JP3738528B2 - Stator for rotating electrical machine and method for manufacturing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a stator for a rotating electrical machine.
[0002]
[Prior art]
In recent years, there is an increasing demand for higher performance in rotating electrical machines, and it is necessary to achieve higher occupancy rates and higher efficiency for stator windings in order to increase output. Japanese Patent Application Laid-Open No. 8-19196 discloses a method in which a straight core developed in a straight line is wound, and then the straight core is bent in an annular shape. According to this method, it is possible to secure a large slot pitch in the straight core state (the slot pitch increases if the annular core is expanded linearly). A thick coil wire can be used, and accordingly, a higher occupancy rate can be achieved.
[0003]
[Problems to be solved by the invention]
However, in the above method, when the coil is attached to the core, the shape of the coil is liable to collapse. Even after the coil is mounted on the core, the coil wire may jump out of the slot when the core is bent. For this reason, there is a problem that workability is poor because it is necessary to perform winding work (work for attaching the coil to the core) while preventing the coil from collapsing and preventing the coil wire from popping out.
As shown in FIG. 11, since the coil wires 110 are not aligned in the slot 100, stress generated between the coil wires 110 or between the coil wires 110 and the core 120 when the core 120 is bent is applied to the coil wires 110. There was a risk of breaking the insulation coating of the coil wire 110.
[0004]
Further, in the conventional rotating electric machine, it is necessary to insert a wedge part into the slot in order to prevent the coil wire from jumping out of the slot due to vibrations generated during use. For this reason, there has been a problem that the cost is significantly increased as the number of parts is increased and the number of assembling steps is increased.
The present invention has been made based on the above circumstances, and a first object is to facilitate the winding work around the stator core. The second purpose is to prevent the insulation coating of the coil wire from being broken when the straight core is bent to form an annular core. The third purpose is to reduce the cost by eliminating the wedge parts for the purpose of preventing the coil wire from popping out.
[0008]
[Means for Solving the Problems]
(Means of Claim 1 )
A method for manufacturing a stator for an alternator comprising a stator core having magnetic teeth between slots and a coil inserted into a slot around one magnetic teeth or straddling two or more magnetic teeth. A plurality of core sheets (20) are stacked to form a straight core (2A) provided with a plurality of slots (2a) in the longitudinal direction (3-a), and a fusion layer is provided in the coating portion. The coil wire (3a) is aligned and formed into a predetermined coil shape, and the coil wire (3a) is energized or externally heated to melt the fusion layer and fuse the coil wires (3a) to form a block. Coil (3) (3-b, 3-c, 3-d), (4-a, 4-b, 4-c), and the blocked coil (3) is assembled to the straight core (2A) ( 3-e), the coil (3) Bending a straight core attached observed (2A) in an annular shape (3-f), the slot pitch P0 of the straight core (2A), the slot pitch of the stator core after bending P, and magnetic pole teeth width L, and block When the coil width of the whole coil fixed in a shape is C, the relationship P0−L>C> P−L is established.
In this case, when the coil is attached to the straight core, the coil is not collapsed, so that it can be easily inserted into the slot. In addition, when the coil is attached to the straight core, the coil wires can be kept aligned in the slot, so that even when the straight core is bent, almost no stress is applied to the coil wire. It can be prevented from being destroyed.
Furthermore, since the slot entrance width of the straight core (that is, P0-L) is larger than the coil width C of the entire coil fixed in a block shape, when the coil is mounted in the straight core state, it is easy to fit in the slot. A coil wire can be inserted. After the straight core is bent, the slot entrance width (that is, PL) is smaller than the coil width C of the entire coil fixed in a block shape, so that the coil wire can be prevented from jumping out of the slot.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of a linear core and coil.
The stator 1 of this embodiment forms, for example, a field of an AC generator. As shown in FIG. 2, the stator core 2 and a stator coil 3 (hereinafter referred to as a coil 3) mounted on the stator core 2 are provided. Abbreviated).
The stator core 2 is used by bending a linear core (hereinafter referred to as a straight core 2A) as shown in FIG. 1 into an annular shape. The straight core 2A is configured by laminating a plurality of core sheets 20, and a plurality of slots 2a are provided at equal pitches in the longitudinal direction, and the magnetic teeth 2b for winding the coil 3 between the adjacent slots 2a. Is formed.
[0010]
As shown in FIG. 1, the coil 3 is formed by winding the coil wire 3 a in a ring shape in advance to form a predetermined coil shape, and then joining the coil wires 3 a together to fix the entire coil 3 in a block shape. The straight core 2A is inserted into the slot 2a around one magnetic pole tooth 2b or across two or more magnetic pole teeth 2b.
Below, the process until the stator subassembly is manufactured will be described with reference to FIG.
First, the straight core 2A is formed by laminating and fixing a plurality of press-molded core sheets 20 (3-a).
[0011]
On the other hand, the coil wire 3a (here, a self-bonding wire is used) is aligned while being wound in an annular shape and formed into a predetermined coil shape (3-b).
Subsequently, the coil wire 3a is energized or externally heated (3-c), the fusion layer is melted, and the coil wires 3a are fused together to block the entire coil 3 (3-d). As the fusion layer, for example, polyvinyl butyral, nylon, epoxy, or the like is used.
Next, the blocked coil 3 is assembled to the straight core 2A (3-e). FIG. 5 shows a state in which the blocked coil 3 is inserted into the slot 2a of the straight core 2A. Subsequently, the straight core 2A to which the coil 3 is assembled is bent into an annular shape (3-f). Here, as shown in FIG. 6, a wedge part 4 for preventing the coil 3 from jumping out may be inserted into the slot 2a.
The stator subassembly is completed through the above steps.
[0012]
In the above manufacturing method, the self-bonding wire is used as the coil wire 3a in order to block the coil 3, but the coil wires 3a may be joined together by an adhesive.
In this case, as shown in FIG. 4, first, the coil wire 3a is wound into an annular shape and formed into a predetermined coil shape (4-a). Subsequently, by applying an adhesive to the coil wire 3a (4-b) and solidifying the adhesive (4-c), the entire coil 3 can be fixed and blocked. In addition, as an adhesive agent, an epoxy type, an acrylic type, a chloropyrene type etc. can be used, for example.
[0013]
(Effect of this embodiment)
According to the present embodiment, the coil 3 formed by fusing the coil wires 3a to each other is assembled to the straight core 2A, so that the coil shape does not collapse during assembly. For this reason, insertion into the slot 2a is easy, and the coil wire 3a does not jump out of the slot 2a even when the straight core 2A is bent into an annular shape. Can do.
In addition, since the coil wires 3a can be kept aligned in the slot 2a of the straight core 2A, even when the straight core 2A is bent in an annular shape, almost no stress is applied to the coil wire 3a. Thereby, it can prevent that the insulating film of the coil wire 3a is destroyed.
[0014]
(Second embodiment)
FIG. 7 is a partial cross-sectional view of the straight core 2 </ b> A, and FIG. 8 is a partial cross-sectional view of the stator core 2.
In this embodiment, the entrance dimension of the slot 2a is optimally designed so that the coil 3 can be prevented from jumping out of the slot 2a.
Specifically, if the slot pitch of the stator core 2 when the straight core 2A is bent to the inner diameter 2R (see FIG. 2) is P and the number of slots is n, the slot pitch P can be obtained by the following equation.
[Expression 1]
P≈2πR / n
Therefore, when the slot pitch of the straight core 2A is P0, the magnetic teeth width is L, and the entire width of the blocked coil is C, the magnetic teeth width L is set so that the relationship shown in the following formula is satisfied. Yes.
[Expression 2]
P 0 -L>C> P−L = 2πR / n−L> 0
[0015]
In this case, since the inlet dimension (that is, P0 -L) of the slot 2a of the straight core 2A is larger than the width C of the entire coiled coil, it is easy to assemble the coil 3 in the state of the straight core 2A. The coil 3 can be inserted into the slot 2a. After the core is bent, the inlet dimension (that is, P-L) of the slot 2a is smaller than the width C of the entire coiled block, so that the coil 3 can be prevented from jumping out of the slot 2a. As a result, it is possible to reduce the cost by eliminating the conventional wedge parts.
[0016]
(Third embodiment)
FIG. 9 is a partial cross-sectional view of the straight core 2 </ b> A, and FIG. 10 is a partial cross-sectional view of the stator core 2.
In this embodiment, the coil 3 is formed by winding the coil wire 3a a plurality of times around the magnetic pole teeth 2b of the straight core 2A, instead of assembling the pre-formed coil 3 to the straight core 2A. In this configuration, the entrance dimension of the slot 2a is optimally designed so that the coil wire 3a can be prevented from jumping out of the slot 2a.
Specifically, if the slot pitch of the stator core 2 when the straight core 2A is bent to the inner diameter 2R (see FIG. 2) is P and the number of slots is n, the slot pitch P can be obtained by the following equation.
[Equation 3]
P≈2πR / n
Therefore, when the slot pitch of the straight core 2A is P0, the magnetic teeth width is L, and the coil wire diameter is φ, the magnetic teeth width L is set so that the relationship shown in the following equation is established.
[Expression 4]
P0 -L>.phi.> P-L = 2.pi.R / n-L> 0
[0017]
In this case, since the inlet dimension (that is, P0 -L) of the slot 2a of the straight core 2A is larger than the coil wire diameter φ, when the coil wire 3a is wound around the magnetic pole tooth 2b in the state of the straight core 2A, the slot is easily obtained. The coil wire 3a can be inserted into 2a. After the core is bent, the inlet dimension (ie, PL) of the slot 2a is smaller than the coil wire diameter φ, so that the coil wire 3a can be prevented from jumping out of the slot 2a. As a result, it is possible to reduce the cost by eliminating the conventional wedge parts.
[Brief description of the drawings]
FIG. 1 is a perspective view of a straight core and a coil.
FIG. 2 is a side view of a stator.
FIG. 3 is an explanatory view showing a manufacturing process of a stator subassembly.
FIG. 4 is another explanatory view showing the manufacturing process of the stator sub-assembly.
FIG. 5 is a partial cross-sectional view showing a state in which a blocked coil is inserted into a slot of a straight core.
FIG. 6 is a partial cross-sectional view showing a state where a blocked coil is inserted into a slot of a stator core.
FIG. 7 is a partial cross-sectional view showing a slot pitch and a magnetic teeth width of a straight core (second embodiment).
FIG. 8 is a partial cross-sectional view showing a slot pitch of a stator core (second embodiment).
FIG. 9 is a partial cross-sectional view showing a slot pitch and a magnetic teeth width of a straight core (third embodiment).
FIG. 10 is a partial cross-sectional view showing a slot pitch of a stator core (third embodiment).
FIG. 11 is a partial cross-sectional view showing a state where a coil is inserted into a slot of a straight core (prior art).
[Explanation of symbols]
1 Stator 2 Stator Core 2A Straight Core 2a Slot 2b Magnetic Teeth 3 Coil 3a Coil Wire

Claims (1)

A stator core having magnetic teeth between each slot;
A method of manufacturing a stator of an AC generator comprising a coil inserted into the slot around one magnetic tooth or across two or more magnetic teeth,
Laminating a plurality of core sheets (20) to form a straight core (2A) provided with a plurality of slots (2a) in the longitudinal direction (3-a),
The coil wire (3a) having the fusion layer in the coating portion is aligned and formed into a predetermined coil shape, and the coil wire (3a) is energized or externally heated to melt the fusion layer and the coil wire ( 3a) A coil (3) blocked by fusing together (3-b, 3-c, 3-d), (4-a, 4-b, 4-c),
Assembling the coil into blocks (3) into the straight core (2A) (3-e), by bending a said straight core coil (3) is assembled (2A) in an annular shape (3-f),
When the slot pitch of the straight core (2A) is P0, the slot pitch of the bent stator core is P, the magnetic teeth width is L, and the coil width of the whole coil fixed in a block shape is C, A method for manufacturing an alternator stator, wherein the relationship is established .
P0-L>C> P-L

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