JP7036613B2 - How to manufacture the stator - Google Patents

How to manufacture the stator Download PDF

Info

Publication number
JP7036613B2
JP7036613B2 JP2018023233A JP2018023233A JP7036613B2 JP 7036613 B2 JP7036613 B2 JP 7036613B2 JP 2018023233 A JP2018023233 A JP 2018023233A JP 2018023233 A JP2018023233 A JP 2018023233A JP 7036613 B2 JP7036613 B2 JP 7036613B2
Authority
JP
Japan
Prior art keywords
leg
tip
legs
stator core
radial direction
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.)
Active
Application number
JP2018023233A
Other languages
Japanese (ja)
Other versions
JP2019140823A (en
Inventor
葉月 川村
一志 恩田
修 中川
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
Aisin Corp
Original Assignee
Aisin Seiki Co Ltd
Toyota Motor Corp
Aisin Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Aisin Seiki Co Ltd, Toyota Motor Corp, Aisin Corp filed Critical Aisin Seiki Co Ltd
Priority to JP2018023233A priority Critical patent/JP7036613B2/en
Publication of JP2019140823A publication Critical patent/JP2019140823A/en
Application granted granted Critical
Publication of JP7036613B2 publication Critical patent/JP7036613B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Landscapes

  • Windings For Motors And Generators (AREA)
  • Manufacture Of Motors, Generators (AREA)

Description

本開示は、ステータコアおよびコイルを含むステータの製造方法に関する。 The present disclosure relates to a method of manufacturing a stator including a stator core and a coil.

従来、回転電機のステータの製造方法として、ステータコアのスロットから突出する複数のセグメントコイルのリード線部を径方向に拡張させた後、リード部分をステータコアの径方向に捻り、隣り合うリード部分同士を溶接してステータコアにコイルを巻回するものが知られている（例えば、特許文献１参照）。この方法では、第１拡張工程にて、ステータコアのスロットから突出するリード部分群に軸方向から第１予備拡張ブレードを近接させ、当該リード部分群のうちの第４リード部分をスロット内に納められるスロット内導線部よりステータコアの径方向に偏心させ、第４リード部分と隣接する第５リード部分との間に第１隙間部分を形成する。次いで、第２拡張工程にて、第１拡張ブレードおよび当該第１拡張ブレードとは長さの異なる第２拡張ブレードを軸方向からリード部分群に近接させ、第１拡張ブレードによりリード部分群のうちの第３リード部分にスロット内導線部よりステータコアの径方向に偏心した第１シフト部分内側を形成すると共に、第４リード部分に第１シフト部分外側を形成する。更に、第２拡張工程では、第２拡張ブレードを第１隙間部分に挿入して、第５リード部分にスロット内導線部よりステータコアの径方向に偏心した第２シフト部分内側を形成し、第６リード部分に第２シフト部分外側を形成する。このように、第１予備拡張ブレードによって隙間部分を形成しておくことで、第２変形ブレードとセグメントコイルの先端部分との干渉リスクを抑えることができる。 Conventionally, as a method of manufacturing a stator of a rotary electric machine, after expanding the lead wire portions of a plurality of segment coils protruding from the slots of the stator core in the radial direction, the lead portions are twisted in the radial direction of the stator core, and the adjacent lead portions are connected to each other. It is known that a coil is wound around a stator core by welding (see, for example, Patent Document 1). In this method, in the first expansion step, the first preliminary expansion blade is brought close to the lead portion group protruding from the slot of the stator core from the axial direction, and the fourth lead portion of the lead portion group is housed in the slot. It is eccentric in the radial direction of the stator core from the lead wire portion in the slot, and a first gap portion is formed between the fourth lead portion and the adjacent fifth lead portion. Next, in the second expansion step, the first expansion blade and the second expansion blade having a length different from that of the first expansion blade are brought close to the lead subgroup from the axial direction, and the lead portion group is formed by the first expansion blade. The inside of the first shift portion eccentric in the radial direction of the stator core is formed in the third lead portion of the above slot, and the outside of the first shift portion is formed in the fourth lead portion. Further, in the second expansion step, the second expansion blade is inserted into the first gap portion to form the inside of the second shift portion eccentric in the radial direction of the stator core from the in-slot conducting wire portion in the fifth lead portion, and the sixth. The outside of the second shift portion is formed on the lead portion. By forming the gap portion by the first preliminary expansion blade in this way, the risk of interference between the second deformation blade and the tip portion of the segment coil can be suppressed.

特開２０１４－１０７８７７号公報Japanese Unexamined Patent Publication No. 2014-107877

上記従来の方法によりステータを製造する際には、第１予備拡張ブレードが間に挿入される第４および第５リード部分を面取り部同士が向かい合うように配置すると共に、第１拡張ブレードが間に挿入される第２および第３リード部分を面取り部同士が向かい合うように配置する必要がある。すなわち、上記方法は、リード部分の先端部に面取り部が形成されていることを前提としており、面取り部同士を背中合わせにして配置されて極めて狭い隙間を介して隣接する２つのリード部分の間に拡張ブレードを挿入して両者を径方向に拡張し得ないものである。 When manufacturing the stator by the above-mentioned conventional method, the fourth and fifth lead portions into which the first preliminary expansion blade is inserted are arranged so that the chamfered portions face each other, and the first expansion blade is interposed. It is necessary to arrange the second and third lead portions to be inserted so that the chamfered portions face each other. That is, the above method is based on the premise that a chamfered portion is formed at the tip of the lead portion, and the chamfered portions are arranged back to back and between two adjacent lead portions via an extremely narrow gap. It is not possible to expand both in the radial direction by inserting an expansion blade.

そこで、本開示は、隣接したセグメントコイルの先端部同士の隙間が極めて狭い場合であっても、ステータコアのスロットから突出した複数のセグメントコイルの脚部を当該ステータコアの径方向に拡張可能にすることを主目的とする。 Therefore, the present disclosure makes it possible to expand the legs of a plurality of segment coils protruding from the slots of the stator core in the radial direction of the stator core even when the gap between the tips of the adjacent segment coils is extremely narrow. Is the main purpose.

本開示のステータの製造方法は、それぞれ径方向に延在すると共に周方向に間隔をおいて形成された複数のスロットを含むステータコアと、互いに異なる前記スロットに差し込まれる一対の脚部を有すると共に対応する前記脚部の先端部同士の電気的接合によりステータコイルを形成する複数のセグメントコイルとを含むステータの製造方法において、
前記複数のスロットの各々から複数の前記脚部が突出するように前記複数のセグメントコイルを前記径方向に隣接させて前記ステータコアに組み付け、前記スロットから突出して前記径方向に隣接する２つの脚部に対して拡張治具を移動させ、前記拡張治具により前記径方向に隣接する２つの脚部の一方の脚部を前記先端部が他方の脚部の前記先端部から前記周方向に離間するように押圧しながら、前記他方の脚部を前記先端部が前記一方の脚部の前記先端部から前記径方向に離間するように押圧し、前記スロットから突出した前記複数の脚部を前記径方向に拡張するものである。 The method of manufacturing a stator of the present disclosure comprises a stator core including a plurality of slots each extending radially and formed at intervals in the circumferential direction, and a pair of legs inserted into the slots different from each other. In a method for manufacturing a stator including a plurality of segment coils forming a stator coil by electrically joining the tips of the legs to each other.
The plurality of segment coils are assembled to the stator core so as to project the plurality of legs from each of the plurality of slots so as to be adjacent to each other in the radial direction, and the two legs projecting from the slots and adjacent to each other in the radial direction. The expansion jig is moved with respect to the above, and the tip portion of one leg of the two legs adjacent to each other in the radial direction is separated from the tip portion of the other leg in the circumferential direction by the expansion jig. While pressing in such a manner, the other leg is pressed so that the tip thereof is radially separated from the tip of the one leg, and the plurality of legs protruding from the slot are pressed in the radial direction. It expands in the direction.

本開示のステータの製造方法は、ステータコアのスロットから突出して径方向に隣接する２つの脚部の間に拡張治具を差し込んで、当該２つの脚部をステータコアの径方向に拡張するものである。径方向に隣接する２つの脚部をステータコアの径方向に拡張する際には、当該２つの脚部に対して拡張治具を移動させ、当該拡張治具により径方向に隣接する２つの脚部の一方の脚部を先端部が他方の脚部の先端部から周方向に離間するように押圧しながら、当該他方の脚部を先端部が当該一方の脚部の先端部から径方向に離間するように押圧する。これにより、径方向に隣接する２つの脚部の先端部の間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部の間に拡張治具を差し込んでいくことができる。この結果、隣接したセグメントコイルの先端部同士の隙間が極めて狭い場合であっても、ステータコアのスロットから突出した複数のセグメントコイルの脚部を当該ステータコアの径方向に拡張することが可能となる。 In the method of manufacturing a stator of the present disclosure, an expansion jig is inserted between two legs protruding radially from a slot of the stator core, and the two legs are expanded in the radial direction of the stator core. .. When expanding two legs adjacent to each other in the radial direction in the radial direction of the stator core, the expansion jig is moved with respect to the two legs, and the two legs adjacent to each other in the radial direction are moved by the expansion jig. While pressing one leg so that the tip is circumferentially separated from the tip of the other leg, the tip of the other leg is radially separated from the tip of the other leg. Press to do. As a result, a gap is formed between the tips of the two legs adjacent to each other in the radial direction (the gap is widened), and the expansion jig can be inserted between the two legs through the formed gap. can. As a result, even when the gap between the tip portions of the adjacent segment coils is extremely narrow, the legs of the plurality of segment coils protruding from the slots of the stator core can be expanded in the radial direction of the stator core.

また、前記複数のスロットの各々から偶数個の前記脚部が突出するように前記複数のセグメントコイルを前記ステータコアに組み付けてもよく、前記偶数個の前記脚部に対して複数の前記拡張治具を２つの前記脚部ずつ順番に差し込んで、少なくとも前記スロットの両端から突出する前記脚部以外の前記脚部を前記スロット側が前記ステータコアの軸方向に対して前記径方向に傾斜すると共に前記先端部側が前記軸方向に延在するように曲げてもよく、前記スロットから突出する前記偶数個の前記脚部に対して複数の前記拡張治具を差し込んだ状態で、前記偶数個の前記脚部を前記径方向における一側から支持しながら他側から加圧し、前記スロットの両端から突出する前記脚部の少なくとも何れか一方を前記スロット側が前記軸方向に対して径方向に傾斜すると共に前記先端部側が前記軸方向に延在するように曲げてもよい。 Further, the plurality of segment coils may be assembled to the stator core so that the even number of the legs protrude from each of the plurality of slots, and the plurality of expansion jigs may be attached to the even number of the legs. The two legs are inserted in order, and at least the legs other than the legs protruding from both ends of the slot are inclined in the radial direction with respect to the axial direction of the stator core and the tip portion. The side may be bent so as to extend in the axial direction, and the even-numbered legs may be inserted into the even-numbered legs protruding from the slot with the expansion jigs inserted. While supporting from one side in the radial direction, pressure is applied from the other side, and at least one of the legs protruding from both ends of the slot is inclined in the radial direction with respect to the axial direction and the tip portion. The side may be bent so as to extend in the axial direction.

更に、前記偶数個の前記脚部を前記径方向における一側から支持しながら他側から加圧した後に、前記複数のスロットから突出した複数の前記脚部を、前記径方向に隣り合う２つの前記脚部の前記先端部がそれぞれ前記ステータコアの軸心に対して傾斜すると共に前記周方向に沿って互いに逆向きに延在するように倒してもよい。 Further, after the even number of the legs are supported from one side in the radial direction and pressed from the other side, the plurality of legs protruding from the plurality of slots are adjacent to each other in the radial direction. The tip portions of the legs may be tilted with respect to the axial center of the stator core and tilted so as to extend in opposite directions along the circumferential direction.

また、前記セグメントコイルを絶縁被膜が成膜された導電体により形成してもよく、前記先端部の前記脚部の倒し方向と反対側の表面が前記倒し方向側に傾斜するように前記先端部を加工すると共に前記先端部から前記絶縁被膜を除去してもよい。 Further, the segment coil may be formed of a conductor on which an insulating film is formed, and the tip portion thereof is inclined so that the surface of the tip portion opposite to the tilting direction of the leg portion is inclined toward the tilting direction side. And the insulating film may be removed from the tip portion.

更に、互いに対向する前記先端部同士をレーザー溶接により接合してもよい。 Further, the tip portions facing each other may be joined by laser welding.

本開示の拡張治具は、それぞれ径方向に延在すると共に周方向に間隔をおいて形成された複数のスロットを含むステータコアと、互いに異なる前記スロットに差し込まれる一対の脚部を有すると共に対応する前記脚部の先端部同士の電気的接合によりステータコイルを形成する複数のセグメントコイルとを含むステータの製造に用いられ、前記複数のスロットの各々から突出して前記径方向に隣接する２つの脚部の間に差し込まれて前記２つの脚部を前記径方向に拡張する拡張治具において、前記２つの脚部の一方の脚部を前記先端部が他方の脚部の前記先端部から前記周方向に離間するように押圧する第１押圧面と、前記第１押圧面により前記一方の脚部が押圧されるのに伴って、前記他方の脚部を前記先端部が前記一方の脚部の前記先端部から前記径方向に離間するように押圧する第２押圧面とを含むものである。 The expansion fittings of the present disclosure have and correspond to a stator core each including a plurality of slots extending radially and spaced apart in the circumferential direction, and a pair of legs inserted into said slots that are different from each other. Used in the manufacture of a stator that includes a plurality of segment coils that form a stator coil by electrically joining the tips of the legs to each other, and two legs that project from each of the plurality of slots and are adjacent to each other in the radial direction. In an expansion jig inserted between the two legs to expand the two legs in the radial direction, one leg of the two legs is provided with the tip of the other leg in the circumferential direction from the tip of the other leg. As the one leg is pressed by the first pressing surface and the first pressing surface, the tip of the other leg is the same as the one leg. It includes a second pressing surface that presses the tip portion so as to be separated from the tip portion in the radial direction.

本開示の拡張治具は、複数のスロットの各々から突出して径方向に隣接する２つの脚部の間に差し込まれて当該２つの脚部を径方向に拡張するものであり、第１および第２押圧面を含む。第１押圧面は、ステータコアの径方向に隣接する２つの脚部の一方の脚部を先端部が他方の脚部の先端部から周方向に離間するように押圧する。また、第２押圧面は、第１押圧面により当該一方の脚部が押圧されるのに伴って、当該他方の脚部を先端部が一方の脚部の先端部から径方向に離間するように押圧する。すなわち、本開示の拡張治具をステータコアのスロットから突出して径方向に隣接する２つの脚部に対して移動させていくと、当該２つの脚部の一方の脚部は、拡張治具の第１押圧面により先端部が他方の脚部の先端部から周方向に離間するように押圧され、第１押圧面により一方の脚部が押圧されるのに伴って、当該他方の脚部は、拡張治具の第２押圧面により先端部が当該一方の脚部の先端部から径方向に離間するように押圧される。これにより、径方向に隣接する２つの脚部の先端部の間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部の間に治具を差し込んでいくことができる。この結果、隣接したセグメントコイルの先端部同士の隙間が極めて狭い場合であっても、ステータコアのスロットから突出した複数のセグメントコイルの脚部を当該ステータコアの径方向に拡張することが可能となる。 The expansion jig of the present disclosure protrudes from each of the plurality of slots and is inserted between two legs adjacent to each other in the radial direction to expand the two legs in the radial direction. 2 Includes pressing surface. The first pressing surface presses one leg of two legs adjacent to each other in the radial direction of the stator core so that the tip thereof is separated from the tip of the other leg in the circumferential direction. Further, in the second pressing surface, as the one leg is pressed by the first pressing surface, the tip of the other leg is radially separated from the tip of the one leg. Press on. That is, when the expansion jig of the present disclosure protrudes from the slot of the stator core and is moved with respect to two legs adjacent to each other in the radial direction, one leg of the two legs becomes the first leg of the expansion jig. As the tip is pressed by the pressing surface so as to be separated from the tip of the other leg in the circumferential direction, and one leg is pressed by the first pressing surface, the other leg is pressed. The tip portion is pressed by the second pressing surface of the expansion jig so as to be radially separated from the tip portion of the one leg portion. As a result, a gap can be formed between the tips of the two legs adjacent to each other in the radial direction (the gap is widened), and the jig can be inserted between the two legs through the formed gap. .. As a result, even when the gap between the tip portions of the adjacent segment coils is extremely narrow, the legs of the plurality of segment coils protruding from the slots of the stator core can be expanded in the radial direction of the stator core.

また、前記拡張治具は、前記ステータコアの軸方向に延在するように形成された平坦な第１底面と、前記第１底面よりも前記周方向に深い位置で前記軸方向に延在するように形成された平坦な第２底面と、前記軸方向に延在すると共に前記第１底面と前記第２底面との間で前記周方向に突出するように形成された壁部とを含んでもよく、前記第１押圧面は、前記壁部よりも治具先端側で前記第１底面に連続すると共に前記壁部側から前記治具先端側に向かうにつれて前記周方向において前記第２底面に近接するように傾斜する傾斜面であってもよく、前記第２押圧面は、前記壁部の前記第２底面側の側面に連続して前記第１底面および前記第１押圧面に沿って前記治具先端側に延在すると共に前記治具先端側から前記壁部側に向かうにつれて前記径方向において前記第２底面の前記壁部とは反対側の側縁部に近接するように傾斜する傾斜面であってもよい。これにより、例えば脚部の先端部の面取り部の省略により隣接した脚部の先端部同士の隙間が実質的に無くなっているような場合であっても、拡張治具により上記一方の脚部を先端部が上記他方の脚部の先端部から周方向に離間するように押圧しながら、他方の脚部を先端部が一方の脚部の先端部から径方向に離間するように押圧することが可能となる。 Further, the expansion jig has a flat first bottom surface formed so as to extend in the axial direction of the stator core, and extends in the axial direction at a position deeper in the circumferential direction than the first bottom surface. It may include a flat second bottom surface formed in the above, and a wall portion extending in the axial direction and formed so as to project in the circumferential direction between the first bottom surface and the second bottom surface. The first pressing surface is continuous with the first bottom surface on the jig tip side of the wall portion and approaches the second bottom surface in the circumferential direction from the wall portion side toward the jig tip side. The second pressing surface may be an inclined surface that is inclined in such a manner, and the second pressing surface is continuous with the side surface of the wall portion on the second bottom surface side, and the jig is along the first bottom surface and the first pressing surface. An inclined surface that extends toward the tip side and inclines so as to approach the side edge portion of the second bottom surface opposite to the wall portion in the radial direction as it extends from the jig tip side toward the wall portion side. There may be. As a result, even if the gap between the tips of adjacent legs is substantially eliminated due to the omission of the chamfered portion at the tip of the leg, for example, the expansion jig can be used to hold the one leg. While pressing the tip so as to be circumferentially separated from the tip of the other leg, the other leg may be pressed so that the tip is radially separated from the tip of one leg. It will be possible.

更に、前記壁部の前記第２底面側の前記側面と前記第２押圧面との連続部には、前記第２押圧面により押圧された前記脚部を前記スロット側が前記軸方向に対して前記径方向に傾斜すると共に前記先端部側が前記軸方向に延在するように曲げるための成形面が形成されてもよい。 Further, in the continuous portion between the side surface of the wall portion on the second bottom surface side and the second pressing surface, the leg portion pressed by the second pressing surface is provided on the slot side with respect to the axial direction. A molded surface may be formed so as to be inclined in the radial direction and bent so that the tip end side extends in the axial direction.

また、前記拡張治具は、前記スロットの前記径方向における一端側に配置された２つの前記脚部の間に差し込まれる第１拡張治具と、前記一端側に配置された前記２つの前記脚部よりも前記径方向における他端側に配置された２つの前記脚部の間に差し込まれる第２拡張治具とを含んでもよく、前記第２拡張治具は、前記壁部と間隔おいて対向するように前記第１底面の側縁部に沿って延在する第２の壁部を含んでもよく、前記壁部の前記第２底面側の前記側面と前記第２押圧面との連続部には、前記脚部を前記スロット側が前記軸方向に対して前記径方向に傾斜すると共に前記先端部側が前記軸方向に延在するように曲げるための成形面が形成されてもよく、前記第２の壁部の前記治具先端側の端部には、前記壁部と反対側で隣り合う前記第１または前記第２拡張治具の前記第２押圧面により押圧された前記脚部を前記スロット側が前記軸方向に対して前記径方向に傾斜すると共に前記先端部側が前記軸方向に延在するように曲げるための成形面が形成されてもよい。これにより、ステータコアのスロットから突出する偶数個の脚部に対して第１および第２拡張治具を２つの脚部ずつ順番に差し込んでいくことで、少なくともスロットの両端から突出する脚部以外の脚部をスロット側がステータコアの軸方向に対して径方向に傾斜すると共に先端部側が軸方向に延在するように曲げていくことが可能となる。 Further, the expansion jig includes a first expansion jig inserted between the two legs arranged on one end side of the slot in the radial direction, and the two legs arranged on the one end side. A second expansion jig inserted between the two legs arranged on the other end side in the radial direction of the portion may be included, and the second expansion jig may be spaced apart from the wall portion. A second wall portion extending along the side edge portion of the first bottom surface may be included so as to face each other, and a continuous portion between the side surface of the wall portion on the second bottom surface side and the second pressing surface. May be formed with a molding surface for bending the leg portion so that the slot side is inclined in the radial direction with respect to the axial direction and the tip portion side extends in the axial direction. At the end of the wall portion on the tip end side of the jig, the leg portion pressed by the second pressing surface of the first or second expansion jig adjacent to the wall portion on the opposite side is described. A molded surface may be formed so that the slot side is inclined in the radial direction with respect to the axial direction and the tip end side is bent so as to extend in the axial direction. As a result, the first and second expansion jigs are inserted into the even number of legs protruding from the slots of the stator core in order for each of the two legs, so that at least the legs other than the legs protruding from both ends of the slot are inserted. It is possible to bend the leg portion so that the slot side is inclined in the radial direction with respect to the axial direction of the stator core and the tip portion side extends in the axial direction.

更に、前記複数のスロットから突出した複数の前記脚部は、前記径方向に隣り合う２つの前記脚部の前記先端部がそれぞれ前記ステータコアの軸心に対して傾斜すると共に前記周方向に沿って互いに逆向きに延在するように倒されてもよく、前記先端部の前記脚部の倒し方向と反対側の表面は、前記倒し方向側に傾斜するように形成されてもよく、前記対応する前記脚部の前記先端部同士は、レーザー溶接部を介して接合されてもよい。 Further, in the plurality of legs protruding from the plurality of slots, the tips of the two legs adjacent to each other in the radial direction are inclined with respect to the axial center of the stator core and along the circumferential direction. It may be tilted so as to extend in opposite directions to each other, and the surface of the tip portion opposite to the tilting direction of the leg may be formed so as to be inclined toward the tilting direction. The tips of the legs may be joined to each other via a laser welded portion.

本開示の方法により製造されるステータを含む回転電機を示す概略構成図である。It is a schematic block diagram which shows the rotary electric machine including the stator manufactured by the method of this disclosure. 図１の回転電機を示す平面図である。It is a top view which shows the rotary electric machine of FIG. 本開示の方法により製造されるステータのステータコイルを示す模式図である。It is a schematic diagram which shows the stator coil of the stator manufactured by the method of this disclosure. 本開示の方法により製造されるステータにおけるセグメントコイルの先端部同士の接合部を示す要部拡大図である。It is an enlarged view of the main part which shows the joint part between the tip parts of the segment coil in the stator manufactured by the method of this disclosure. 本開示の方法により製造されるステータにおけるセグメントコイルの先端部同士の接合部を示す要部拡大図である。It is an enlarged view of the main part which shows the joint part between the tip parts of the segment coil in the stator manufactured by the method of this disclosure. 本開示の方法を説明するためのフローチャートである。It is a flowchart for demonstrating the method of this disclosure. 本開示の拡張治具を含む拡張装置を示す概略構成図である。It is a schematic block diagram which shows the expansion apparatus including the expansion jig of this disclosure. 本開示の拡張治具の要部を示す平面図である。It is a top view which shows the main part of the expansion jig of this disclosure. 第１拡張治具の要部を示す拡大斜視図である。It is an enlarged perspective view which shows the main part of the 1st expansion jig. 第２拡張治具の要部を示す拡大斜視図である。It is an enlarged perspective view which shows the main part of the 2nd expansion jig. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure. 本開示の方法を説明するための説明図である。It is explanatory drawing for demonstrating the method of this disclosure.

次に、図面を参照しながら本開示の発明を実施するための形態について説明する。 Next, a mode for carrying out the invention of the present disclosure will be described with reference to the drawings.

図１は、本開示の方法により製造されるステータ１を含む回転電機を示す概略構成図であり、図２は、回転電機Ｍを示す平面図である。これらの図面に示す回転電機Ｍは、例えば電気自動車やハイブリッド車両の走行駆動源あるいは発電機として用いられる三相交流電動機である。図示するように、回転電機Ｍは、ステータ１と、エアギャップを介してステータ１内に回転自在に配置されるロータ１０とを含む FIG. 1 is a schematic configuration diagram showing a rotary electric machine including a stator 1 manufactured by the method of the present disclosure, and FIG. 2 is a plan view showing a rotary electric machine M. The rotary electric machine M shown in these drawings is a three-phase AC electric motor used as a traveling drive source or a generator of, for example, an electric vehicle or a hybrid vehicle. As shown in the figure, the rotary electric machine M includes a stator 1 and a rotor 10 rotatably arranged in the stator 1 via an air gap.

ステータ１は、ステータコア２および複数のステータコイル３ｕ，３ｖ，３ｗを含む。ステータコア２は、例えばプレス加工により円環状に形成された電磁鋼板２ｐ（図２参照）を複数積層することにより形成され、全体として円環状を呈する。また、ステータコア２は、環状の外周部（ヨーク）から周方向に間隔をおいて径方向内側に突出する複数のティース部２ｔと、それぞれ互いに隣り合うティース部２ｔの間に形成された複数のスロット２ｓ（何れも図２参照）とを含む。複数のスロット２ｓは、それぞれステータコア２の径方向に延在すると共に一定の間隔をおいて周方向に並び、各スロット２ｓ内には、図示しないインシュレータ（絶縁紙）が配置される。なお、ステータコア２は、例えば強磁性粉体を加圧成形すると共に焼結させることより一体に形成されてもよい。 The stator 1 includes a stator core 2 and a plurality of stator coils 3u, 3v, 3w. The stator core 2 is formed by, for example, laminating a plurality of electromagnetic steel sheets 2p (see FIG. 2) formed in an annular shape by press working, and exhibits an annular shape as a whole. Further, the stator core 2 has a plurality of slots formed between a plurality of teeth portions 2t protruding inward in the radial direction at intervals in the circumferential direction from an annular outer peripheral portion (yoke) and a plurality of teeth portions 2t adjacent to each other. Includes 2s (both see FIG. 2). The plurality of slots 2s extend in the radial direction of the stator core 2 and are arranged in the circumferential direction at regular intervals, and an insulator (insulating paper) (not shown) is arranged in each slot 2s. The stator core 2 may be integrally formed, for example, by pressure-molding and sintering ferromagnetic powder.

ステータコイル３ｕ，３ｖ，３ｗは、図３に示すように、シングルスター結線（１Ｙ結線）により結線される。本実施形態において、Ｕ相のステータコイル３ｕは、第１コイルＵ１および第２コイルＵ２を含む。同様に、Ｖ相のステータコイル３ｖは、第１コイルＶ１および第２コイルＶ２を含み、Ｗ相のステータコイル３ｗは、第１コイルＷ１および第２コイルＷ２を含む。また、各第１コイルＵ１，Ｖ１，Ｗ１は、それぞれ引出線Ｌｕ，ＬｖまたはＬｗを含み、各第２コイルＵ２，Ｖ２，Ｗ２は、それぞれ中性線Ｎを含む。 As shown in FIG. 3, the stator coils 3u, 3v, and 3w are connected by a single star connection (1Y connection). In the present embodiment, the U-phase stator coil 3u includes a first coil U1 and a second coil U2. Similarly, the V-phase stator coil 3v includes the first coil V1 and the second coil V2, and the W-phase stator coil 3w includes the first coil W1 and the second coil W2. Further, each of the first coils U1, V1 and W1 includes a leader line Lu, Lv or Lw, and each of the second coils U2, V2 and W2 contains a neutral line N, respectively.

各ステータコイル３ｕ，３ｖ，３ｗは、ステータコア２の複数のスロット２ｓに差し込まれる複数のセグメントコイル４を電気的に接合することにより形成される。セグメントコイル４は、例えばエナメル樹脂等からなる絶縁被膜が表面に成膜された平角線（導電体）を略Ｕ字状に曲げ加工することにより形成され、それぞれ絶縁被膜が除去された先端部Ｔを有する一対の脚部４０（何れも図１参照）を有する。各セグメントコイル４の一対の脚部４０は、それぞれステータコア２の互いに異なるスロット２ｓに挿通され、各脚部４０のステータコア２の一端面（図１における上端面）から突出した部分には、図示しない倒し加工装置を用いた倒し加工が施される。倒し加工により、各セグメントコイル４の先端部Ｔは、対応する他のセグメントコイル４の先端部Ｔに径方向に隣接し、両先端部Ｔは、レーザー溶接により電気的に接合される。すなわち、図４に示すように、径方向内側に位置する脚部４０の先端部Ｔの外側面Ｔｓｏと、径方向外側に位置する脚部４０の先端部Ｔの内側面Ｔｓｉとは、レーザー溶接部ＷＬを介して互いに接合される。 Each of the stator coils 3u, 3v, 3w is formed by electrically joining a plurality of segment coils 4 inserted into a plurality of slots 2s of the stator core 2. The segment coil 4 is formed by bending a flat wire (conductor) having an insulating film made of, for example, enamel resin on the surface into a substantially U shape, and the tip portion T from which the insulating film has been removed. Has a pair of legs 40 (both see FIG. 1). The pair of leg portions 40 of each segment coil 4 are inserted into different slots 2s of the stator core 2, and are not shown in a portion of each leg portion 40 protruding from one end surface (upper end surface in FIG. 1) of the stator core 2. Flipping processing is performed using a tilting processing device. By the tilting process, the tip portion T of each segment coil 4 is radially adjacent to the tip portion T of the corresponding other segment coil 4, and both tip portions T are electrically joined by laser welding. That is, as shown in FIG. 4, the outer surface Tso of the tip portion T of the leg portion 40 located radially inside and the inner surface Tsi of the tip portion T of the leg portion 40 located radially outside are laser welded. They are joined to each other via a portion WL.

より詳細には、複数のセグメントコイル４は、脚部４０（平角線）の長辺側の側面（フラットワイズ面）が互いに当接するように重ね合わされた状態で複数のスロット２ｓの各々から同数かつ偶数個（例えば、６－１０個、本実施形態では６個）の脚部４０が突出するようにステータコア２に組み付けられる。また、各スロット２ｓから突出した複数の脚部４０は、ステータコア２の径方向に拡張される。更に、ステータコア２の軸心側から奇数番目（奇数層上）の脚部４０は、ステータコア２の軸心周りに捻られながら周方向における一側に倒され、偶数番目（偶数層上）の脚部４０は、ステータコア２の軸心周りに捻られながら周方向における他側に倒される。これにより、径方向に隣り合う任意の２つの脚部４０の先端部Ｔは、それぞれステータコア２の軸心に対して傾斜すると共に周方向に沿って互いに逆向きに延在する。更に、互いに接合されるべき２つの脚部４０の先端部Ｔ同士がステータコア２の径方向に隣り合う More specifically, the plurality of segment coils 4 are the same number from each of the plurality of slots 2s in a state where the side surfaces (flatwise surfaces) on the long side of the leg portion 40 (flat wire) are overlapped so as to be in contact with each other. An even number of legs (for example, 6-10, 6 in this embodiment) are assembled to the stator core 2 so as to project. Further, the plurality of legs 40 protruding from each slot 2s are expanded in the radial direction of the stator core 2. Further, the odd-numbered (on the odd-numbered layer) leg 40 from the axial center side of the stator core 2 is tilted to one side in the circumferential direction while being twisted around the axial center of the stator core 2, and the even-numbered (on the even-numbered layer) leg. The portion 40 is tilted to the other side in the circumferential direction while being twisted around the axis of the stator core 2. As a result, the tip portions T of any two leg portions 40 adjacent to each other in the radial direction are inclined with respect to the axial center of the stator core 2 and extend in opposite directions along the circumferential direction. Further, the tip portions T of the two leg portions 40 to be joined to each other are adjacent to each other in the radial direction of the stator core 2.

そして、ｍ個（ただし、“ｍ”は、第１および第２コイルＵ１－Ｗ２の総数である。）おきのスロット２ｓから突出する脚部４０の対応する先端部Ｔ同士をレーザー溶接により接合することで、ステータコア２に対して、ステータコイル３ｕ，３ｖ，３ｗの第１および第２コイルＵ１－Ｗ２が巻回される。すなわち、ステータ１では、（ｉ＋（ｊ－１）・ｍ）番目（ただし、ｉ＝１，…，ｍであり，ｊ＝１，…，総スロット数／ｍである。）のスロット２ｓから突出する脚部４０の先端部同士の電気的接合によりｍ個のコイルＵ１－Ｗ２がステータコア２に巻回される。 Then, the corresponding tip portions T of the legs 40 protruding from the slots 2s every m (where "m" is the total number of the first and second coils U1-W2) are joined to each other by laser welding. As a result, the first and second coils U1-W2 of the stator coils 3u, 3v, 3w are wound around the stator core 2. That is, in the stator 1, it protrudes from the (i + (j-1) · m) th slot 2s (where i = 1, ..., m, j = 1, ..., Total number of slots / m). M coils U1-W2 are wound around the stator core 2 by electrical bonding between the tips of the legs 40.

本実施形態において、ステータコイル３ｕの第１および第２コイルＵ１，Ｕ２は、ステータコア２に対して互いに１スロットだけ周方向にずらして巻回される。また、第１コイルＵ１の一端側の脚部４０は、引出線Ｌｕとして利用され、第２コイルＵ２の一端側の脚部４０は、中性線Ｎとして利用される。更に、第１コイルＵ１の引出線Ｌｕとは反対側の端部を形成する脚部４０の先端部Ｔと、第２コイルＵ２の中性線Ｎとは反対側の端部を形成する脚部４０の先端部Ｔとが接合され、それにより、ステータコイル３ｕがステータコア２に分布巻きされる。 In the present embodiment, the first and second coils U1 and U2 of the stator coil 3u are wound around the stator core 2 by shifting each other by one slot in the circumferential direction. Further, the leg portion 40 on one end side of the first coil U1 is used as a leader line Lu, and the leg portion 40 on one end side of the second coil U2 is used as a neutral wire N. Further, the tip portion T of the leg portion 40 forming the end portion opposite to the leader line Lu of the first coil U1 and the leg portion forming the end portion opposite to the neutral wire N of the second coil U2. The tip portion T of 40 is joined, whereby the stator coil 3u is distributedly wound around the stator core 2.

ステータコイル３ｖの第１コイルＶ１は、ステータコイル３ｕの第２コイルＵ２に対して第１コイルＵ１とは反対側に１スロットだけ周方向にずらして巻回される。また、ステータコイル３ｖの第２コイルＶ２は、第１コイルＶ１に対してステータコイル３ｕの第２コイルＵ２とは反対側に１スロットだけ周方向にずらして巻回される。第１コイルＶ１の一端側の脚部４０は、引出線Ｌｖとして利用され、第２コイルＶ２の一端側の脚部４０は、中性線Ｎとして利用される。更に、第１コイルＶ１の引出線Ｌｖとは反対側の端部を形成する脚部４０の先端部Ｔと、第２コイルＶ２の中性線Ｎとは反対側の端部を形成する脚部４０の先端部Ｔとが接合され、それにより、ステータコイル３ｖがステータコア２に分布巻きされる。 The first coil V1 of the stator coil 3v is wound around the second coil U2 of the stator coil 3u on the opposite side of the first coil U1 by shifting it by one slot in the circumferential direction. Further, the second coil V2 of the stator coil 3v is wound around the first coil V1 on the opposite side of the second coil U2 of the stator coil 3u by shifting it by one slot in the circumferential direction. The leg 40 on one end side of the first coil V1 is used as a leader line Lv, and the leg 40 on one end side of the second coil V2 is used as a neutral wire N. Further, the tip portion T of the leg portion 40 forming the end portion opposite to the leader line Lv of the first coil V1 and the leg portion forming the end portion opposite to the neutral wire N of the second coil V2. The tip portion T of 40 is joined, whereby the stator coil 3v is distributedly wound around the stator core 2.

ステータコイル３ｗの第１コイルＷ１は、ステータコイル３ｖの第２コイルＶ２に対して第１コイルＶ１とは反対側に１スロットだけ周方向にずらして巻回される。また、ステータコイル３ｗの第２コイルＷ２は、第１コイルＷ１に対してステータコイル３ｖの第２コイルＶ２とは反対側に１スロットだけ周方向にずらして巻回される。第１コイルＷ１の一端側の脚部４０は、引出線Ｌｗとして利用され、第２コイルＷ２の一端側の脚部４０は、中性線Ｎとして利用される。更に、第１コイルＷ１の引出線Ｌｗとは反対側の端部を形成する脚部４０の先端部Ｔと、第２コイルＷ２の中性線Ｎとは反対側の端部を形成する脚部４０の先端部Ｔとが接合され、それにより、ステータコイル３ｗがステータコア２に分布巻きされる。 The first coil W1 of the stator coil 3w is wound around the second coil V2 of the stator coil 3v on the opposite side of the first coil V1 by shifting it by one slot in the circumferential direction. Further, the second coil W2 of the stator coil 3w is wound around the first coil W1 on the opposite side of the second coil V2 of the stator coil 3v by shifting it by one slot in the circumferential direction. The leg 40 on one end side of the first coil W1 is used as a leader line Lw, and the leg 40 on one end side of the second coil W2 is used as a neutral wire N. Further, the tip portion T of the leg portion 40 forming the end portion on the side opposite to the leader line Lw of the first coil W1 and the leg portion forming the end portion on the side opposite to the neutral wire N of the second coil W2. The tip portion T of 40 is joined, whereby the stator coil 3w is distributedly wound around the stator core 2.

ステータコイル３ｕの引出線Ｌｕは、図２に示すように、Ｕ相の端子６ｕに電気的に接合された動力線５ｕの先端部に溶接により電気的に接合される。また、ステータコイル３ｖの引出線Ｌｖは、Ｖ相の端子６ｖに電気的に接合された動力線５ｖの先端部に溶接により電気的に接合される。更に、ステータコイル３ｗの引出線Ｌｗは、Ｗ相の端子６ｗに電気的に接合された動力線５ｗの先端部に溶接により電気的に接合される。なお、動力線５ｕ，５ｖ，５ｗは、それぞれ樹脂製の保持部材７に固定される。端子６ｕ－６ｗは、回転電機Ｍのハウジングにステータ１が組み付けられた際に当該ハウジングに設置（固定）された図示しない端子台に固定され、図示しない電力線を介してインバータ（図示省略）に接続される。 As shown in FIG. 2, the leader line Lu of the stator coil 3u is electrically connected to the tip of the power line 5u electrically connected to the U-phase terminal 6u by welding. Further, the leader wire Lv of the stator coil 3v is electrically joined to the tip of the power line 5v electrically joined to the terminal 6v of the V phase by welding. Further, the leader wire Lw of the stator coil 3w is electrically joined to the tip of the power line 5w electrically joined to the terminal 6w of the W phase by welding. The power lines 5u, 5v, and 5w are fixed to the resin holding member 7, respectively. The terminals 6u-6w are fixed to a terminal block (not shown) installed (fixed) in the housing of the rotary electric machine M when the stator 1 is assembled, and are connected to an inverter (not shown) via a power line (not shown). Will be done.

上述のようにしてステータコア２に巻回される複数のステータコイル３ｕ，３ｖ，３ｗにおいて、多数の先端部Ｔ同士の接合部は、所定数ずつ径方向に並んでステータコア２の軸方向における図１中上側の端面から外側に突出する環状のコイルエンド部３ａを形成する。図１および図５に示すように、複数のスロット２ｓから突出した複数の脚部４０は、径方向に隣り合う２つの脚部４０の先端部Ｔがそれぞれステータコア２の軸心（図中、一点鎖線参照）に対して傾斜すると共に周方向に沿って互いに逆向きに延在するように倒されている。従って、ステータ１では、セグメントコイル４の先端部Ｔ同士の接合部を多数含むコイルエンド部３ａの軸長を大幅に短縮化することができる。 In the plurality of stator coils 3u, 3v, 3w wound around the stator core 2 as described above, a predetermined number of joints of the tip portions T are arranged in the radial direction in FIG. 1 in the axial direction of the stator core 2. An annular coil end portion 3a projecting outward from the upper middle end face is formed. As shown in FIGS. 1 and 5, in the plurality of leg portions 40 protruding from the plurality of slots 2s, the tip portions T of the two leg portions 40 adjacent to each other in the radial direction are the axial centers of the stator core 2 (one point in the drawing). It is tilted with respect to the chain line) and tilted so that it extends in opposite directions along the circumferential direction. Therefore, in the stator 1, the axial length of the coil end portion 3a including a large number of joints between the tip portions T of the segment coil 4 can be significantly shortened.

また、本実施形態において、各脚部４０の先端部Ｔは、セグメントコイル４のステータコア２への組み付けに先立って、打ち抜き加工により先細かつ短辺側の側面が凸曲面状に延在するように形成されている（図５参照）。すなわち、各先端部Ｔの脚部４０の倒し方向と反対側の表面は、当該倒し方向側に傾斜するように形成されている。これにより、コイルエンド部３ａの軸長をより一層短縮化することが可能となる。加えて、各先端部Ｔの倒し方向と反対側の表面を曲面状に形成することで、先端部Ｔ同士の接合面積を充分に確保しつつ、コイルエンド部３ａをよりフラットにすることが可能となる。なお、先端部Ｔの絶縁被膜は、上記打ち抜き加工後に例えばレーザー照射により剥離される。そして、セグメントコイル４において、先端部Ｔの周縁部への面取り加工は省略されている。これにより、セグメントコイル４ひいてはステータ１および回転電機Ｍの製造コストの増加を抑制することが可能となる。 Further, in the present embodiment, the tip portion T of each leg portion 40 is tapered so that the side surface on the short side extends in a convex curved surface shape by punching before assembling the segment coil 4 to the stator core 2. It is formed (see FIG. 5). That is, the surface of the leg portion 40 of each tip portion T on the side opposite to the tilting direction is formed so as to be inclined toward the tilting direction side. This makes it possible to further shorten the axial length of the coil end portion 3a. In addition, by forming the surface of each tip T on the side opposite to the tilting direction into a curved surface, it is possible to make the coil end 3a flatter while ensuring a sufficient joint area between the tip Ts. It becomes. The insulating film of the tip portion T is peeled off by, for example, laser irradiation after the punching process. Further, in the segment coil 4, the chamfering process to the peripheral edge portion of the tip portion T is omitted. This makes it possible to suppress an increase in the manufacturing cost of the segment coil 4, the stator 1, and the rotary electric machine M.

また、ステータコア２には、図１中上側のコイルエンド部３ａ側から図１中下側のコイルエンド部３ｂ側に向けてワニス等の樹脂が塗布される。これにより、当該樹脂により各セグメントコイル４や図示しないインシュレータがステータコア２に固定される。また、本実施形態のステータ１は、コイルエンド部３ａを覆う環状のモールド部８を含む。モールド部８は、樹脂により形成されており、当該樹脂が隣り合うセグメントコイル４同士の隙間に入り込むことで、先端部Ｔ同士の接合部や、引出線Ｌｕ－Ｌｗと動力線５ｕ－５ｗとの接合部といった導電体の露出部が良好に絶縁される。ただし、セグメントコイル４の先端部Ｔ同士の接合部といった導電体の露出部には、絶縁用の粉体が塗布されてもよい。 Further, the stator core 2 is coated with a resin such as varnish from the coil end portion 3a side on the upper side in FIG. 1 toward the coil end portion 3b side on the lower side in FIG. As a result, each segment coil 4 and an insulator (not shown) are fixed to the stator core 2 by the resin. Further, the stator 1 of the present embodiment includes an annular mold portion 8 that covers the coil end portion 3a. The mold portion 8 is formed of a resin, and when the resin enters the gap between the adjacent segment coils 4, the joint portion between the tip portions T and the leader line Lu-Lw and the power line 5u-5w can be connected to each other. Exposed parts of the conductor, such as joints, are well insulated. However, insulating powder may be applied to the exposed portion of the conductor such as the joint portion between the tip portions T of the segment coil 4.

図２に示すように、回転電機Ｍのロータ１０は、図示しない回転シャフトに固定されるロータコア１１と、複数（本実施形態では、例えば８極）の磁極を構成するようにロータコア１１に埋設される複数（本実施形態では、例えば１６個）の永久磁石１５とを含む、いわゆる埋込磁石型（ＩＰＭ型）のロータである。ロータ１０のロータコア１１は、電磁鋼板等により環状に形成されたコアプレートを複数積層することにより形成されており、上記回転シャフトが挿入・固定される中心孔１２と、それぞれ永久磁石１５を保持するように形成された長孔状の孔部である複数の磁石埋設孔１４とを含む。複数の磁石埋設孔１４は、それぞれロータコア１１を軸方向に貫通するように、２つずつ所定間隔をおいて当該ロータコア１１に配設される。対をなす２つの磁石埋設孔１４は、ロータ１０の軸心側から外周側に向かうにつれて互いに離間するように（略Ｖ字状をなすように）形成される。永久磁石１５は、例えばネオジム磁石等の希土類焼結磁石等であり、略直方体状に形成されている。対をなす２つの永久磁石１５は、ロータ１０の外周側に位置する極が互いに同一となるように対応する磁石埋設孔１４に挿入・固定される。これにより、対をなす２つの永久磁石１５は、ロータ１０の軸心側から外周側に向かうにつれて互いに離間するようにロータコア１１に配設されて当該ロータ１０の１つの磁極を形成する。 As shown in FIG. 2, the rotor 10 of the rotary electric machine M is embedded in the rotor core 11 so as to form a rotor core 11 fixed to a rotary shaft (not shown) and a plurality of (for example, 8 poles in this embodiment) magnetic poles. It is a so-called embedded magnet type (IPM type) rotor including a plurality of (for example, 16 in this embodiment) permanent magnets 15. The rotor core 11 of the rotor 10 is formed by laminating a plurality of core plates formed in an annular shape by an electromagnetic steel plate or the like, and holds a central hole 12 into which the rotary shaft is inserted and fixed, and a permanent magnet 15, respectively. It includes a plurality of magnet-embedded holes 14 which are elongated hole portions formed as described above. The plurality of magnet embedding holes 14 are arranged in the rotor core 11 at predetermined intervals of two so as to penetrate the rotor core 11 in the axial direction. The two paired magnet embedding holes 14 are formed so as to be separated from each other (so as to form a substantially V shape) from the axial center side to the outer peripheral side of the rotor 10. The permanent magnet 15 is, for example, a rare earth sintered magnet such as a neodymium magnet, and is formed in a substantially rectangular parallelepiped shape. The two paired permanent magnets 15 are inserted and fixed in the corresponding magnet embedding holes 14 so that the poles located on the outer peripheral side of the rotor 10 are identical to each other. As a result, the two paired permanent magnets 15 are arranged on the rotor core 11 so as to be separated from each other from the axial center side to the outer peripheral side of the rotor 10 to form one magnetic pole of the rotor 10.

図６は、回転電機Ｍのステータ１の製造手順を示すフローチャートである。同図に示すように、ステータ１の製造工程は、セグメントコイル組付工程（Ｓ１０）と、脚部拡張工程（Ｓ２０）と、脚部倒し工程（Ｓ３０）と、レーザー溶接工程（Ｓ４０）と、コイル固定工程（Ｓ５０）と、樹脂モールド形成工程（Ｓ６０）とを含む。 FIG. 6 is a flowchart showing a manufacturing procedure of the stator 1 of the rotary electric machine M. As shown in the figure, the manufacturing process of the stator 1 includes a segment coil assembly process (S10), a leg expansion process (S20), a leg tilting process (S30), and a laser welding process (S40). The coil fixing step (S50) and the resin mold forming step (S60) are included.

セグメントコイル組付工程（Ｓ１０）は、長辺側の側面（フラットワイズ面）同士が互いに当接するようにステータコア２の径方向に隣り合わせにした複数のセグメントコイル４を複数のスロット２ｓの各々から同数かつ偶数個（本実施形態では、６個）の脚部４０が突出するようにステータコア２に組み付ける工程である。脚部拡張工程（Ｓ２０）は、ステータコア２に対する先端部Ｔの位置が脚部倒し工程の実施時に要求される位置になるように各スロット２ｓから突出した複数の脚部４０をステータコア２の径方向に拡張する工程である。脚部倒し工程（Ｓ３０）は、図示しない倒し加工装置を用いて、例えばステータコア２の軸心側から奇数番目（奇数層上）の脚部４０をステータコア２の軸心周りに捻りながら周方向における一側に倒すと共に、偶数番目（偶数層上）の脚部４０をステータコア２の軸心周りに捻りながら周方向における他側に倒す工程である。レーザー溶接工程（Ｓ４０）は、互いに対応する脚部４０の先端部Ｔ同士をレーザー溶接により接合したり、引出線Ｌｕ－Ｌｗと動力線５ｕ－５ｗとをレーザー溶接により接合したりする工程である。コイル固定工程（Ｓ５０）は、ワニス等の樹脂を用いて複数のセグメントコイル４等をステータコア２に固定する工程である。樹脂モールド形成工程（Ｓ６０）は、複数のステータコイル３ｕ，３ｖ，３ｗのコイルエンド部３ａを覆う環状のモールド部８を形成する工程である。 In the segment coil assembling step (S10), a plurality of segment coils 4 arranged adjacent to each other in the radial direction of the stator core 2 so that the side surfaces (flatwise surfaces) on the long side abut against each other are equal in number from each of the plurality of slots 2s. In addition, it is a step of assembling to the stator core 2 so that an even number (6 in this embodiment) of the legs 40 project. In the leg expansion step (S20), a plurality of legs 40 protruding from each slot 2s are provided in the radial direction of the stator core 2 so that the position of the tip T with respect to the stator core 2 is the position required at the time of performing the leg tilting step. It is a process to expand to. In the leg tilting step (S30), for example, the leg portion 40 at the odd number (on the odd-numbered layer) from the axial center side of the stator core 2 is twisted around the axial center of the stator core 2 in the circumferential direction by using a tilting processing device (not shown). This is a step of tilting to one side and tilting the even-numbered (on the even-numbered layer) leg 40 to the other side in the circumferential direction while twisting around the axis of the stator core 2. The laser welding step (S40) is a step of joining the tip portions T of the corresponding leg portions 40 by laser welding, or joining the leader line Lu-Lw and the power line 5u-5w by laser welding. .. The coil fixing step (S50) is a step of fixing a plurality of segment coils 4 and the like to the stator core 2 using a resin such as varnish. The resin mold forming step (S60) is a step of forming an annular mold portion 8 that covers the coil end portions 3a of the plurality of stator coils 3u, 3v, 3w.

図７は、図６のＳ２０における脚部拡張工程にて用いられる拡張装置５０を示す斜視図である。図示するように、拡張装置５０は、本開示の拡張治具である内側拡張治具（第１拡張治具）５１、中間拡張治具（第２拡張治具）５２および外側拡張治具（第２拡張治具）５３、拡張治具５１－５３を移動させる移動機構５４、複数のセグメントコイル４が組み付けられたステータコア２を支持する回転テーブル５５、円環状の内側支持部材５６、フォーク部材５７、加圧部材５８および制御装置５９を含む。 FIG. 7 is a perspective view showing an expansion device 50 used in the leg expansion step in S20 of FIG. As shown in the figure, the expansion device 50 includes an inner expansion jig (first expansion jig) 51, an intermediate expansion jig (second expansion jig) 52, and an outer expansion jig (first expansion jig), which are the expansion jigs of the present disclosure. 2 expansion jig) 53, a moving mechanism 54 for moving the expansion jig 51-53, a rotary table 55 for supporting the stator core 2 to which a plurality of segment coils 4 are assembled, an annular inner support member 56, a fork member 57, The pressurizing member 58 and the control device 59 are included.

内側拡張冶具５１は、図７に示すように、移動機構５４に連結される基端部５１ａと、当該基端部５１ａから延出された細幅の加工部５１０とを含む。加工部５１０は、平坦な背面を有すると共に、図８および図９に示すように、平坦な第１底面５１１、平坦な第２底面５１２、壁部（仕切壁）５１３、第１押圧面５１４、第２押圧面５１５、成形面５１６および５１７を含む。第１底面５１１は、ステータコア２の軸方向に延在するように加工部５１０に形成されている。第２底面５１２は、第１底面５１１よりもステータコア２の周方向に沿った深い位置（図８および図９における紙面奥側）で当該軸方向に延在するように加工部５１０に形成されている。第１および第２底面５１１，５１２は、それぞれ加工部５１０の背面と平行に延在する。また、第１および第２底面５１１，５１２の幅は、セグメントコイル４の脚部４０（平角線）の短辺幅よりも若干短く定められる。壁部５１３は、ステータコア２の軸方向に延在すると共に第１底面５１１と第２底面５１２との間で両者に直交してステータコア２の周方向に突出するように加工部５１０に形成されている。 As shown in FIG. 7, the inner expansion jig 51 includes a base end portion 51a connected to the moving mechanism 54 and a narrow processing portion 510 extending from the base end portion 51a. The machined portion 510 has a flat back surface, and as shown in FIGS. 8 and 9, a flat first bottom surface 511, a flat second bottom surface 512, a wall portion (partition wall) 513, and a first pressing surface 514. Includes a second pressing surface 515, molded surfaces 516 and 517. The first bottom surface 511 is formed in the machined portion 510 so as to extend in the axial direction of the stator core 2. The second bottom surface 512 is formed in the machined portion 510 so as to extend in the axial direction at a position deeper along the circumferential direction of the stator core 2 (the back side of the paper surface in FIGS. 8 and 9) than the first bottom surface 511. There is. The first and second bottom surfaces 511, 512 extend in parallel with the back surface of the machined portion 510, respectively. Further, the widths of the first and second bottom surfaces 511, 512 are set to be slightly shorter than the short side width of the leg portion 40 (flat wire) of the segment coil 4. The wall portion 513 extends in the axial direction of the stator core 2 and is formed in the machined portion 510 so as to project between the first bottom surface 511 and the second bottom surface 512 orthogonal to both in the circumferential direction of the stator core 2. There is.

第１押圧面５１４は、加工部５１０の先端（図８および図９における下端、以下、「治具先端」という）側に形成されており、壁部５１３よりも治具先端側で第１底面５１１に連続する例えば平坦な傾斜面である。図９に示すように、第１押圧面５１４は、壁部５１３側から治具先端側に向かうにつれてステータコア２の周方向において第２底面５１２に近接するように（図８および図９における紙面奥側に）傾斜する。第２押圧面５１５は、壁部５１３の第２底面５１２側の側面５１３ｓに連続して第１底面５１１の一部および第１押圧面５１４に沿って治具先端側に延在する例えば平坦な傾斜面である。図８および図９に示すように、第２押圧面５１５は、治具先端側から壁部５１３側に向かうにつれてステータコア２の径方向において第２底面５１２の壁部５１３とは反対側の側縁部（図８における右側の側縁部）に近接するように傾斜する。なお、第１および第２押圧面５１４，５１５は、凸曲面状の傾斜面であってもよい。 The first pressing surface 514 is formed on the tip end side (lower end in FIGS. 8 and 9, hereinafter referred to as “jig tip”) of the machined portion 510, and the first bottom surface is closer to the jig tip side than the wall portion 513. For example, a flat inclined surface continuous with 511. As shown in FIG. 9, the first pressing surface 514 is closer to the second bottom surface 512 in the circumferential direction of the stator core 2 from the wall portion 513 side toward the jig tip side (the depth of the paper surface in FIGS. 8 and 9). Tilt to the side). The second pressing surface 515 is continuous with the side surface 513s on the second bottom surface 512 side of the wall portion 513 and extends to a part of the first bottom surface 511 and the jig tip side along the first pressing surface 514, for example, flat. It is an inclined surface. As shown in FIGS. 8 and 9, the second pressing surface 515 has a side edge opposite to the wall portion 513 of the second bottom surface 512 in the radial direction of the stator core 2 from the jig tip side toward the wall portion 513 side. It is inclined so as to be close to the portion (the right side edge portion in FIG. 8). The first and second pressing surfaces 514 and 515 may be inclined surfaces having a convex curved surface.

成形面５１６および５１７は、壁部５１３の治具先端側の端部に形成されている。成形面５１６は、壁部５１３の側面５１３ｓと第２押圧面５１５との連続部に形成された凸曲面であり、側面５１３ｓと第２押圧面５１５との双方に滑らかに連続する。成形面５１７は、壁部５１３の第１底面５１１側の側面に滑らかに連続する凸曲面であり、本実施形態では、壁部５１３の軸心に関して成形面５１６の概ね反対側に位置する。また、壁部５１３の治具先端の端面は、成形面５１６および５１７に滑らかに連続する凸曲面状に形成されている。 The molding surfaces 516 and 517 are formed at the end portion of the wall portion 513 on the jig tip side. The molded surface 516 is a convex curved surface formed on a continuous portion between the side surface 513s of the wall portion 513 and the second pressing surface 515, and is smoothly continuous with both the side surface 513s and the second pressing surface 515. The molded surface 517 is a convex curved surface that smoothly continues to the side surface of the wall portion 513 on the first bottom surface 511 side, and in the present embodiment, is located substantially opposite to the molded surface 516 with respect to the axial center of the wall portion 513. Further, the end surface of the tip of the jig of the wall portion 513 is formed in a convex curved surface shape that is smoothly continuous with the molding surfaces 516 and 517.

中間拡張冶具５２は、図７に示すように、移動機構５４に連結される基端部５２ａと、当該基端部５２ａから延出された細幅の加工部５２０とを含む。加工部５２０は、平坦な背面を有すると共に、図８および図１０に示すように、平坦な第１底面５２１、平坦な第２底面５２２、壁部（仕切壁）５２３、第１押圧面５２４、第２押圧面５２５、および成形面５２６を含む。第１底面５２１は、ステータコア２の軸方向に延在するように加工部５２０に形成されている。第２底面５２２は、第１底面５２１よりもステータコア２の周方向に沿った深い位置（図８および図１０における紙面奥側）で当該軸方向に延在するように加工部５１０に形成されている。第１および第２底面５２１，５２２は、それぞれ加工部５２０の背面と平行に延在する。また、第２底面５２２の幅は、セグメントコイル４の脚部４０（平角線）の短辺幅よりも若干短く定められる。壁部５２３は、ステータコア２の軸方向に延在すると共に第１底面５２１と第２底面５２２との間で両者に直交してステータコア２の周方向に突出するように加工部５２０に形成されている。 As shown in FIG. 7, the intermediate expansion jig 52 includes a base end portion 52a connected to the moving mechanism 54 and a narrow processing portion 520 extending from the base end portion 52a. The machined portion 520 has a flat back surface, and as shown in FIGS. 8 and 10, a flat first bottom surface 521, a flat second bottom surface 522, a wall portion (partition wall) 523, and a first pressing surface 524. Includes a second pressing surface 525 and a molded surface 526. The first bottom surface 521 is formed in the machined portion 520 so as to extend in the axial direction of the stator core 2. The second bottom surface 522 is formed in the machined portion 510 so as to extend in the axial direction at a position deeper along the circumferential direction of the stator core 2 (the back side of the paper surface in FIGS. 8 and 10) than the first bottom surface 521. There is. The first and second bottom surfaces 521 and 522 extend parallel to the back surface of the machined portion 520, respectively. Further, the width of the second bottom surface 522 is set to be slightly shorter than the short side width of the leg portion 40 (flat wire) of the segment coil 4. The wall portion 523 is formed in the machined portion 520 so as to extend in the axial direction of the stator core 2 and project between the first bottom surface 521 and the second bottom surface 522 in the circumferential direction of the stator core 2 at right angles to both. There is.

第１押圧面５２４は、加工部５２０の治具先端側に形成されており、壁部５２３よりも治具先端側で第１底面５２１に連続する例えば平坦な傾斜面である。図９に示すように、第１押圧面５２４は、壁部５２３側から治具先端側に向かうにつれてステータコア２の周方向において第２底面５２２に近接するように（図８および図１０における紙面奥側に）傾斜する。第２押圧面５２５は、壁部５２３の第２底面５２２側の側面５２３ｓに連続して第１押圧面５２４に沿って治具先端側に延在する例えば平坦な傾斜面である。図８および図１０に示すように、第２押圧面５２５は、治具先端側から壁部５２３側に向かうにつれてステータコア２の径方向において第２底面５２２の壁部５２３とは反対側の側縁部（図８における右側の側縁部）に近接するように傾斜する。なお、第１および第２押圧面５２４，５２５は、凸曲面状の傾斜面であってもよい。成形面５２６は、壁部５２３の治具先端側の端部に形成されている。成形面５２６は、壁部５２３の第２底面５２２側の側面５２３ｓと第２押圧面５２５との連続部に形成された凸曲面であり、側面５２３ｓと第２押圧面５２５との双方に滑らかに連続する。 The first pressing surface 524 is formed on the jig tip side of the machined portion 520, and is, for example, a flat inclined surface continuous with the first bottom surface 521 on the jig tip side of the wall portion 523. As shown in FIG. 9, the first pressing surface 524 is closer to the second bottom surface 522 in the circumferential direction of the stator core 2 from the wall portion 523 side toward the jig tip side (the depth of the paper surface in FIGS. 8 and 10). Tilt to the side). The second pressing surface 525 is, for example, a flat inclined surface extending toward the tip of the jig continuously along the first pressing surface 524 on the side surface 523s on the second bottom surface 522 side of the wall portion 523. As shown in FIGS. 8 and 10, the second pressing surface 525 has a side edge opposite to the wall portion 523 of the second bottom surface 522 in the radial direction of the stator core 2 from the jig tip side toward the wall portion 523 side. It is inclined so as to be close to the portion (the right side edge portion in FIG. 8). The first and second pressing surfaces 524 and 525 may be inclined surfaces having a convex curved surface. The molding surface 526 is formed at the end portion of the wall portion 523 on the jig tip side. The molded surface 526 is a convex curved surface formed on a continuous portion between the side surface 523s on the second bottom surface 522 side of the wall portion 523 and the second pressing surface 525, and is smoothly formed on both the side surface 523s and the second pressing surface 525. Continuous.

更に、中間拡張治具５２は、図８および図１０に示すように、ステータコア２の軸方向に延在するように形成された第２の壁部５２８を含む。第２の壁部５２８は、壁部５２３と間隔おいて対向するように第１底面５２１の側縁部（図８における左側の側縁部）に沿って当該壁部５２３と平行に延在する。壁部５２３と第２の壁部５２８との間隔（互いに対向する側面同士の間隔）は、セグメントコイル４の脚部４０（平角線）の短辺幅よりも若干長く定められる。また、壁部５２３の治具先端側の端部には、成形面５２９が形成されている。成形面５２９は、第２の壁部５２８の壁部５２３側の側面に滑らかに連続する凸曲面である。また、壁部５２３の治具先端の端面は、成形面５２９に滑らかに連続する凸曲面状に形成されている。 Further, the intermediate expansion jig 52 includes a second wall portion 528 formed so as to extend in the axial direction of the stator core 2, as shown in FIGS. 8 and 10. The second wall portion 528 extends parallel to the wall portion 523 along the side edge portion (left side edge portion in FIG. 8) of the first bottom surface 521 so as to face the wall portion 523 at a distance. .. The distance between the wall portion 523 and the second wall portion 528 (distance between the side surfaces facing each other) is set to be slightly longer than the short side width of the leg portion 40 (flat line) of the segment coil 4. Further, a molding surface 529 is formed at the end of the wall portion 523 on the jig tip side. The molded surface 529 is a convex curved surface that is smoothly continuous with the side surface of the second wall portion 528 on the wall portion 523 side. Further, the end surface of the tip of the jig of the wall portion 523 is formed in a convex curved surface shape that is smoothly continuous with the molding surface 529.

外側拡張治具５３は、各部の寸法を除いて、上記中間拡張治具５２と共通の構造を有するものである。図７に示すように、外側拡張治具５３は、基端部５３ａおよび加工部５３０を含む。そして、加工部５３０には、図８に示すように、上記第１底面５２１と同一構造を有する第１底面５３１、上記第２底面５２２と同一構造を有する第２底面５３２、上記壁部５２３と同一構造を有する壁部（仕切壁）５３３、上記第１押圧面５２４と同一構造を有する第１押圧面５３４、上記第２押圧面５２５と同一構造を有する第２押圧面５３５、上記成形面５２６と同一構造を有する成形面５３６、上記第２の壁部５２８と同一構造を有する第２の壁部５３８、および上記成形面５２９と同一構造を有する成形面５３９が形成されている。外側拡張治具５３においても、第２底面５３２の幅は、セグメントコイル４の脚部４０（平角線）の短辺幅よりも若干短く定められる。また、壁部５３３と第２の壁部５３８との間隔（互いに対向する側面同士の間隔）は、セグメントコイル４の脚部４０（平角線）の短辺幅よりも若干長く定められる。 The outer expansion jig 53 has a structure common to that of the intermediate expansion jig 52, except for the dimensions of each part. As shown in FIG. 7, the outer expansion jig 53 includes a base end portion 53a and a machined portion 530. Then, as shown in FIG. 8, the processed portion 530 includes a first bottom surface 531 having the same structure as the first bottom surface 521, a second bottom surface 532 having the same structure as the second bottom surface 522, and the wall portion 523. A wall portion (partition wall) 533 having the same structure, a first pressing surface 534 having the same structure as the first pressing surface 524, a second pressing surface 535 having the same structure as the second pressing surface 525, and the molding surface 526. A molding surface 536 having the same structure as the above, a second wall portion 538 having the same structure as the second wall portion 528, and a molding surface 539 having the same structure as the molding surface 529 are formed. Also in the outer expansion jig 53, the width of the second bottom surface 532 is set to be slightly shorter than the short side width of the leg portion 40 (flat wire) of the segment coil 4. Further, the distance between the wall portion 533 and the second wall portion 538 (distance between the side surfaces facing each other) is set to be slightly longer than the short side width of the leg portion 40 (flat line) of the segment coil 4.

そして、上記第１押圧面５１４，５２４，５３４の傾斜角度、第２押圧面５１５，５２５，５３５の傾斜角度、成形面５１６，５１７，５２６，５２９，５３６，５３９の曲率、壁部５１３，５２３，５３３，５２８，５３９の厚みや端部の形状等は、ステータコア２のスロット２ｓから突出した全脚部４０の先端部Ｔの脚部倒し工程の実施時に要求される位置に応じて脚部４０のスプリングバックを考慮して定められる。更に、壁部５１３，５２３，５３３の第１底面５１１，５２１，５３１からの高さ、壁部５１３，５２３，５３３および第２の壁部５２８，５３８の第２底面５１２，５２２，５３２からの高さは、スロット２ｓの周方向における間隔や全脚部４０の先端部Ｔの脚部倒し工程の実施時に要求される位置等に応じてセグメントコイル４の脚部４０（平角線）の短辺幅よりも高く定められる。 Then, the inclination angle of the first pressing surface 514, 524, 534, the inclination angle of the second pressing surface 515, 525, 535, the curvature of the molded surface 516, 517, 526, 529, 536, 539, and the wall portion 513, 523. , 533, 528, 539, the thickness, the shape of the end, etc., depend on the position required at the time of performing the leg tilting step of the tip T of all the legs 40 protruding from the slot 2s of the stator core 2. It is determined in consideration of the springback of. Further, the height of the wall portions 513,523,533 from the first bottom surface 511,521,531 and the heights of the wall portions 513,523,533 and the second wall portions 528,538 from the second bottom surface 521,522,532. The height is the short side of the leg portion 40 (flat wire) of the segment coil 4 according to the spacing in the circumferential direction of the slot 2s and the position required at the time of performing the leg portion tilting step of the tip portion T of the entire leg portion 40. It is set higher than the width.

図７および図８に示すように、拡張治具５１－５３は、ステータコア２の軸心側から加工部５１０，５２０，５３０という順番で並ぶと共に加工部５１０，５２０，５３０の背面同士が隣り合うように移動機構５４にそれぞれ連結される。また、拡張治具５１－５３は、内側拡張治具５１の壁部５１３（側面５１３ｓ）と中間拡張治具５２の第２の壁部５２８（内側拡張治具５１側の側面）との間隔、および中間拡張治具５２の壁部５２３（側面５２３ｓ）と外側拡張治具５３の第２の壁部５３８（中間拡張治具５２側の側面）との間隔がセグメントコイル４の脚部４０（平角線）の短辺幅よりも若干長い間隔となるように並べられる。 As shown in FIGS. 7 and 8, the expansion jigs 51-53 are arranged in the order of the machined portions 510, 520, 530 from the axial center side of the stator core 2, and the back surfaces of the machined portions 510, 520, 530 are adjacent to each other. It is connected to each of the moving mechanisms 54 as described above. Further, the expansion jig 51-53 has a distance between the wall portion 513 (side surface 513s) of the inner expansion jig 51 and the second wall portion 528 (side surface on the inner expansion jig 51 side) of the intermediate expansion jig 52. The distance between the wall portion 523 (side surface 523s) of the intermediate expansion jig 52 and the second wall portion 538 (side surface on the intermediate expansion jig 52 side) of the outer expansion jig 53 is the leg portion 40 (flat angle) of the segment coil 4. Lines) are arranged so that they are slightly longer than the short side width.

移動機構５４は、内側拡張治具５１、中間拡張治具５２および外側拡張治具５３をそれぞれ独立にステータコア２の軸方向に進退移動させるものである。移動機構５４は、拡張治具５１－５３が回転テーブル５５上のステータコア２の径方向に沿って並ぶように当該回転テーブル５５の上方に設置される。移動機構５４は、下方に位置するスロット２ｓから突出した偶数個の脚部４０に対して、各拡張治具５１，－５３を対応する脚部４０に曲げ荷重を付与するように個別に高速で下降（移動）させることができる。 The moving mechanism 54 moves the inner expansion jig 51, the intermediate expansion jig 52, and the outer expansion jig 53 independently in the axial direction of the stator core 2. The moving mechanism 54 is installed above the rotary table 55 so that the expansion jigs 51-53 are arranged along the radial direction of the stator core 2 on the rotary table 55. The moving mechanism 54 individually applies a bending load to the corresponding leg portions 40 of the expansion jigs 51 and −53 with respect to the even number of leg portions 40 protruding from the slot 2s located below at high speed. It can be lowered (moved).

回転テーブル５５は、ステータコア２を軸心周りに回転させる図示しない回転駆動機構を含む。内側支持部材５６は、回転テーブル５５上のステータコア２の中心孔部内に配置される。内側支持部材５６の外周面は、円柱面状に形成されており、当該外周面は、ステータコア２の各スロット２ｓの最内層側から突出する脚部４０の内側面（長辺側の側面）と対向する。フォーク部材５７は、ステータコア２の端面近傍で拡張治具５１－５３の下方に位置するスロット２ｓから突出した偶数個の脚部４０をステータコア２の周方向における両側および径方向外側から支持可能なものである。フォーク部材５７は、フォーク駆動装置５７０によりステータコア２の径方向に進退移動させられる。フォーク駆動装置５７０は、フォーク部材５７をスロット２ｓから突出した偶数個の脚部４０をステータコア２の軸心に向けて加圧した状態に保持可能である。 The rotary table 55 includes a rotation drive mechanism (not shown) that rotates the stator core 2 around the axis. The inner support member 56 is arranged in the central hole portion of the stator core 2 on the rotary table 55. The outer peripheral surface of the inner support member 56 is formed in a cylindrical surface shape, and the outer peripheral surface is the inner surface (long side side surface) of the leg portion 40 protruding from the innermost layer side of each slot 2s of the stator core 2. opposite. The fork member 57 can support an even number of legs 40 protruding from the slots 2s located below the expansion jig 51-53 near the end surface of the stator core 2 from both sides in the circumferential direction and from the radial outside of the stator core 2. Is. The fork member 57 is moved back and forth in the radial direction of the stator core 2 by the fork drive device 570. The fork drive device 570 can hold the fork member 57 in a state where the even number of legs 40 protruding from the slot 2s is pressurized toward the axial center of the stator core 2.

加圧部材５８は、拡張治具５１－５３の下方に位置するスロット２ｓの最外層側から突出する脚部４０の外側面（長辺側の側面）と対向するように配置され、加圧装置５８０によりステータコア２の径方向に進退移動させられる。加圧装置５８０は、最外層側の脚部４０をステータコア２の軸心に向けて加圧する状態に加圧部材５８を保持可能である。制御装置５９は、ＣＰＵ，ＲＯＭ，ＲＡＭ等を有するコンピュータや各種駆動回路等を含み、上述の移動機構５４、回転テーブル５５、フォーク駆動装置５７０および加圧装置５８０を制御する。 The pressurizing member 58 is arranged so as to face the outer surface (side surface on the long side) of the leg portion 40 protruding from the outermost layer side of the slot 2s located below the expansion jig 51-53, and is arranged so as to face the pressurizing device. The stator core 2 is moved forward and backward in the radial direction by the 580. The pressurizing device 580 can hold the pressurizing member 58 in a state where the leg portion 40 on the outermost layer side is pressurized toward the axial center of the stator core 2. The control device 59 includes a computer having a CPU, ROM, RAM, etc., various drive circuits, and the like, and controls the above-mentioned moving mechanism 54, rotary table 55, fork drive device 570, and pressurizing device 580.

続いて、上述の拡張装置５０を用いて複数のスロット２ｓから突出した複数の脚部４０をステータコア２の径方向に拡張する脚部拡張工程（Ｓ３０）について詳細に説明する。 Subsequently, a leg expansion step (S30) for expanding the plurality of legs 40 protruding from the plurality of slots 2s in the radial direction of the stator core 2 by using the expansion device 50 described above will be described in detail.

脚部拡張工程の開始に際しては、図１１に示すように、対象となるスロット２ｓから突出する偶数個（本実施形態では、６個）の脚部４０が初期位置で整列した拡張治具５１－５３の下方に位置するようにステータコア２を位置決めし、内側拡張治具５１の壁部５１３の端部（図中下側の端部）と、スロット２ｓの最内層側で径方向に隣接する２つの脚部４０の先端部Ｔ同士の隙間とを対向させる。ここでは、図示するように、１つのスロット２ｓから突出する偶数個の脚部４０をステータコア２の軸心側から順番に脚部４１，４２，４３，４４，４５，４６といい、適宜、脚部４１－４６を総称して脚部４０という。また、ステータコア２の中心孔部内には、内側支持部材５６が配置される。更に、フォーク駆動装置５７０によりフォーク部材５７を内側支持部材５６に向けて移動させ、フォーク部材５７にスロット２ｓから突出した偶数個の脚部４０（４１－４６）をステータコア２の周方向における両側および径方向外側から支持させる。 At the start of the leg expansion process, as shown in FIG. 11, the expansion jig 51-in which an even number (6 in this embodiment) of legs 40 protruding from the target slot 2s are aligned at the initial position. The stator core 2 is positioned so as to be located below the 53, and is radially adjacent to the end of the wall portion 513 of the inner expansion jig 51 (lower end in the figure) and the innermost layer side of the slot 2s. The gaps between the tip portions T of the two leg portions 40 are opposed to each other. Here, as shown in the figure, the even number of legs 40 protruding from one slot 2s are referred to as legs 41, 42, 43, 44, 45, 46 in order from the axial center side of the stator core 2, and the legs are appropriately referred to. The parts 41-46 are collectively called the leg part 40. Further, an inner support member 56 is arranged in the central hole portion of the stator core 2. Further, the fork member 57 is moved toward the inner support member 56 by the fork drive device 570, and an even number of legs 40 (41-46) protruding from the slot 2s are provided on both sides of the stator core 2 in the circumferential direction and on the fork member 57. Support from the outside in the radial direction.

次いで、移動機構５４により内側拡張治具５１を最内層側の２つの脚部４１，４２に対して下降（移動）させる。内側拡張治具５１が下降すると、図１２に示すように、上述のような傾斜面である内側拡張治具５１の第１押圧面５１４が壁部５１３の端部よりも先に最内層側の脚部４１の先端部Ｔの側面（短辺側の側面）に当接する。この際、本実施形態において、内側拡張治具５１の第１押圧面５１４は、脚部倒し工程での脚部４１の倒し方向（図１２における右側）と反対側の先端部Ｔの表面に当接する。これにより、最内層側の脚部４１は、図１３に示すように、下降する内側拡張治具５１の第１押圧面５１４によりステータコア２の周方向における一側（図中右側、脚部倒し工程での脚部４１の倒し側）に押圧され、脚部４１の先端部Ｔと、それに隣り合う脚部４２の先端部Ｔとは、ステータコア２の周方向に離間する。また、第１押圧面５１４により最内層側の脚部４１が押圧されるのに伴って、脚部４２は、内側拡張治具５１の第２押圧面５１５により先端部Ｔが最内層側の脚部４１の先端部Ｔから径方向に離間するように押圧される。この結果、面取り部の省略により隣接した脚部４１，４２の先端部Ｔ同士の隙間が実質的に無くなっていたとしても、径方向に隣接する２つの脚部４１，４２の先端部Ｔの間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部４１，４２の間に内側拡張治具５１の壁部５１３を差し込んでいくことができる。 Next, the inner expansion jig 51 is lowered (moved) with respect to the two legs 41, 42 on the innermost layer side by the moving mechanism 54. When the inner expansion jig 51 is lowered, as shown in FIG. 12, the first pressing surface 514 of the inner expansion jig 51, which is an inclined surface as described above, is on the innermost layer side before the end portion of the wall portion 513. It abuts on the side surface (side surface on the short side side) of the tip portion T of the leg portion 41. At this time, in the present embodiment, the first pressing surface 514 of the inner expansion jig 51 hits the surface of the tip portion T on the side opposite to the tilting direction (right side in FIG. 12) of the leg portion 41 in the leg portion tilting step. Contact. As a result, as shown in FIG. 13, the leg 41 on the innermost layer side is on one side in the circumferential direction of the stator core 2 by the first pressing surface 514 of the descending inner expansion jig 51 (right side in the figure, leg tilting step). The tip portion T of the leg portion 41 and the tip portion T of the leg portion 42 adjacent thereto are separated from each other in the circumferential direction of the stator core 2. Further, as the leg 41 on the innermost layer side is pressed by the first pressing surface 514, the leg portion 42 has a leg whose tip portion T is on the innermost layer side by the second pressing surface 515 of the inner expansion jig 51. It is pressed so as to be radially separated from the tip portion T of the portion 41. As a result, even if the gap between the tip portions T of the adjacent leg portions 41 and 42 is substantially eliminated due to the omission of the chamfered portion, the space between the tip portions T of the two leg portions 41 and 42 adjacent in the radial direction is substantially eliminated. A gap can be formed (widen the gap), and the wall portion 513 of the inner expansion jig 51 can be inserted between the two legs 41 and 42 from the formed gap.

図１４に示すように、内側拡張冶具５１の下降（移動）は、脚部４１，４２の間に壁部５１３が所定長さだけ差し込まれた段階で移動機構５４により停止させられる。脚部４１，４２の間に内側拡張冶具５１の壁部５１３が差し込まれることで、最内層側の脚部４１の先端部Ｔ側の部分は、内側拡張冶具５１の成形面５１７により径方向内側すなわち内側支持部材５６側に押圧され、内側支持部材５６と壁部５１３とにより挟み付けられる。これにより、脚部４１は、スロット２ｓ側が軸方向に対して径方向内側に傾斜すると共に先端部Ｔ側が軸方向に延在するように、成形面５１７を起点にして僅かに曲げられる（塑性変形する）。また、脚部４１に隣接する脚部４２は、内側拡張治具５１の第２押圧面５１５や成形面５１６により、先端部Ｔがステータコア２の外周側に移動するように径方向外側に押圧されて傾斜する。更に、脚部４３－４６も、脚部４２により先端部Ｔがステータコア２の外周側に移動するように径方向外側に押圧されて傾斜する。 As shown in FIG. 14, the lowering (movement) of the inner expansion jig 51 is stopped by the moving mechanism 54 when the wall portion 513 is inserted between the legs 41 and 42 by a predetermined length. By inserting the wall portion 513 of the inner expansion jig 51 between the legs 41 and 42, the portion on the tip T side of the leg 41 on the innermost layer side is radially inside by the molding surface 517 of the inner expansion jig 51. That is, it is pressed toward the inner support member 56 side and is sandwiched between the inner support member 56 and the wall portion 513. As a result, the leg portion 41 is slightly bent from the molding surface 517 so that the slot 2s side is inclined inward in the radial direction with respect to the axial direction and the tip portion T side extends in the axial direction (plastic deformation). do). Further, the leg portion 42 adjacent to the leg portion 41 is pressed outward in the radial direction by the second pressing surface 515 and the molding surface 516 of the inner expansion jig 51 so that the tip portion T moves toward the outer peripheral side of the stator core 2. Tilt. Further, the leg portions 43-46 are also tilted by being pressed outward in the radial direction so that the tip portion T is moved toward the outer peripheral side of the stator core 2 by the leg portion 42.

更に、図１５に示すように、移動機構５４により中間拡張治具５２を中央の２つの脚部４３，４４に対して下降（移動）させる。中間拡張治具５２が下降すると、上述のような傾斜面である中間拡張治具５２の第１押圧面５２４が壁部５２３の端部よりも先に内層側の脚部４３の先端部Ｔの側面（短辺側の側面）に当接する（図１２参照）。これにより、内層側の脚部４３は、下降する中間拡張治具５２の第１押圧面５２４によりステータコア２の周方向における一側（脚部倒し工程での脚部４３の倒し側）に押圧され、脚部４３の先端部Ｔと、それに隣り合う脚部４４の先端部Ｔとは、ステータコア２の周方向に離間する（図１３参照）。また、第１押圧面５２４により内層側の脚部４３が押圧されるのに伴って、脚部４４は、中間拡張治具５２の第２押圧面５２５により先端部Ｔが内層側の脚部４３の先端部Ｔから径方向に離間するように押圧される。この結果、面取り部の省略により隣接した脚部４３，４４の先端部Ｔ同士の隙間が実質的に無くなっていたとしても、径方向に隣接する２つの脚部４３，４４の先端部Ｔの間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部４３，４４の間に中間拡張治具５２の壁部５２３を差し込んでいくことができる。 Further, as shown in FIG. 15, the moving mechanism 54 lowers (moves) the intermediate expansion jig 52 with respect to the two central legs 43 and 44. When the intermediate expansion jig 52 is lowered, the first pressing surface 524 of the intermediate expansion jig 52, which is an inclined surface as described above, is formed on the tip portion T of the leg portion 43 on the inner layer side before the end portion of the wall portion 523. It abuts on the side surface (side surface on the short side) (see FIG. 12). As a result, the leg portion 43 on the inner layer side is pressed by the first pressing surface 524 of the descending intermediate expansion jig 52 to one side in the circumferential direction of the stator core 2 (the tilting side of the leg portion 43 in the leg tilting process). , The tip portion T of the leg portion 43 and the tip portion T of the leg portion 44 adjacent thereto are separated from each other in the circumferential direction of the stator core 2 (see FIG. 13). Further, as the leg portion 43 on the inner layer side is pressed by the first pressing surface 524, the leg portion 44 has the tip portion T of the leg portion 43 on the inner layer side by the second pressing surface 525 of the intermediate expansion jig 52. It is pressed so as to be radially separated from the tip portion T of the. As a result, even if the gap between the tip portions T of the adjacent leg portions 43 and 44 is substantially eliminated due to the omission of the chamfered portion, the space between the tip portions T of the two leg portions 43 and 44 adjacent in the radial direction is substantially eliminated. A gap can be formed in the space (widen the gap), and the wall portion 523 of the intermediate expansion jig 52 can be inserted between the two legs 43 and 44 from the formed gap.

図１５に示すように、中間拡張冶具５２の下降（移動）は、脚部４３，４４の間に壁部５１３が比較的短い長さだけ差し込まれた段階で移動機構５４により一旦停止させられる。また、脚部４３，４４の間に中間拡張冶具５２の壁部５２３が差し込まれるのに伴い、内側拡張治具５１の第２押圧面５１５や成形面５１６により押圧された脚部４２と、当該脚部４２に径方向外側で隣り合う脚部４３との間には、中間拡張治具５２の第２の壁部５２８が差し込まれる。脚部４２，４３の間に第２の壁部５２８が差し込まれると、脚部４２の先端部Ｔ側の部分は、内側拡張冶具５１の成形面５１６により径方向外側すなわち第２の壁部５２８側に押圧された状態で、内側拡張治具５１の壁部５１３と中間拡張冶具５２の第２の壁部５２８とにより挟み付けられる。 As shown in FIG. 15, the descent (movement) of the intermediate expansion jig 52 is temporarily stopped by the moving mechanism 54 when the wall portion 513 is inserted between the legs 43 and 44 by a relatively short length. Further, as the wall portion 523 of the intermediate expansion jig 52 is inserted between the leg portions 43 and 44, the leg portion 42 pressed by the second pressing surface 515 and the molding surface 516 of the inner expansion jig 51 and the relevant portion 42. A second wall portion 528 of the intermediate expansion jig 52 is inserted between the leg portion 43 and the leg portion 43 adjacent to the leg portion 42 on the outer side in the radial direction. When the second wall portion 528 is inserted between the legs 42 and 43, the portion of the leg 42 on the tip T side is radially outward due to the molding surface 516 of the inner expansion jig 51, that is, the second wall portion 528. While pressed to the side, it is sandwiched between the wall portion 513 of the inner expansion jig 51 and the second wall portion 528 of the intermediate expansion jig 52.

これにより、脚部４２は、スロット２ｓ側が軸方向に対して径方向外側に傾斜すると共に先端部Ｔ側が軸方向に延在するように、成形面５１６を起点にして僅かに曲げられる（塑性変形する）。また、外層側の脚部４３の先端部Ｔは、中間拡張冶具５２の壁部５２３と第２の壁部５２８とにより挟み込まれる。更に、脚部４３に径方向外側で隣接する脚部４４は、中間拡張治具５２の第２押圧面５２５や成形面５２６により、先端部Ｔがステータコア２の外周側に移動するように径方向外側に押圧されて傾斜する。加えて、脚部４５－４６も、脚部４４により先端部Ｔがステータコア２の外周側に移動するように径方向外側に押圧されて傾斜する。 As a result, the leg portion 42 is slightly bent from the molding surface 516 so that the slot 2s side is inclined outward in the radial direction with respect to the axial direction and the tip portion T side extends in the axial direction (plastic deformation). do). Further, the tip portion T of the leg portion 43 on the outer layer side is sandwiched between the wall portion 523 and the second wall portion 528 of the intermediate expansion jig 52. Further, the leg portion 44 adjacent to the leg portion 43 on the radial outer side is radially outward so that the tip portion T is moved to the outer peripheral side of the stator core 2 by the second pressing surface 525 and the molding surface 526 of the intermediate expansion jig 52. It is pressed outward and tilts. In addition, the legs 45-46 are also tilted by being pressed outward in the radial direction so that the tip T is moved toward the outer peripheral side of the stator core 2 by the legs 44.

中間拡張冶具５２の移動を一旦停止させた後、移動機構５４により外側拡張治具５３を最外層側の２つの脚部４５，４６に対して下降（移動）させる。外側拡張治具５３が下降すると、上述のような傾斜面である外側拡張治具５３の第１押圧面５３４が壁部５３３の端部よりも先に内層側の脚部４５の先端部Ｔの側面（短辺側の側面）に当接する（図１２参照）。これにより、内層側の脚部４５は、下降する外側拡張治具５３の第１押圧面５３４によりステータコア２の周方向における一側（脚部倒し工程での脚部４５の倒し側）に押圧され、脚部４５の先端部Ｔと、それに隣り合う脚部４６の先端部Ｔとは、ステータコア２の周方向に離間する（図１３参照）。また、第１押圧面５３４により内層側の脚部４５が押圧されるのに伴って、脚部４６は、外側拡張治具５３の第２押圧面５３５により先端部Ｔが内層側の脚部４５の先端部Ｔから径方向に離間するように押圧される。この結果、面取り部の省略により隣接した脚部４５，４６の先端部Ｔ同士の隙間が実質的に無くなっていたとしても、径方向に隣接する２つの脚部４５，４６の先端部Ｔの間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部４５，４６の間に外側拡張治具５３の壁部５３３を差し込んでいくことができる。 After temporarily stopping the movement of the intermediate expansion jig 52, the outer expansion jig 53 is lowered (moved) with respect to the two legs 45, 46 on the outermost layer side by the moving mechanism 54. When the outer expansion jig 53 is lowered, the first pressing surface 534 of the outer expansion jig 53, which is an inclined surface as described above, is formed on the tip portion T of the leg portion 45 on the inner layer side before the end portion of the wall portion 533. It abuts on the side surface (side surface on the short side) (see FIG. 12). As a result, the leg portion 45 on the inner layer side is pressed to one side in the circumferential direction of the stator core 2 (the tilting side of the leg portion 45 in the leg tilting process) by the first pressing surface 534 of the descending outer expansion jig 53. , The tip portion T of the leg portion 45 and the tip portion T of the leg portion 46 adjacent thereto are separated from each other in the circumferential direction of the stator core 2 (see FIG. 13). Further, as the leg portion 45 on the inner layer side is pressed by the first pressing surface 534, the tip portion T of the leg portion 46 is the leg portion 45 on the inner layer side by the second pressing surface 535 of the outer expansion jig 53. It is pressed so as to be radially separated from the tip portion T of the. As a result, even if the gap between the tip portions T of the adjacent leg portions 45 and 46 is substantially eliminated due to the omission of the chamfered portion, the space between the tip portions T of the two leg portions 45 and 46 adjacent in the radial direction is substantially eliminated. A gap can be formed in the space (widen the gap), and the wall portion 533 of the outer expansion jig 53 can be inserted between the two legs 45 and 46 from the formed gap.

図１６に示すように、外側拡張冶具５３の下降（移動）は、脚部４５，４６の間に壁部５３３が所定長さだけ差し込まれた段階で移動機構５４により停止させられる。また、脚部４５，４６の間に外側拡張冶具５３の壁部５３３が差し込まれるのに伴い、中間拡張治具５２の第２押圧面５２５や成形面５２６により押圧された脚部４４と、当該脚部４４に径方向外側で隣り合う脚部４５との間には、外側拡張治具５３の第２の壁部５３８が差し込まれる。脚部４４，４５の間に第２の壁部５３８が差し込まれた際、脚部４４の先端部Ｔは、中間拡張治具５２の壁部５２３と外側拡張冶具５３の第２の壁部５３８とにより挟み込まれる。 As shown in FIG. 16, the lowering (movement) of the outer expansion jig 53 is stopped by the moving mechanism 54 when the wall portion 533 is inserted between the legs 45 and 46 by a predetermined length. Further, as the wall portion 533 of the outer expansion jig 53 is inserted between the leg portions 45 and 46, the leg portion 44 pressed by the second pressing surface 525 and the molding surface 526 of the intermediate expansion jig 52 and the relevant portion 44. A second wall portion 538 of the outer expansion jig 53 is inserted between the leg portion 45 and the leg portion 45 adjacent to the leg portion 44 on the outer side in the radial direction. When the second wall portion 538 is inserted between the legs 44 and 45, the tip portion T of the leg portion 44 is the second wall portion 538 of the wall portion 523 of the intermediate expansion jig 52 and the outer expansion jig 53. It is sandwiched by.

また、脚部４４，４５の間に第２の壁部５３８が差し込まれると、脚部４５の先端部Ｔ側の部分は、外側拡張冶具５３の成形面５３９により径方向外側に押圧された状態で、第２の壁部５３８と壁部５３３とにより挟み付けられる。これにより、脚部４５は、スロット２ｓ側が軸方向に対して径方向外側に傾斜すると共に先端部Ｔ側が軸方向に延在するように、成形面５３９を起点にして曲げられる（塑性変形する）。更に、脚部４５に隣接する脚部４６は、外側拡張治具５３の第２押圧面５３５や成形面５３６により、先端部Ｔがステータコア２の外周側に移動するように径方向外側に押圧されて傾斜する。 Further, when the second wall portion 538 is inserted between the leg portions 44 and 45, the portion of the leg portion 45 on the tip T side is pressed outward in the radial direction by the molding surface 539 of the outer expansion jig 53. Then, it is sandwiched between the second wall portion 538 and the wall portion 533. As a result, the leg portion 45 is bent (plastically deformed) starting from the molding surface 539 so that the slot 2s side is inclined outward in the radial direction with respect to the axial direction and the tip portion T side extends in the axial direction. .. Further, the leg portion 46 adjacent to the leg portion 45 is pressed radially outward by the second pressing surface 535 and the molding surface 536 of the outer expansion jig 53 so that the tip portion T moves toward the outer peripheral side of the stator core 2. Tilt.

続いて、移動機構５４により一旦停止させた中間拡張冶具５２を再度下降させ、図１７に示すように、脚部４３，４４の間に壁部５２３が所定長さだけ差し込まれた段階で中間拡張冶具５２の移動を停止させる。これにより、脚部４３の先端部Ｔ側の部分は、中間拡張冶具５２の成形面５２９により径方向外側に押圧された状態で第２の壁部５２８と壁部５２３とにより挟み付けられ、スロット２ｓ側が軸方向に対して径方向外側に傾斜すると共に先端部Ｔ側が軸方向に延在するように、成形面５２９を起点にして曲げられる（塑性変形する）。また、脚部４４の先端部Ｔ側の部分は、中間拡張冶具５２の成形面５２６により径方向外側に押圧された状態で、中間拡張冶具５２の壁部５２３と外側拡張冶具５３の第２の壁部５３８とにより挟み付けられる。これにより、脚部４４は、スロット２ｓ側が軸方向に対して径方向外側に傾斜すると共に先端部Ｔ側が軸方向に延在するように、成形面５２６を起点にして曲げられる（塑性変形する）。 Subsequently, the intermediate expansion jig 52 once stopped by the moving mechanism 54 is lowered again, and as shown in FIG. 17, the intermediate expansion is performed when the wall portion 523 is inserted between the legs 43 and 44 by a predetermined length. Stop the movement of the jig 52. As a result, the portion on the tip T side of the leg portion 43 is sandwiched between the second wall portion 528 and the wall portion 523 in a state of being pressed radially outward by the molding surface 529 of the intermediate expansion jig 52, and the slot is formed. It is bent (plastically deformed) starting from the molding surface 529 so that the 2s side is inclined outward in the radial direction with respect to the axial direction and the tip T side extends in the axial direction. Further, the portion on the tip T side of the leg portion 44 is pressed outward in the radial direction by the molding surface 526 of the intermediate expansion jig 52, and the wall portion 523 of the intermediate expansion jig 52 and the second portion of the outer expansion jig 53 are second. It is sandwiched by the wall portion 538. As a result, the leg portion 44 is bent (plastically deformed) starting from the molding surface 526 so that the slot 2s side is inclined outward in the radial direction with respect to the axial direction and the tip portion T side extends in the axial direction. ..

上述のように、スロット２ｓから突出する偶数個の脚部４０に対して拡張治具５１－５３を２つの脚部４０ずつ順番に差し込んでいくことで、最内層側の脚部４１と、スロット２ｓの両端から突出しない脚部４２－４５をスロット２ｓ側がステータコア２の軸方向に対して径方向に傾斜すると共に先端部Ｔ側が軸方向に延在するように曲げることが可能となる。また、本実施形態のように、中間拡張治具５２を脚部４３，４４間に浅く差し込み、外側拡張治具５３を脚部４５，４６間に差し込んだ後に中間拡張治具５２を脚部４３，４４間に深く差し込むことで、脚部４３，４４および４５の拡張精度（曲げ部の成形精度）をより向上させることができる。 As described above, by inserting the expansion jigs 51-53 into the even number of legs 40 protruding from the slots 2s in order of the two legs 40, the legs 41 on the innermost layer side and the slots The legs 42-45 that do not protrude from both ends of 2s can be bent so that the slot 2s side is inclined in the radial direction with respect to the axial direction of the stator core 2 and the tip portion T side extends in the axial direction. Further, as in the present embodiment, the intermediate expansion jig 52 is shallowly inserted between the legs 43 and 44, the outer expansion jig 53 is inserted between the legs 45 and 46, and then the intermediate expansion jig 52 is inserted between the legs 43. By deeply inserting the legs 43, 44 and 45, the expansion accuracy (molding accuracy of the bent portion) of the legs 43, 44 and 45 can be further improved.

そして、図１８に示すように、スロット２ｓから突出する脚部４１－４６に対して複数の拡張治具５１－５３を差し込んだ状態で加圧装置５８０により加圧部材５８をステータコア２の軸心側に移動させ、内側支持部材５６によりスロット２ｓの最内層側の脚部４１を支持しながら最外層側の脚部４６を加圧部材５８により径方向外側から加圧する。これにより、最外層側の脚部４６を外側拡張治具５３の成形面５３６を起点にしてスロット２ｓ側が軸方向に対して径方向外側に傾斜すると共に先端部Ｔ側が軸方向に延在するように曲げることができる。 Then, as shown in FIG. 18, in a state where a plurality of expansion jigs 51-53 are inserted into the legs 41-46 protruding from the slot 2s, the pressurizing member 58 is inserted into the axial center of the stator core 2 by the pressurizing device 580. It is moved to the side, and the leg portion 46 on the outermost layer side is pressed from the outside in the radial direction by the pressurizing member 58 while the leg portion 41 on the innermost layer side of the slot 2s is supported by the inner support member 56. As a result, the leg portion 46 on the outermost layer side is inclined outward in the radial direction with respect to the axial direction from the molding surface 536 of the outer expansion jig 53, and the tip portion T side extends in the axial direction. Can be bent into.

最外層側の脚部４６の曲げ加工が完了した後、拡張治具５１－５３、フォーク部材５７および加圧部材５８を初期位置へと戻す。その後、回転テーブル５５をステータコア２の軸心周りに回転させて、次の加工対象となる偶数個の脚部４０が拡張治具５１－５３の下方に位置するようにステータコア２を位置決めし、拡張治具５１－５３を用いた上述の一連の処理を繰り返し実行する。これにより、全スロット２ｓから突出する全脚部４０をステータコア２に対する先端部Ｔの位置が脚部倒し工程の実施時に要求される位置になるように精度よく径方向に拡張させることが可能となる。 After the bending of the leg portion 46 on the outermost layer side is completed, the expansion jig 51-53, the fork member 57, and the pressure member 58 are returned to the initial positions. After that, the rotary table 55 is rotated around the axis of the stator core 2, and the stator core 2 is positioned and expanded so that the even number of legs 40 to be processed next are located below the expansion jigs 51-53. The above-mentioned series of processes using the jigs 51-53 are repeatedly executed. As a result, all the legs 40 protruding from all the slots 2s can be accurately expanded in the radial direction so that the position of the tip T with respect to the stator core 2 is the position required when the leg tilting process is performed. ..

以上説明したように、本開示のステータ１の製造方法では、径方向に隣接する２つの脚部４０を当該径方向に拡張する際に、当該２つの脚部４０に対して拡張治具５１，５２または５３を移動させ、当該拡張治具５１，５２または５３により径方向に隣接する２つの脚部４０の一方の脚部４１，４３，４５を先端部Ｔが他方の脚部４２，４４，４６の先端部Ｔから周方向に離間するように押圧しながら、他方の脚部４２，４４，４６を先端部Ｔが一方の脚部４１，４３，４５の先端部Ｔから径方向に離間するように押圧する。 As described above, in the method of manufacturing the stator 1 of the present disclosure, when the two legs 40 adjacent to each other in the radial direction are expanded in the radial direction, the expansion jig 51, with respect to the two legs 40, 52 or 53 is moved, and one leg 41, 43, 45 of the two legs 40 radially adjacent to each other by the expansion jig 51, 52 or 53 is provided with the tip T on the other leg 42, 44. While pressing the other leg portion 42, 44, 46 so as to be separated from the tip portion T of the 46 in the circumferential direction, the tip portion T is radially separated from the tip portion T of the one leg portion 41, 43, 45. Press.

これにより、径方向に隣接する２つの脚部４０の先端部Ｔの間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部４０の間に拡張治具５１，５２または５３の壁部５１３，５２３，５３３を差し込んでいくことができる。この結果、隣接したセグメントコイル４の先端部Ｔ同士の隙間が極めて狭い場合であっても、ステータコア２のスロット２ｓから突出した複数のセグメントコイル４の脚部４０を当該ステータコア２の径方向に拡張することが可能となる。 As a result, a gap is formed between the tip portions T of the two leg portions 40 adjacent in the radial direction (the gap is widened), and the expansion jigs 51 and 52 are formed between the two leg portions 40 from the formed gap. Alternatively, the wall portions 513, 523, 533 of 53 can be inserted. As a result, even when the gap between the tip portions T of the adjacent segment coils 4 is extremely narrow, the leg portions 40 of the plurality of segment coils 4 protruding from the slots 2s of the stator core 2 are expanded in the radial direction of the stator core 2. It becomes possible to do.

また、本開示の拡張治具５１，５２，５３は、ステータコア２の径方向に隣接する２つの脚部４０の一方の脚部４１，４３または４５を先端部Ｔが他方の脚部４２，４４または４６の先端部Ｔから周方向に離間するように押圧する第１押圧面５１４，５２または５３４と、第１押圧面５１４，５２４または５３４により一方の脚部４１，４３または４５が押圧されるのに伴って、他方の脚部４２，４４または４６を先端部Ｔが一方の脚部４１，４３または４５の先端部Ｔから径方向に離間するように押圧する第２押圧面５１５，５２５または５３５をそれぞれ含む。 Further, in the expansion jigs 51, 52, 53 of the present disclosure, one leg 41, 43 or 45 of two leg portions 40 adjacent to each other in the radial direction of the stator core 2 is provided with the tip portion T of the other leg portion 42, 44. Alternatively, one leg 41, 43 or 45 is pressed by the first pressing surface 514, 52 or 534 and the first pressing surface 514, 524 or 534 that presses the 46 so as to be separated from the tip T in the circumferential direction. Second pressing surface 515, 525 or pressing the other leg 42, 44 or 46 so that the tip T is radially separated from the tip T of the one leg 41, 43 or 45. 535 is included respectively.

これにより、径方向に隣接する２つの脚部４０の先端部Ｔの間に隙間を形成し（隙間を拡げ）、形成された隙間から当該２つの脚部４０の間に拡張治具５１，５２または５３の壁部５１３，５２３，５３３を差し込んでいくことができる。この結果、拡張治具５１，５２，５３を用いることで、隣接したセグメントコイル４の先端部Ｔ同士の隙間が極めて狭い場合であっても、ステータコア２のスロット２ｓから突出した複数のセグメントコイル４の脚部４０を当該ステータコア２の径方向に拡張することが可能となる。 As a result, a gap is formed between the tip portions T of the two leg portions 40 adjacent in the radial direction (the gap is widened), and the expansion jigs 51 and 52 are formed between the two leg portions 40 from the formed gap. Alternatively, the wall portions 513, 523, 533 of 53 can be inserted. As a result, by using the expansion jigs 51, 52, and 53, a plurality of segment coils 4 protruding from the slots 2s of the stator core 2 even when the gap between the tip portions T of the adjacent segment coils 4 is extremely narrow. The leg portion 40 of the above can be expanded in the radial direction of the stator core 2.

なお、拡張治具５１－５３によりステータコア２の周方向に押圧される脚部４１，４３，４５は、拡張治具５１－５３からの荷重により若干曲げられることもあるが、上述のように、脚部４１，４３，４５は、それぞれ拡張治具５１，５２または５３により脚部倒し工程での倒し側に押圧される。従って、脚部拡張工程において脚部４１，４３，４５が周方向に若干曲げられたとしても、それにより脚部倒し工程後の先端部Ｔ等の位置精度に影響を与えてしまうことは実質的にない。また、中間拡張治具５２を脚部４３，４４間に浅く差し込み、外側拡張治具５３を脚部４５，４６間に差し込んだ後に中間拡張治具５２を脚部４３，４４間に深く差し込む代わりに、拡張治具５１，５２，５３をこの順番で複数の脚部４１－４６に対して差し込んで当該脚部４１－４６を径方向に拡張してもよい。更に、上記実施形態において、スロット２ｓの最内層側から突出する脚部４１は、内側拡張治具５１により曲げられるが、これに限られるものではない。すなわち、脚部４１は、脚部拡張工程において曲げられなくてもよく、最外層側の脚部４６が加圧部材により加圧された際に内側支持部材５６に押し付けられて曲げられてもよい。また、スロット２ｓから突出する脚部４０の数が８以上の偶数である場合には、中間拡張治具５２（あるいは外側拡張治具５３）の数を増やせばよい。 The legs 41, 43, 45 pressed by the expansion jig 51-53 in the circumferential direction may be slightly bent by the load from the expansion jig 51-53, but as described above, The legs 41, 43, and 45 are pressed toward the tilting side in the leg tilting step by the expansion jigs 51, 52, or 53, respectively. Therefore, even if the legs 41, 43, and 45 are slightly bent in the circumferential direction in the leg expansion step, it substantially affects the position accuracy of the tip portion T and the like after the leg tilting step. Not in. Further, instead of inserting the intermediate expansion jig 52 shallowly between the legs 43 and 44, inserting the outer expansion jig 53 between the legs 45 and 46, and then inserting the intermediate expansion jig 52 deeply between the legs 43 and 44. The expansion jigs 51, 52, and 53 may be inserted into the plurality of legs 41-46 in this order to expand the legs 41-46 in the radial direction. Further, in the above embodiment, the leg portion 41 protruding from the innermost layer side of the slot 2s is bent by the inner expansion jig 51, but the present invention is not limited to this. That is, the leg 41 does not have to be bent in the leg expansion step, and may be pressed against the inner support member 56 and bent when the outermost leg 46 is pressed by the pressurizing member. .. When the number of legs 40 protruding from the slot 2s is an even number of 8 or more, the number of intermediate expansion jigs 52 (or outer expansion jigs 53) may be increased.

そして、本開示の発明は上記実施形態に何ら限定されるものではなく、本開示の外延の範囲内において様々な変更をなし得ることはいうまでもない。更に、上記実施形態は、あくまで発明の概要の欄に記載された発明の具体的な一形態に過ぎず、発明の概要の欄に記載された発明の要素を限定するものではない。 It goes without saying that the invention of the present disclosure is not limited to the above-described embodiment, and various changes can be made within the scope of the extension of the present disclosure. Further, the above embodiment is merely a specific embodiment of the invention described in the column of the outline of the invention, and does not limit the elements of the invention described in the column of the outline of the invention.

本開示の発明は、ステータの製造分野等において利用可能である。 The invention of the present disclosure can be used in the field of manufacturing a stator and the like.

１ ステータ、２ ステータコア、２ｐ 電磁鋼板、２ｓ スロット、２ｔ ティース部、３ａ，３ｂ コイルエンド部、３ｕ，３ｖ，３ｗ ステータコイル、４ セグメントコイル、５ｕ，５ｖ，５ｗ 動力線、６ｕ，６ｖ，６ｗ 端子、７ 保持部材、８ モールド部、１０ ロータ、１１ ロータコア、１２ 中心孔、１４ 磁石埋設孔、１５ 永久磁石、４０，４１，４２，４３，４４，４５，４６ 脚部、５０ 拡張装置、５１ 内側拡張冶具、５１ａ，５２ａ，５３ａ 基端部、５１０，５２０，５３０ 加工部、５１１，５２１，５３１ 第１底面、５１２，５２２，５３２ 第２底面、５１３，５２３，５３３ 壁部、５１３ｓ、５２３ｓ 側面、５１４、５２４，５３４ 第１押圧面、５１５，５２５，５３５ 第２押圧面、５１６，５１７，５２６，５２９，５３６，５３９ 成形面、５２ 中間拡張治具、第２の壁部 ５２８，５３９、５３ 外側拡張冶具、５４ 移動機構、５５ 回転テーブル、５６ 内側支持部材、５７ フォーク部材、５７０ フォーク駆動装置、５８ 加圧部材、５８０ 加圧装置、５９ 制御装置、Ｌｕ，Ｌｖ，Ｌｗ 引出線、Ｍ 回転電機、Ｔ 先端部、Ｔｓｉ 内側面、Ｔｓｏ 外側面、Ｕ１，Ｖ１，Ｗ１ 第１コイル、Ｕ２，Ｖ２，Ｗ２ 第２コイル、ＷＬ レーザー溶接部。 1 stator, 2 stator core, 2p electromagnetic steel plate, 2s slot, 2t teeth part, 3a, 3b coil end part, 3u, 3v, 3w stator coil, 4 segment coil, 5u, 5v, 5w power line, 6u, 6v, 6w terminal , 7 Retaining member, 8 Mold part, 10 Rotor, 11 Rotor core, 12 Center hole, 14 Magnet embedding hole, 15 Permanent magnet, 40, 41, 42, 43, 44, 45, 46 Legs, 50 Expansion device, 51 Inside Expansion jig, 51a, 52a, 53a base end, 510,520,530 processed part, 511,521,531 first bottom surface, 512,522,532 second bottom surface, 513,523,533 wall part, 513s, 523s side surface , 514, 524,534 1st pressing surface, 515,525,535 2nd pressing surface, 516,517,526,529,536,539 molding surface, 52 intermediate expansion jig, 2nd wall part 528,539, 53 Outer expansion jig, 54 Moving mechanism, 55 Rotating table, 56 Inner support member, 57 Fork member, 570 Fork drive device, 58 Pressurizing member, 580 Pressurizing device, 59 Control device, Lu, Lv, Lw Leader, M Rotating electric machine, T tip, Tsi inner side surface, Tso outer side surface, U1, V1, W1 first coil, U2, V2, W2 second coil, WL laser welded part.

Claims (1)

それぞれ径方向に延在すると共に周方向に間隔をおいて形成された複数のスロットを含むステータコアと、互いに異なる前記スロットに差し込まれる一対の脚部を有すると共に対応する前記脚部の先端部同士の電気的接合によりステータコイルを形成する複数のセグメントコイルとを含むステータの製造方法において、
前記複数のスロットの各々から複数の前記脚部が突出するように前記複数のセグメントコイルを前記径方向に隣接させて前記ステータコアに組み付け、
前記スロットから突出して前記径方向に隣接する２つの脚部に対して第１押圧面および第２押圧面が形成された拡張治具を移動させ、前記拡張治具の前記第１押圧面により前記径方向に隣接する２つの脚部の一方の脚部を前記先端部が他方の脚部の前記先端部から前記周方向に離間するように押圧しながら、前記拡張治具の前記第２押圧面により前記他方の脚部を前記先端部が前記一方の脚部の前記先端部から前記径方向に離間するように押圧し、前記スロットから突出した前記複数の脚部を前記径方向に拡張する、
ステータの製造方法。

A stator core that includes a plurality of slots, each extending radially and spaced apart in the circumferential direction, and a pair of legs that are inserted into the slots that are different from each other and that have corresponding tips of the legs. In a method of manufacturing a stator including a plurality of segment coils forming a stator coil by electrical joining.
The plurality of segment coils are adjacent to each other in the radial direction so that the plurality of legs project from each of the plurality of slots, and the plurality of segment coils are assembled to the stator core.
An expansion jig having a first pressing surface and a second pressing surface formed on two legs protruding from the slot and adjacent to each other in the radial direction is moved by the first pressing surface of the expansion jig. The second pressing surface of the expansion jig while pressing one leg of two radially adjacent legs so that the tip thereof is separated from the tip of the other leg in the circumferential direction. Presses the other leg so that the tip thereof is radially separated from the tip of the one leg, and the plurality of legs protruding from the slot are expanded in the radial direction.
How to manufacture the stator.
JP2018023233A 2018-02-13 2018-02-13 How to manufacture the stator Active JP7036613B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP2018023233A JP7036613B2 (en) 2018-02-13 2018-02-13 How to manufacture the stator

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2018023233A JP7036613B2 (en) 2018-02-13 2018-02-13 How to manufacture the stator

Publications (2)

Publication Number Publication Date
JP2019140823A JP2019140823A (en) 2019-08-22
JP7036613B2 true JP7036613B2 (en) 2022-03-15

Family

ID=67695583

Family Applications (1)

Application Number Title Priority Date Filing Date
JP2018023233A Active JP7036613B2 (en) 2018-02-13 2018-02-13 How to manufacture the stator

Country Status (1)

Country Link
JP (1) JP7036613B2 (en)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP7327091B2 (en) * 2019-11-11 2023-08-16 株式会社デンソー STATOR MANUFACTURING APPARATUS AND STATOR MANUFACTURING METHOD
WO2023145211A1 (en) * 2022-01-25 2023-08-03 日本発條株式会社 Production method for armature
JP7263635B1 (en) * 2022-01-25 2023-04-24 日本発條株式会社 Armature manufacturing method

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001268837A (en) 2000-03-16 2001-09-28 Mitsubishi Electric Corp Stator of alternator for vehicle and method of manufacturing the same
JP2017085701A (en) 2015-10-23 2017-05-18 トヨタ自動車株式会社 Stator coil forming method
JP2019140732A (en) 2018-02-07 2019-08-22 本田技研工業株式会社 Electric conductor bending method and device

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001268837A (en) 2000-03-16 2001-09-28 Mitsubishi Electric Corp Stator of alternator for vehicle and method of manufacturing the same
JP2017085701A (en) 2015-10-23 2017-05-18 トヨタ自動車株式会社 Stator coil forming method
JP2019140732A (en) 2018-02-07 2019-08-22 本田技研工業株式会社 Electric conductor bending method and device

Also Published As

Publication number Publication date
JP2019140823A (en) 2019-08-22

Similar Documents

Publication Publication Date Title
JP6974206B2 (en) Stator manufacturing method and bending equipment
CN107925319B (en) Method and two-part tool arrangement for producing a stator of an electric machine
US10594182B2 (en) Stator manufacturing method and stator
JP6146219B2 (en) Concentric winding coil forming method and forming apparatus
US10305355B2 (en) Stator manufacturing method and coil
US20190020239A1 (en) Stator for rotating electric machine and method of manufacturing the stator
JP7036613B2 (en) How to manufacture the stator
US6885123B2 (en) Stator coil made of joined conductor segments for rotary electric machinery and method for manufacturing the same
JP2015144546A (en) Motor and manufacturing method of the same
US20220352796A1 (en) Method of manufacturing stator
US11799341B2 (en) Stator and rotary electric machine
JP6959163B2 (en) Bending machine
JP6206051B2 (en) Concentric winding coil forming method and forming apparatus
JP7146137B2 (en) stator
JP2019140819A (en) Manufacturing method of stator
WO2020100311A1 (en) Stator manufacturing method
JP7160650B2 (en) Clamping device and stator manufacturing method using the clamping device
CN112510934B (en) Apparatus and method for manufacturing stator
JP6848131B1 (en) Stator and how to manufacture the stator
JP5098854B2 (en) Stator coil welding method
JP2012161148A (en) Method of manufacturing armature for rotary electric machine, and armature for rotary electric machine
JP2022035822A (en) Twist processing device and twist processing method
JP2020102921A (en) Stator manufacturing method
JP6848129B1 (en) Stator manufacturing method and stator manufacturing equipment
JP5280652B2 (en) Coil unit for linear motor and linear motor

Legal Events

Date Code Title Description
A621 Written request for application examination

Free format text: JAPANESE INTERMEDIATE CODE: A621

Effective date: 20210115

A711 Notification of change in applicant

Free format text: JAPANESE INTERMEDIATE CODE: A712

Effective date: 20210423

A131 Notification of reasons for refusal

Free format text: JAPANESE INTERMEDIATE CODE: A131

Effective date: 20211116

A977 Report on retrieval

Free format text: JAPANESE INTERMEDIATE CODE: A971007

Effective date: 20211118

A521 Request for written amendment filed

Free format text: JAPANESE INTERMEDIATE CODE: A523

Effective date: 20211228

TRDD Decision of grant or rejection written
A01 Written decision to grant a patent or to grant a registration (utility model)

Free format text: JAPANESE INTERMEDIATE CODE: A01

Effective date: 20220208

A61 First payment of annual fees (during grant procedure)

Free format text: JAPANESE INTERMEDIATE CODE: A61

Effective date: 20220303

R151 Written notification of patent or utility model registration

Ref document number: 7036613

Country of ref document: JP

Free format text: JAPANESE INTERMEDIATE CODE: R151