split cores 2a, 2a to each other with the groove 2b and the protrusion 2c. At this time, the stator winding 3 is clamped between the two split cores 2a, 2a and is fixedly fastened to the inner periphery of the stator core 2.
The integration process of the stator windings 3 using the outer diameter jig 11 is omitted, and after assembling the stator core 2, a resin is filled between the stator core 2 and the inner diameter jig 10.
The integration of the stator winding 3 and the fixing of the stator winding 3 to the stator core 2 may be performed.
【００１９】ところで、単位コイルのコイル辺間ピッチ
が上記の如く１８０°と大きくなると、Ｕ，Ｖ，Ｗの３
相の単位コイルのコイル端同士が重なり合い、コイル端
を径方向外側に曲げなくても、ステータ巻線３のコイル
端部分の外径はステータコア２の内径より大きくなって
しまう。然し、上記の如く分割コア２ａ，２ａをステー
タ巻線３の外周側から組付けてステータコア２を組立て
ることにより、コイル端に邪魔されることなく作業性良
くステータ巻線３をステータコア２の内周に装着でき
る。By the way, when the pitch between coil sides of the unit coil is as large as 180 ° as described above, three of U, V and W
The coil ends of the unit coils of the phase overlap with each other, and the outer diameter of the coil end portion of the stator winding 3 becomes larger than the inner diameter of the stator core 2 without bending the coil ends radially outward. However, by assembling the stator core 2 by assembling the split cores 2a, 2a from the outer peripheral side of the stator winding 3 as described above, the stator winding 3 can be easily mounted on the inner periphery of the stator core 2 without being hindered by coil ends. Can be attached to
【００２０】また、通常は、ステータ巻線３をステータ
コア２の内周に装着した後に、コイル端全体を径方向外
側に曲げて、コイル端がロータに接触することを防止し
ているが、これではＵ，Ｖ，Ｗの３相の単位コイルのコ
イル端同士がステータ１の軸方向に重なり、特に、単位
コイルをワイヤ状のコイル素材で形成する場合は、コイ
ル端を小さな曲率半径で曲げることができないため、コ
イル端を含むステータ１全体の軸長が増加し、また、各
単位コイルを内径治具１０の外周に並べて配設する際、
各単位コイルのコイル端と隣接する単位コイルのコイル
端とが干渉し、単位コイルの配設作業が面倒になる。Normally, after the stator winding 3 is mounted on the inner periphery of the stator core 2, the entire coil end is bent radially outward to prevent the coil end from contacting the rotor. Then, the coil ends of the U, V, W three-phase unit coils overlap in the axial direction of the stator 1. In particular, when the unit coils are formed of a wire-like coil material, the coil ends are bent with a small radius of curvature. Therefore, the axial length of the entire stator 1 including the coil ends increases, and when the unit coils are arranged side by side on the outer periphery of the inner diameter jig 10,
The coil ends of the unit coils and the coil ends of the adjacent unit coils interfere with each other, and the work of arranging the unit coils is complicated.
【００２１】そこで、本実施形態では、各単位コイルの
コイル端を、図７にＵ相の第１単位コイル４Ｕで代表し
て示すように、ステータ巻線３の径方向内層部に配置す
る内層コイル辺Ｕ２，Ｕ４，Ｕ６の配置部におけるステ
ータ巻線３の接線方向に屈曲した内層コイル辺側の接線
方向屈曲部４ａと、ステータ巻線３の径方向外側に屈曲
した、ステータ巻線３の径方向外層部に配置する外層コ
イル辺Ｕ１，Ｕ３，Ｕ５，Ｕ７側の径方向屈曲部４ｂ
と、接線方向屈曲部４ａから径方向屈曲部４ｂに向かっ
てステータ巻線３の軸方向内方への傾斜角を持って螺旋
状にのびる螺旋部４ｃとを有する形状にプレス成形して
いる。これによれば、各単位コイルの内層コイル辺から
外層コイル辺に向かう方向を正方向として、図３及び図
４に示すように、各単位コイルのコイル端の接線方向屈
曲部４ａが正方向に隣接する単位コイルのコイル端の接
線方向屈曲部４ａの径方向外側を通り、また、螺旋部４
ｃが正方向に隣接する単位コイルの次の単位コイルのコ
イル端の径方向屈曲部４ｂの軸方向外側を通り、更に、
径方向屈曲部４ｂが正方向に隣接する単位コイルのコイ
ル端の螺旋部４ｃの軸方向内側を通り、コイル端同士の
干渉が防止される。かくて、内径治具１０に対する単位
コイルの配設作業が容易になる。更に、コイル端を単位
コイル毎に予めプレス成形するため、ステータコア２の
内周にステータ巻線３を装着してからコイル端全体を径
方向外側に曲げる場合に比し、コイル端の軸方向張出し
長さを必要最小限に抑えることができ、コイル端を含む
ステータ１全体の軸長を短縮できる。Therefore, in the present embodiment, as shown by the U-phase first unit coil 4U in FIG. 7, the coil end of each unit coil is disposed in the inner layer of the stator winding 3 in the radial inner layer. The tangential bent portion 4a on the inner layer coil side bent in the tangential direction of the stator winding 3 in the arrangement portion of the coil sides U2, U4, U6, and the stator winding 3 bent radially outward of the stator winding 3 Outer layer coil sides U1, U3, U5 and U7 side radial bent portion 4b arranged in the radial outer layer portion
It is press-formed into a shape having a spiral portion 4c extending spirally from the tangential bent portion 4a to the radial bent portion 4b with an inclination angle inward in the axial direction of the stator winding 3. According to this, the direction from the inner layer coil side to the outer layer coil side of each unit coil is defined as the positive direction, and as shown in FIG. 3 and FIG. It passes radially outside of the tangential bent portion 4a at the coil end of the adjacent unit coil, and
c passes axially outside the radially bent portion 4b at the coil end of the unit coil next to the unit coil adjacent in the positive direction, and
The radial bent portion 4b passes inside the spiral portion 4c of the coil end of the unit coil adjacent in the positive direction in the axial direction, so that interference between the coil ends is prevented. Thus, the work of disposing the unit coil on the inner diameter jig 10 is facilitated. Furthermore, since the coil ends are pre-pressed for each unit coil, the coil ends are protruded in the axial direction as compared with a case where the stator windings 3 are attached to the inner periphery of the stator core 2 and the entire coil ends are bent radially outward. The length can be reduced to a necessary minimum, and the axial length of the entire stator 1 including the coil ends can be reduced.
【００２２】次に、上記単位コイルの製造方法をＵ相の
第１単位コイル４Ｕを例にして説明する。先ず、図８
（Ａ）に示す巻き枠１２を用い、多数の自己融着電線を
束ねたワイヤ状のコイル素材を巻き枠１２に巻回して、
３．５ターンの重ね巻コイル４′を形成する。次に、巻
き枠１２をプレス金型１３の下型１３０に外嵌セットす
る。下型１３０には、図８（Ｂ）に示す如く、重ね巻コ
イル４′のＵ１，Ｕ３，Ｕ５，Ｕ７とＵ２，Ｕ４，Ｕ６
のコイル辺を受け入れる複数の凹溝１３０ａが形成され
ている。そして、これら凹溝１２ａに対向する複数の突
起１３１ａを形成したプレス金型１３の上型１３１を下
降させ、各コイル辺を凹溝１３０ａ内で突起１３１ａに
より加圧し、この状態で下型１３０及び上型１３１に埋
設したヒータ（図示せず）により各コイル辺を加熱し
て、自己融着電線同士の融着により各コイル辺を断面台
形に押し固めてプレス成形する。Next, a method of manufacturing the unit coil will be described by taking the U-phase first unit coil 4U as an example. First, FIG.
(A), a wire-shaped coil material in which many self-fused electric wires are bundled is wound around the winding frame 12 using the winding frame 12 shown in FIG.
A 3.5-turn lap wound coil 4 'is formed. Next, the winding frame 12 is externally set on the lower die 130 of the press die 13. As shown in FIG. 8B, the lower mold 130 has U1, U3, U5, U7 and U2, U4, U6 of the lap wound coil 4 '.
A plurality of concave grooves 130a for receiving the coil sides are formed. Then, the upper die 131 of the press die 13 having the plurality of protrusions 131a opposed to the concave grooves 12a is lowered, and each coil side is pressed by the protrusions 131a in the concave grooves 130a. Each coil side is heated by a heater (not shown) embedded in the upper die 131, and each coil side is pressed into a trapezoidal cross section by fusion of the self-fused electric wires, and press-formed.
【００２３】次に、図９（Ａ）に示す第１治具１４に重
ね巻コイル４′をセットする。これを詳述するに、第１
治具１４は、図９（Ｂ）に示す如く、外周面に、ステー
タ巻線３の径方向外層部の内径と等径の外層コイル辺装
着部１４ａと、ステータ巻線３の径方向内層部の内径と
等径の内層コイル辺装着部１４ｂとを単位コイルのコイ
ル辺間ピッチと等ピッチ（略１８０°）で形成すると共
に、単位コイルのコイル端の螺旋部４ｃの内周形状に合
致する突部１４ｃを両コイル辺装着部１４ａ，１４ｂの
軸方向外方部分に突設して成るものに構成されており、
重ね巻コイル４′のＵ１，Ｕ３，Ｕ５，Ｕ７のコイル辺
が外層コイル辺装着部１４ａ、Ｕ２，Ｕ４，Ｕ６のコイ
ル辺が内層コイル装着部１４ｂに夫々装着されるように
重ね巻コイル４′を第１治具１４にセットする。Next, the lap winding coil 4 'is set on the first jig 14 shown in FIG. To elaborate on this, the first
As shown in FIG. 9 (B), the jig 14 has, on its outer peripheral surface, an outer coil side mounting portion 14 a having the same diameter as the inner diameter of the radial outer layer portion of the stator winding 3, and a radial inner layer portion of the stator winding 3. The inner coil side mounting portion 14b having the same diameter as the inner coil is formed at the same pitch (approximately 180 °) as the pitch between the coil sides of the unit coil, and conforms to the inner peripheral shape of the spiral portion 4c at the coil end of the unit coil. The projecting portion 14c is configured to project from the axially outer portion of both coil side mounting portions 14a, 14b.
The lap-wound coil 4 'such that the coil sides of U1, U3, U5, and U7 of the lap-wound coil 4' are mounted on the outer-layer coil-side mounting portion 14a, and the coil sides of U2, U4, and U6 are mounted on the inner-layer coil mounting portion 14b. Is set on the first jig 14.
【００２４】次に、第１治具１４の周囲に、図９（Ｂ）
に仮想線で示す如く、周方向に２分割されたセグメント
１５ａ，１５ａから成る第２治具１５をセットして、重
ね巻コイル４′の各コイル辺を第１治具１４との間に挟
み込み、この状態で第２治具１５の軸方向両側から、図
９（Ｃ）に示す如く、１対の押型１６，１６を第２治具
１５に向けて押動させる。ここで、第２治具１５の軸方
向一端と他端の各端面には、図９（Ｄ）に示す如く、単
位コイルのコイル端の接線方向屈曲部４ａ、径方向屈曲
部４ｂ及び螺旋部４ｃの軸方向内側面に合致する形状の
成形面１５ｂが形成され、また、各押型１６の第２治具
１５に対向する軸方向端面には、単位コイルのコイル端
の径方向屈曲部４ｂ及び螺旋部４ｃの軸方向外側面に合
致する形状の成形面１６ａが形成されている。かくて、
各押型１６を第２治具１５に向けて押動させると、コイ
ル端が外層コイル辺側で径方向外側に屈曲されて径方向
屈曲部４ｂが成形されると共に、コイル端の中間部分が
第１治具１４の突部１４ｃの周囲において径方向屈曲部
４ｂに向かって軸方向内方に傾斜する螺旋状に押し潰さ
れて螺旋状部４ｃが成形され、更に、コイル端の内層コ
イル辺側の部分が接線方向に引っ張られて接線方向屈曲
部４ａが成形される。そして、各押型１６によりコイル
端を加圧した状態で各押型１６と第２治具１５とに埋設
したヒータによりコイル端を加熱して、自己融着電線同
士の融着によりコイル端を押し固めてプレス成形し、単
位コイルを製造する。Next, around the first jig 14, FIG.
As shown by a virtual line, a second jig 15 composed of segments 15a, 15a divided in the circumferential direction is set, and each coil side of the lap winding coil 4 'is sandwiched between the first jig 14 and each coil side. In this state, a pair of pressing dies 16, 16 is pushed toward the second jig 15 from both axial sides of the second jig 15 as shown in FIG. Here, as shown in FIG. 9D, the tangentially bent portion 4a, the radially bent portion 4b, and the spiral portion of the coil end of the unit coil are provided on each end face of the second jig 15 at one end and the other end in the axial direction. A molding surface 15b having a shape conforming to the axial inner side surface of the pressing die 4c is formed, and a radial bending portion 4b of the coil end of the unit coil is provided on an axial end surface of each of the pressing dies 16 facing the second jig 15. A molding surface 16a having a shape conforming to the axially outer surface of the spiral portion 4c is formed. Thus,
When each of the pressing dies 16 is pushed toward the second jig 15, the coil end is bent radially outward on the side of the outer layer coil side to form the radial bent portion 4b, and the intermediate portion of the coil end is formed in the middle. The helical portion 4c is formed by being crushed in a spiral shape inclining inward in the axial direction toward the radially bent portion 4b around the projection 14c of the jig 14 to form a helical portion 4c. Is pulled in the tangential direction to form the tangential bent portion 4a. Then, the coil ends are heated by heaters embedded in each of the pressing dies 16 and the second jig 15 in a state where the coil ends are pressed by the respective pressing dies 16, and the coil ends are compacted by fusion of the self-fused electric wires. Press molding to produce unit coils.
【００２５】[0025]
【発明の効果】以上の説明から明らかなように、本発明
の単位コイルによれば、ステータ巻線の組立作業が容易
になると共に、コイル端の軸方向張り出し長さを必要最
小限に抑えて、コイル端を含むステータ全体の軸長を短
縮でき、また、本発明方法によれば、コイル端を所要の
形状に正確に、且つ、能率良く成形でき、生産性が向上
する。As is apparent from the above description, according to the unit coil of the present invention, the work of assembling the stator winding is facilitated, and the axially extending length of the coil end is minimized. According to the method of the present invention, the coil end can be accurately and efficiently formed into a required shape, and the productivity can be improved.
【図１】 本発明に係る単位コイルを用いたスロットレ
ス型ステータの一例の側面図FIG. 1 is a side view of an example of a slotless stator using a unit coil according to the present invention.
【図２】（Ａ）図１のII−II線截断面図、（Ｂ）ステー
タ巻線の結線図。2A is a sectional view taken along the line II-II of FIG. 1, and FIG. 2B is a connection diagram of a stator winding.
【図３】図１の右側面図。FIG. 3 is a right side view of FIG. 1;
【図４】図１の左側面図。FIG. 4 is a left side view of FIG. 1;
【図５】（Ａ）内径治具の截断側面図、（Ｂ）図５
（Ａ）のＶＢ−ＶＢ線截断面図。5A is a cutaway side view of an inner diameter jig, and FIG.
FIG. 5A is a sectional view taken along line VB-VB.
【図６】（Ａ）内径治具の外周にコイルを装着してステ
ータ巻線を組立てた状態の断面図、（Ｂ）ステータ巻線
を外径治具で囲った状態の断面図、（Ｃ）ステータ巻線
の外周でステータコアを組立てた状態の断面図。6A is a cross-sectional view of a state where a coil is mounted on an outer circumference of an inner diameter jig to assemble a stator winding, FIG. 6B is a cross-sectional view of a state where the stator winding is surrounded by an outer diameter jig, and FIG. FIG. 4 is a cross-sectional view of a state where the stator core is assembled around the outer periphery of the stator winding.
【図７】単位コイルの斜視図。FIG. 7 is a perspective view of a unit coil.
【図８】（Ａ）単位コイルの元になる重ね巻コイル用の
巻き枠をプレス金型にセットした状態の平面図、（Ｂ）
図８（Ａ）のVIIIＢ−VIIIＢ線で截断した重ね巻コイル
のコイル辺成形時の断面図。FIG. 8A is a plan view showing a state in which a winding frame for a lap winding coil serving as a base of a unit coil is set in a press die, and FIG.
FIG. 9 is a cross-sectional view of the lap wound coil taken along the line VIIIB-VIIIB in FIG.
【図９】（Ａ）単位コイル製造用の第１治具に重ね巻コ
イルをセットした状態の斜視図、（Ｂ）図９（Ａ）のIX
Ｂ−IXＢ線で截断した第１治具の断面図、（Ｃ）第１治
具の周囲に第２治具をセットして押型によりコイル端を
押圧した状態の斜視図、（Ｄ）第２治具と押型との展開
側面図。9A is a perspective view showing a state in which a lap winding coil is set on a first jig for manufacturing a unit coil, and FIG. 9B is a perspective view showing IX in FIG. 9A.
(C) A perspective view of a state in which a second jig is set around the first jig and a coil end is pressed by a pressing die, and (D) a second view of the first jig taken along the line B-IXB. FIG. 4 is a development side view of the jig and the pressing die.
２ ステータコア ２ａ 分割コア ３ ステータ巻線 ４Ｕ，４Ｖ，４Ｗ 第１単位コイル ４Ｕ′，４Ｖ′，４Ｗ′ 第２単位コイル ４ａ 接線方向屈曲部 ４ｂ 径方向屈曲部 ４ｃ 螺旋部 ４′ 重ね巻コイル １４ 第１治具 １４ａ 外層コイル辺装着部 １４ｂ 内層コイル辺装着部 １４ｃ 突部 １５ 第２治具 １５ｂ 成形面 １６ 押型 １６ａ 成形面 Reference Signs List 2 stator core 2a split core 3 stator winding 4U, 4V, 4W first unit coil 4U ', 4V', 4W 'second unit coil 4a tangential bent part 4b radial bent part 4c spiral part 4' lap wound coil 14th 1 jig 14a outer layer coil side mounting part 14b inner layer coil side mounting part 14c protrusion 15 second jig 15b forming surface 16 stamping die 16a forming surface
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Claims (2)
成される、スロットを有しない円筒状のステータコアの
内周に装着する２層円筒状のステータ巻線を構成する単
位コイルであって、 ステータ巻線の径方向外層部に周方向に並べて配置する
複数の外層コイル辺と、ステータ巻線の径方向内層部に
周方向に並べて配置する複数の内層コイル辺と、これら
外層コイル辺と内層コイル辺とを橋渡しする複数のコイ
ル端とを有するものにおいて、 単位コイルのコイル端が、内層コイル辺の配置部におけ
るステータ巻線の接線方向に屈曲した内層コイル辺側の
接線方向屈曲部と、ステータ巻線の径方向外側に屈曲し
た外層コイル辺側の径方向屈曲部と、接線方向屈曲部か
ら径方向屈曲部に向ってステータ巻線の軸方向内方への
傾斜角を持って螺旋状にのびる螺旋部とを有する形状に
成形されている、 ことを特徴とするスロットレス型ステータ用巻線の単位
コイル。1. A unit coil constituting a two-layer cylindrical stator winding mounted on the inner periphery of a cylindrical stator core having no slot, comprising a plurality of divided cores divided in a circumferential direction. A plurality of outer layer coil sides arranged in a circumferential direction on a radial outer layer portion of the stator winding, a plurality of inner layer coil sides arranged in a circumferential direction on a radial inner layer portion of the stator winding, and these outer coil sides. A plurality of coil ends bridging the inner coil side, wherein a coil end of the unit coil is bent in a tangential direction of the inner coil side in a tangential direction of the stator winding in a portion where the inner layer coil is disposed; A spiral having a radially bent portion on the side of the outer layer coil bent to the radially outward side of the stator winding, and an inclination angle inward in the axial direction of the stator winding from the tangentially bent portion toward the radially bent portion. Condition It extends and is molded into a shape having a spiral section, the slot-less unit coil of the stator winding, characterized in that.
方法であって、 多数の自己融着電線を束ねたワイヤ状のコイル素材で形
成した重ね巻コイルの各コイル辺を加圧加熱して、自己
融着電線同士の融着により各コイル辺を所定の断面形状
に成形する工程と、 外周面に、ステータ巻線の径方向外層部の内径と等径の
外層コイル辺装着部と、ステータ巻線の径方向内層部の
内径と等径の内層コイル辺装着部とを単位コイルのコイ
ル辺間ピッチと等ピッチで形成すると共に、単位コイル
のコイル端の螺旋部の内周形状に合致する突部を両コイ
ル辺装着部間の軸方向外方部分に突設した第１治具に、
外層コイル辺装着部と内層コイル辺装着部とに夫々重ね
巻コイルの対応するコイル辺が装着されるように重ね巻
コイルをセットする工程と、 第１治具の周囲に、重ね巻コイルの各コイル辺を第１治
具との間に挟み込むと共に、軸方向端面に単位コイルの
コイル端の接線方向屈曲部、径方向屈曲部及び螺旋部の
軸方向内側面に合致する形状の成形面を形成して成る第
２治具をセットする工程と、 軸方向端面に単位コイルのコイル端の少なくとも径方向
屈曲部及び螺旋部の軸方向外側面に合致する形状の成形
面を形成して成る押型により重ね巻コイルのコイル端を
第２治具との間で加圧加熱して、自己融着電線同士の融
着によりコイル端を成形する工程とから成る、 ことを特徴とするスロットレス型ステータ用巻線の単位
コイルの製造方法。2. The method for manufacturing a unit coil according to claim 1, wherein each coil side of the lap wound coil formed of a wire-shaped coil material in which a number of self-fused electric wires are bundled is heated under pressure. A step of forming each coil side into a predetermined cross-sectional shape by fusing the self-fused electric wires to each other; and, on the outer peripheral surface, an outer coil side mounting portion having the same diameter as the inner diameter of the radial outer layer portion of the stator winding; The inner coil side mounting part of the same diameter as the inner diameter of the inner layer part of the stator winding is formed at the same pitch as the pitch between the coil sides of the unit coil, and matches the inner peripheral shape of the spiral part at the coil end of the unit coil. A first jig having a projecting portion projecting in an axially outer portion between both coil side mounting portions,
Setting the lap wound coil such that the corresponding coil sides of the lap wound coil are mounted on the outer layer coil side mounting portion and the inner layer coil side mounting portion, respectively; A coil side is sandwiched between the first jig and a molding surface is formed on the axial end surface so as to have a shape matching the tangential bent portion, the radial bent portion, and the spiral inner surface of the coil end of the unit coil. Setting a second jig formed by: forming a forming surface having a shape matching at least the radially bent portion of the coil end of the unit coil and the axially outer surface of the spiral portion on the axial end surface by a pressing die. Forming a coil end by heating the coil end of the lap-wound coil with a second jig and fusing the self-fused electric wires to each other. Manufacturing method of unit coil for winding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001136347A JP4695774B2 (en) | 2001-05-07 | 2001-05-07 | Unit coil of slotless type stator winding and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001136347A JP4695774B2 (en) | 2001-05-07 | 2001-05-07 | Unit coil of slotless type stator winding and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2002330572A true JP2002330572A (en) | 2002-11-15 |
| JP4695774B2 JP4695774B2 (en) | 2011-06-08 |
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ID=18983641
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2001136347A Expired - Fee Related JP4695774B2 (en) | 2001-05-07 | 2001-05-07 | Unit coil of slotless type stator winding and manufacturing method thereof |
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| EP1643619A2 (en) | 2004-09-30 | 2006-04-05 | Hitachi, Ltd. | Coil for rotating electrical machine |
| JP2009268221A (en) * | 2008-04-24 | 2009-11-12 | Denso Corp | Method of manufacturing stator coil |
| US7990013B2 (en) * | 2008-06-23 | 2011-08-02 | Korea Electronics Technology Institute | Slotless motor |
| WO2011111682A1 (en) * | 2010-03-11 | 2011-09-15 | 株式会社 豊田自動織機 | Stator for rotating electrical machine, method for manufacturing stator, and method for manufacturing coil for stator |
| JP2011188724A (en) * | 2010-03-11 | 2011-09-22 | Toyota Industries Corp | Stator for rotary electric machine, and method for manufacturing coil of the same |
| JP2011229285A (en) * | 2010-04-20 | 2011-11-10 | Toyota Industries Corp | Method for manufacturing stator of rotating electric machine and stator of rotating electric machine |
| WO2016021974A1 (en) * | 2014-08-07 | 2016-02-11 | Valeo Electrical Systems Korea Ltd. | Wire assembly for rotary electric machine and corresponding method to obtain the wire assembly |
| WO2018194208A1 (en) * | 2017-04-19 | 2018-10-25 | 엘지전자 주식회사 | Stator of rotating electric apparatus |
| CN113454883A (en) * | 2019-02-25 | 2021-09-28 | 株式会社电装 | Armature and rotating electrical machine |
| WO2021220761A1 (en) * | 2020-04-28 | 2021-11-04 | 株式会社デンソー | Dynamo-electrical machine and method for manufacturing same |
| CN114303303A (en) * | 2019-08-29 | 2022-04-08 | 株式会社电装 | Rotating electrical machine |
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Cited By (22)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1643619A2 (en) | 2004-09-30 | 2006-04-05 | Hitachi, Ltd. | Coil for rotating electrical machine |
| US7569966B2 (en) | 2004-09-30 | 2009-08-04 | Hitachi, Ltd. | Rotating electrical machine and coil |
| JP2009268221A (en) * | 2008-04-24 | 2009-11-12 | Denso Corp | Method of manufacturing stator coil |
| US7990013B2 (en) * | 2008-06-23 | 2011-08-02 | Korea Electronics Technology Institute | Slotless motor |
| US9590479B2 (en) | 2010-03-11 | 2017-03-07 | Kabushiki Kaisha Toyota Jidoshokki | Stator for rotating electrical machine, method for manufacturing stator, and method for manufacturing coil for stator |
| CN102812620A (en) * | 2010-03-11 | 2012-12-05 | 株式会社丰田自动织机 | Stator for rotating electrical machine, method for manufacturing stator, and method for manufacturing coil for stator |
| WO2011111682A1 (en) * | 2010-03-11 | 2011-09-15 | 株式会社 豊田自動織機 | Stator for rotating electrical machine, method for manufacturing stator, and method for manufacturing coil for stator |
| JP2011188724A (en) * | 2010-03-11 | 2011-09-22 | Toyota Industries Corp | Stator for rotary electric machine, and method for manufacturing coil of the same |
| JP2011229285A (en) * | 2010-04-20 | 2011-11-10 | Toyota Industries Corp | Method for manufacturing stator of rotating electric machine and stator of rotating electric machine |
| US10666105B2 (en) | 2014-08-07 | 2020-05-26 | Valeo Electrical Systems Korea Ltd. | Wire assembly for rotary electric machine and corresponding method to obtain the wire assembly |
| WO2016021974A1 (en) * | 2014-08-07 | 2016-02-11 | Valeo Electrical Systems Korea Ltd. | Wire assembly for rotary electric machine and corresponding method to obtain the wire assembly |
| KR20160017967A (en) * | 2014-08-07 | 2016-02-17 | 발레오전장시스템스코리아 주식회사 | Wire assembly for rotary electric machine and corresponding method to obtain the wire assmebly |
| JP2017524334A (en) * | 2014-08-07 | 2017-08-24 | ヴァレオ、エレクトリカル、システムズ、コリア、リミテッドＶａｌｅｏ Ｅｌｅｃｔｒｉｃａｌ Ｓｙｓｔｅｍｓ Ｋｏｒｅａ Ｌｔｄ． | Wire assembly for rotating electrical machines and corresponding method for obtaining the wire assembly |
| KR102272772B1 (en) * | 2014-08-07 | 2021-07-02 | 발레오전장시스템스코리아 주식회사 | Wire assembly for rotary electric machine and corresponding method to obtain the wire assmebly |
| US10658897B2 (en) | 2017-04-19 | 2020-05-19 | Lg Electronics Inc. | Stator for rotary electric machine |
| WO2018194208A1 (en) * | 2017-04-19 | 2018-10-25 | 엘지전자 주식회사 | Stator of rotating electric apparatus |
| CN113454883A (en) * | 2019-02-25 | 2021-09-28 | 株式会社电装 | Armature and rotating electrical machine |
| CN113454883B (en) * | 2019-02-25 | 2023-12-22 | 株式会社电装 | Armature and rotating electrical machine |
| CN114303303A (en) * | 2019-08-29 | 2022-04-08 | 株式会社电装 | Rotating electrical machine |
| CN114303303B (en) * | 2019-08-29 | 2023-10-27 | 株式会社电装 | Rotary electric machine |
| WO2021220761A1 (en) * | 2020-04-28 | 2021-11-04 | 株式会社デンソー | Dynamo-electrical machine and method for manufacturing same |
| JP7472631B2 (en) | 2020-04-28 | 2024-04-23 | 株式会社デンソー | Rotating electric machine and manufacturing method thereof |
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