JP5321875B2 - Method for forming coil end of stator coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil end molding method of a stator coil that can suppress the bulge of the coil in the molding by bending a coil end. <P>SOLUTION: The method has a right-angle bending step in which part of an insulated coated conductor 30 that falls on a coil end is bent at right angle. In this right-angle bending step, using a die 52 having a guide groove 52d of almost the same width with that of the conductor 30, the conductor 30 is bent at right angle by moving a punch 54 relatively to the die 52 side with the conductor 30 fitted into the guide groove 52d of the die 52. Thus, both sides of the conductor 30 contact the sidewalls of the guide groove 52d of the die 52, so that a force of both sides of the conductor 30 tending to bulge is suppressed by the sidewalls of the guide groove 52d of the die 52 and thereby the bulge can be suppressed. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to a method for forming a coil end of a stator coil, and more particularly to a method for forming a coil end of a stator coil having a coil end formed by bending an insulation-coated rectangular wire stepwise.

  Conventionally, in order to realize the demand for downsizing and high performance of rotating electrical machines, it is a challenge to improve the slot space factor of the stator coil and how to reduce the coil end portion that does not contribute to torque generation. .

  By the way, it is suitable for the conductor wire which comprises a stator coil to comprise the rectangular wire which can ensure a big cross-sectional area for the improvement of the in-slot conducting wire space factor of a rotary electric machine (for example, refer patent document 1).

Further, for example, Patent Document 2 discloses a rotating electrical machine having a structure in which a stator coil having a coil end portion formed in advance using this type of flat wire is accommodated in an open slot type or split core type stator core. In the rotating electrical machine described in Patent Document 2, when the stator coil is accommodated in the stator core, the coil is bent into a predetermined shape at the coil end.
Japanese Patent No. 3115343 Japanese Patent No. 3604326

  As described above, when the coil is formed into a flat wire and the coil end shape is stepped, the height corresponding to the width of the coil is stacked, and the coil end height can be minimized. For this reason, it is desirable that the coil end shape be stepped.

  However, when the coil end shape is stepped, there is a problem that unnecessary bulging occurs due to bending of the coil. That is, the stair-shaped coil end is processed using a press forming method unlike the conventional method called winding. However, when a coil, that is, a rectangular copper wire is bent or press formed, the inside of the bend R is processed. Swelling occurs on the side of the part. Patent Document 1 and Patent Document 2 did not consider this point at all. The occurrence of the bulge causing this problem will be described in detail with reference to FIG.

  15A and 15B are diagrams showing an example of the shape of the stator coil, where FIG. 15A is a side view of a stepped coil end, FIG. 15B is a sectional view of the coil, and FIG. It is sectional drawing of the coil in KK part of ().

  In FIGS. 15A, 15B, and 15C, reference numeral 30 denotes a rectangular coil, and the insulating wire 30a is formed by coating the copper wire 30b with a resin layer such as an enamel layer or PPS (polyphenylene sulfide). This is an insulation-coated rectangular wire having the above structure.

  When the coil end shape is stepped and the stator coil is accommodated in the stator core, it is necessary to overlap the coil ends several times as shown in FIG. The cross-sectional shape of the coil, that is, the insulation-coated rectangular wire 30, is originally a rectangle having the same length L as shown in FIG. be able to.

  However, in the KK cross section of FIG. 15 (a), as shown in FIG. 15 (b), the insulation coated rectangular wire 30 is bent, so that the side surface swells to the length N inside the bend and the side surface is outside. Has a length M. Here, L> M and N> L. If such a situation occurs at various places where the insulation-coated rectangular wire 30 is bent, a gap is generated when the coil ends are overlapped with each other, which becomes an obstacle to improving the conductor space factor. In addition, there is a problem that the dimensional accuracy of the inner and outer diameters of the coil subassembly (coil assembly) is lowered.

  Also, if the insulation coated rectangular wire 30 is bent and bulges, the insulating coating 30a made of resin at that portion becomes thin, the coils become close at the time of assembly, insulation cannot be secured sufficiently, and high voltage (for example, 1000V) ) Has a problem that corona discharge may occur.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a coil end molding method for a stator coil that can suppress the swelling of the coil in bending molding of the coil end portion.

  Hereinafter, each means suitable for solving the above-described problems will be described with additional effects and the like as necessary.

1. In the coil end forming method of a stator coil, a coil end portion of a stator coil is formed into a predetermined shape by bending a predetermined coil end portion of an insulating coated conductor wire formed by insulating and covering a rectangular wire. At the time of bending of the coil end planned portion, the guide surface is brought into contact with both side surfaces of the insulation-coated conductor wire in a direction intersecting the bending direction with the insulation-coated conductor wire fitted into the die and the punch. And a coil end forming method for a stator coil, wherein the bulge deformation of the insulating coated conductor wire is suppressed.

According to means 1, both sides of the insulation-coated conductor wire in a direction intersecting with the bending direction in a state where the insulation-coated conductor wire is fitted into the die and the punch when the coil end planned portion of the insulation-coated conductor wire is folded. By bringing the guide surface into contact with the surface, it is possible to suppress the bulging deformation of the insulating coated conductor wire.

  Since the coil end formed in this way is a rectangle with the original cross-sectional shape, the conductor space factor can be improved without generating an extra gap when the coil ends are overlapped with each other. In addition, the dimensional accuracy of the inner and outer diameters of the coil subassembly can be increased.

  In addition, since deformation in the direction intersecting the bending direction of the insulation-coated conductor wire is suppressed, a thin portion of the insulation-coated conductor wire does not occur, sufficient insulation can be secured, and a structure that can withstand high voltages It can be.

2. A right-angle bending step of bending the coil-end planned portion of the insulation-coated conductor wire at a right angle, and the right-angle bending step uses a die provided with a guide groove having substantially the same width as the width of the insulation-coated conductor wire. , in a state in which is fitted the insulation coated conductor wire into the guide groove of the die, to claim 1, characterized in that folding the insulation coated conductor wire at a right angle by relatively moving the punch to the die side The coil end shaping | molding method of the stator coil of description.

  According to the means 2, in a right-angle bending step of bending a predetermined coil end portion of the insulation-coated conductor wire at a right angle, a guide provided with a guide groove having a width substantially the same as the width of the insulation-coated conductor wire is used. With the insulation-coated conductor wire fitted in the groove, the punch is moved relative to the die side and the insulation-coated conductor wire is bent at a right angle, so that both side surfaces of the insulation-coated conductor wire abut against the side walls of the guide groove. The force to swell both sides of the coated conductor wire is pressed against the side wall of the guide groove of the die, and the bulging deformation of the insulating coated conductor wire can be suppressed.

  3. In the right angle bending step, the die is formed by connecting a plurality of divided blocks capable of dividing the guide groove in the width direction as the die, and after bending the insulating coated conductor wire, the die is divided into the divided blocks. 3. The coil end molding method for a stator coil according to claim 2, wherein the insulation coated conductor wire that is disassembled and taken in the guide groove is taken out.

  According to the means 3, since the die is formed by connecting a plurality of divided blocks that can divide the guide groove in the width direction, the die groove is generated by the force that the both side surfaces of the insulation-coated conductor wire swell. Even if it becomes difficult to pull out the insulated conductor wire from the groove, it becomes possible to easily remove the insulated conductor wire from the die by disassembling the die into divided blocks. .

  4). A step-like forming step of forming the coil end planned portion of the insulation-coated conductor wire in a staircase shape, the step-like forming step having a deepest step at the center and a step-like receiving surface on both sides of the insulation coating step; The insulating coated conductor using a die having a recess provided with a guide having a width substantially the same as the width of the conductor wire, and a punch having a convex portion having a stepped pressing surface corresponding to the receiving surface at the tip. The insulating coated conductor wire is formed in a step shape by inserting the convex portion of the punch into the concave portion of the die in a state where the length direction of the wire is along the guide of the die. The stator coil coil end forming method according to any one of 1 to 3.

  According to the means 4, in the step-like forming step of forming the coil end planned portion of the insulation-coated conductor wire in a staircase shape, the center has the deepest step-shaped receiving surface, and the width of the insulation-coated conductor wire is substantially equal to the width of both sides. Using a die having a concave portion provided with a guide of the same width and a punch having a convex portion having a stepped pressing surface corresponding to the receiving surface at the tip, the length direction of the insulation coated conductor wire is adjusted In the state along the guide, the convex part of the punch was inserted into the concave part of the die, and the insulation-coated conductor wire was formed in a staircase shape, so both sides of the insulation-coated conductor wire and the inner wall of the guide of the die , And the force to swell both side surfaces of the insulating coated conductor wire is pressed against the inner wall of the guide of the die, and the swelling of the insulating coated conductor wire can be suppressed.

  5. A crank bending step of forming the coil end planned portion of the insulating coated conductor wire in a crank shape, the crank bending step having a receiving surface having a step, and the step being substantially the same as the width of the insulating coated conductor wire; Using a die provided with a width guide, the insulating coated conductor wire is fitted into the guide, and a second receiving end of the insulating coated conductor wire is pressed by the shallow receiving surface of the die and the first punch. The other end of the insulation-coated conductor wire is pressed against a deep receiving surface of the die by a punch, and the guide is brought into contact with a side surface of the insulation-coated conductor wire when the crank is bent. Item 5. A method for forming a coil end of a stator coil according to any one of Items 1 to 4.

  According to the means 5, in the crank bending process in which the coil end planned portion of the insulation coated conductor wire is formed in a crank shape, the receiving surface has a step, and a guide having the same width as the width of the insulation coating conductor wire is provided on the step. The insulated coated conductor wire is inserted into the guide using the die, and the insulating punched conductor wire is pressed by the second punch in a state where one end of the insulated coated conductor wire is pressed by the shallow receiving surface of the die and the first punch. The other end was pressed against the deep receiving surface of the die and cranked, and the guide was brought into contact with the side surface of the insulated conductor wire at the time of crank bending, so both sides of the insulated conductor wire and the inner wall of the die guide And the force to swell both side surfaces of the insulation-coated conductor wire is pressed against the inner wall of the die guide, and the bulge can be suppressed.

  By the way, in addition to suppressing the bulge as in the present invention, it is possible to bulge once and then pressurize the bulge to return it to its original size, but in this case, the bulged part is work-hardened. The resin film becomes thin by crushing. That is, the resin film becomes thin when swollen and further thins when crushed. For this reason, it is desirable to use the method of the present invention.

  Hereinafter, an embodiment embodying a method for forming a coil end of a stator coil according to the present invention will be specifically described with reference to the drawings.

(Description of stator coil)
First, a stator coil of this embodiment that employs a stepped coil end will be described with reference to FIGS.

  FIG. 1 is a partial perspective view showing a part of one insulating covering rectangular wire 30, and FIG. 2 is a partial perspective view showing a coil end that is an assembly of stepped coil end portions 42.

  11 is a stator, 12 is a stator core, 13 is an end face of the stator core 12, and 20 is a stator coil. The stator 11 is used for a generator motor for driving a vehicle. A rotor (not shown) is rotatably accommodated inside the stator 11 in the radial direction. A large number of magnetic poles having different polarities alternately in the circumferential direction are formed by permanent magnets on the outer periphery of the rotor. The outer peripheral surface of the rotor faces the inner peripheral surface of the stator 11 via a minute air gap. The stator core 12 is formed by laminating electromagnetic steel plates having a predetermined thickness in the axial direction. The stator coil 20 is a three-phase winding. One phase wave winding is wound around the slot 14, and the same one phase wave winding is wound around the slot 15. In other words, a stator coil 20 having the same phase is wound around two slots 14 and 15 adjacent to each other to form a so-called two-slot structure for each pole per phase.

  One phase coil (wave winding) of the stator coil 20 is formed by bending an insulation-coated rectangular wire 30 that is an insulation-coated conductor wire obtained by insulatingly coating a rectangular wire, and then, the slot 14 having an open slot structure of the stator core 12. Or it is accommodated in 15 and formed. Of course, a split stator core structure may be employed instead of the open slot structure.

  The insulation coated rectangular wire 30 is the same as that shown in FIG. 15B, and a copper wire 30b having a substantially rectangular cross section is covered with an enamel layer (not shown) such as polyamideimide, and further, PPS is provided on the outside thereof. An insulating coating 30a of an extrusion coating resin layer such as (polyphenylene sulfide) is formed.

  The thickness of the insulating coating 30a is set to 100 μm to 170 μm, for example. However, the insulation coating structure of the insulation coating rectangular wire 30 may adopt another known method. In this embodiment, the plurality of insulation coated rectangular wires 30 are arranged in a line in the slot depth direction in the slot, but the present invention is not limited to this, and may be arranged in a matrix in the slot. . In addition, it is usual to provide insulating paper on the inner surface of the slot. However, in this embodiment, the insulating coating 30a is formed of a two-layer insulating layer by the enamel layer and the coating resin layer, so that the insulating paper is omitted. ing.

  The stator coil 20 will be further described with reference to FIGS. The insulation-coated rectangular wire 30 forming the stator coil 20 is separated from the slot accommodating portions 40 accommodated in the slots 14 and 15 of the stator core 12 respectively by 2 in the circumferential direction while extending in the circumferential direction by approximately one magnetic pole pitch. A coil end portion 42 that connects the end portions of the two slot accommodating portions 40 at both axial ends of the stator core 12 is provided.

(Description of shape of coil end portion 42)
The coil end portion 42 of the insulating coated rectangular wire 30 will be described in more detail with reference to FIG. 3 which is a schematic circumferential development view thereof.

  At the center in the circumferential direction of the coil end portion (also referred to as a stepped coil end portion) 42 is provided a crown portion 1 that is a circumferential line portion that is located on the outermost side in the axial direction and extends in the circumferential direction. The part 42 is bent stepwise from the top part (circumferential line part) 1 toward the slot accommodating parts 40 on both sides.

  A step (also referred to as a step in the thickness direction) 3A is provided in the central portion of the top portion (circumferential line portion) 1 in the radial direction (thickness direction) by the substantially thickness of the insulating covering flat wire 30. This thickness direction step 3A is a step for allowing the coil end portion 42 and the other half portion to overlap each other in the radial direction by allowing the conductor end portion to overlap with the other coil end portion. It is.

  2 to 4 are circumferential line portions extending in the circumferential direction, and 6 to 8 are axial line portions extending in the axial direction. C1 to C6 are corner portions forming a boundary portion between one circumferential line portion and one axial line portion adjacent to each other. C <b> 7 is a corner portion that forms a boundary portion between the circumferential line portion 4 and the slot accommodating portion 40.

  The coil end portion 42 is formed in a step shape from the outermost crown 1 in the axial direction toward the left and right slot accommodating portions 40.

  In FIG. 3, the corners C1 to C7 are shown at right angles, but in reality, the corners C1 to C7 are bent or curved with a predetermined radius of curvature within a range where high-density mounting with the other adjacent coil end portions 42 is possible. It only has to be.

(Method for forming coil end portion 42)
Next, a method for forming a coil end of the stator coil according to the present embodiment for forming the coil end portion 42 having the above-described shape will be described in detail with reference to the drawings.

(Right-angle bending process)
In the present embodiment, when the coil end portion 42 is formed with respect to one straight insulating wire rectangular wire 30, first, a right-angle bending process is performed.

  FIG. 4 is a diagram for explaining a right-angle bending process in the coil end forming method of the stator coil according to the present embodiment. FIG. 4A is a diagram showing the insulation covered rectangular wire 30 in a state where the right-angle bending process is performed. And (b) is a schematic plan view for explaining the process of the right-angle bending process.

  The right-angle bending step is a step of bending the straight rod-shaped insulating covering rectangular wire 30 at the corner portion C7 (see FIGS. 3 and 4A). By performing this step, the slot accommodating portion 40 and the coil end planned portion 43 are bent. (See FIG. 4A) can be formed.

  Hereinafter, an outline of the right-angle bending process will be described with reference to FIG.

  In the right angle bending process of the present embodiment, a die 52, a die 53, a punch 54, and a punch 55 are used.

  First, the straight rod-shaped insulating covering rectangular wire 30 is sandwiched and fixed between the die 52 and the die 53. In this state, the punch 54 is relatively moved to the die 52 side, that is, the punch 54 is rotated around an angle as shown by an arrow in the drawing, and the insulating covering rectangular wire 30 is bent at an angle of approximately 90 degrees. This bent corner becomes the corner portion C7 of the insulating covering flat wire 30.

  After that, the insulating coated rectangular wire 30 is sandwiched and fixed as it is by the die 52 and the punch 54, and in this state, the punch 55 is rotated around the corner as indicated by an arrow in the figure, and the insulating coated rectangular wire 30 is moved approximately 90 degrees. Bend at an angle of. This bent corner also becomes the corner portion C7 of the insulating covering flat wire 30. Thereafter, the insulation covered rectangular wire 30 having the corner C7 shown in FIG. 4A is repeatedly obtained.

  By the way, in this embodiment, when forming the corner | angular part C7 in the insulation coating flat wire 30, it can prevent that the side surface inside the corner | angular part C7 swells. The configuration for this will be described with reference to FIGS.

  FIG. 5 is a diagram showing details of the right-angle bending process shown in FIG. 4, (a) is a plan view showing a first state in which the right-angle bending process is performed, and (b) is a direction of (a). It is the side view seen from A. 6 is a diagram showing details of the right-angle bending process shown in FIG. 4, and FIG. 6A is a plan view showing a second state following FIG. 5 in a state in which the right-angle bending process is performed. (B) is the side view which looked at (a) from direction B. 7 is a diagram showing details of the right-angle bending process shown in FIG. 4, and (a) is a plan view showing a third state following FIG. 6 in a state in which the right-angle bending process is performed. (B) is the side view which looked at (a) from direction C.

  The die 52 is configured by providing a lower divided block 52c at the lower end of the base 52b and an upper divided block 52a at the upper portion thereof. The upper divided block 52a is fixed at a position where a guide groove 52d is formed between the upper divided block 52a and the lower divided block 52c. At this time, the groove width of the guide groove 52d is set to be about 0.05 mm wider than the width of the insulating covering rectangular wire 30.

  The insulating coated rectangular wire 30 is fitted into the guide groove 52d, and the insulating coated rectangular wire 30 is fixed by being sandwiched between the die 52 and the die 53, and as shown in FIG. Relative movement is performed, that is, the punch 54 is rotated to bend the insulating covering rectangular wire 30 to form the corner C7 (see FIGS. 6A and 6B).

  Since the corner portion C7 of the insulating covered rectangular wire 30 is formed while being fitted in the guide groove 52d of the die 52, the bulge of the side surface of the insulating covering rectangular wire 30 is caused by the upper divided block 52a and the side wall of the guide groove 52d and It is suppressed by the lower divided block 52c.

  By the way, the upper divided block 52a and the upper divided block 52a are configured so as to be divided in the width direction of the groove so as to widen the guide groove 52d. When the insulating covering rectangular wire 30 is taken out from the guide groove 52d, the upper divided block 52a and the upper divided block 52a are disassembled. This can be done easily by widening 52d.

  In the die 52, an example in which the base 52b, the lower divided block 52c, and the upper divided block 52a are separated from each other is shown. However, the punch 54 also serves as a die, and the punch 54 includes a base and a lower divided block. An example is shown in which the base 54b serves as a lower divided block.

  The punch 54 is configured by providing an upper divided block 54a at the top end of the base 54b. The upper divided block 54a is fixed at a position where a guide groove 54d is formed between the upper divided block 54a and the base 54b. At this time, the groove width of the guide groove 54d is set to be about 0.05 mm wider than the width of the insulating covering rectangular wire 30.

  The insulating covering rectangular wire 30 is fitted into the guide groove 54d, and the insulating covering rectangular wire 30 is fixed by being sandwiched between the die 52 and the punch 54. As shown in FIG. 4B, the punch 55 is placed on the punch 54 side. Relative movement is performed, that is, the punch 55 is rotated to bend the insulating covering rectangular wire 30 to form the corner C7 (see FIGS. 7A and 7B).

  Since the corner portion C7 of the insulating covering rectangular wire 30 is formed while being fitted into the guide groove 54d of the punch 54, the swelling of the side surface of the insulating covering rectangular wire 30 is caused by the upper divided block 54a and the side walls of the guide groove 54d. It is suppressed by the base 54b.

  The upper divided block 54a and the base 54b are configured to be divisible in the width direction of the groove so as to widen the guide groove 54d. When the insulating coated rectangular wire 30 is taken out from the guide groove 54d, it is disassembled to widen the guide groove 54d. This can be done easily.

  According to this embodiment, when the expected coil end portion of the insulation-coated conductor wire is bent, the guide surfaces are brought into contact with both side surfaces of the insulation-coated conductor wire in the direction intersecting the bending direction. Swelling deformation of the line can be suppressed.

  Since the coil end formed in this way is a rectangle with the original cross-sectional shape, the conductor space factor can be improved without generating an extra gap when the coil ends are overlapped with each other. In addition, the dimensional accuracy of the inner and outer diameters of the coil subassembly can be increased.

  In addition, since deformation in a direction different from the bending direction of the insulation-coated conductor wire is suppressed, a thin-coated portion of the insulation-coated conductor wire does not occur, sufficient insulation can be secured, and a structure that can withstand high voltages It can be.

  In addition, in a right-angle bending process in which the coil end planned portion of the insulation-coated conductor wire is bent at a right angle, a die having a guide groove having the same width as the width of the insulation-coated conductor wire is used. With the conductor wire fitted, the insulation-coated conductor wire is bent at a right angle by moving the punch relatively to the die side, so that both side surfaces of the insulation-coated conductor wire abut against the side wall of the guide groove. A force that causes both side surfaces of the die to swell is pressed against the side wall of the guide groove of the die, and the bulge deformation of the insulating coated conductor wire can be suppressed.

  In addition, because the die is formed by connecting a plurality of divided blocks that can divide the guide groove in the width direction, it is in close contact with the inner wall of the die groove with the force that both sides of the insulated conductor wire swell Even if it is difficult to extract the insulation-coated conductor wire from the groove, the insulation-coated conductor wire can be easily extracted from the die by disassembling the die into divided blocks.

(Step-shaped molding process)
In the present embodiment, a step-like forming process is performed on the insulating coated rectangular wire 30 after the above-described right-angle bending process.

  FIG. 8 is a view for explaining a step-shaped forming step in the coil end forming method of the stator coil according to the present embodiment. FIG. 8A shows the insulating coated rectangular wire 30 in a state where the step-shaped forming step is performed. It is a figure and (b) is a schematic plan view explaining the process of a step-shaped shaping | molding process.

  The step-shaped forming step is a step of forming the coil end planned portion 43 of the insulation covered rectangular wire 30 that has undergone the right-angle bending step into a step shape (see FIGS. 3 and 8A). By performing this step, The top part 1, the circumferential line parts 2 to 4, the axial line parts 6 to 8, and the corner parts C1 to C6 can be formed.

  Hereinafter, an outline of the step-shaped forming process will be described with reference to FIG.

  In the step-shaped forming process of the present embodiment, a die 57 having a recess having the deepest center and a step-shaped receiving surface, and a convex portion having a step-shaped pressing surface corresponding to the receiving surface of the die 57 at the tip are provided. Using the provided punch 56, the concave portion of the die 57 and the convex portion of the punch 56 are made to face each other, and the coil end planned portion 43 of the insulation covered rectangular wire 30 is prepared between the die 57 and the punch 56, The convex portion of the punch 56 is inserted into the concave portion of the die 57, and the coil end planned portion 43 is bent by the stepped receiving surface of the concave portion and the stepped pressing surface of the convex portion to form the corner portions C1 to C6.

  By the way, in this embodiment, when forming the corner | angular parts C1-C6 in the insulation coating flat wire 30, it can prevent that the side surface inside the corner | angular parts C1-C6 swells. The configuration for this will be described with reference to FIGS.

  FIG. 9 is a diagram showing details of the step-shaped forming step shown in FIG. 8, (a) is a plan view showing a first state in which the step-shaped forming step is performed, and (b) is (a). It is the side view which looked at from direction D. 10 is a diagram showing details of the step-shaped forming step shown in FIG. 8, and (a) is a plan view showing a second state following FIG. 9 in a state in which the step-shaped forming step is performed. (B) is a side view of (a) as viewed from the direction E.

  The die 57 is configured by providing a lower guide 57c at the lower end of the base 57a and an upper guide 57d at the upper portion thereof. The guide width between the upper guide 57d and the lower guide 57c is set to be approximately 0.05 mm wider than the width of the insulating covering flat wire 30. In the back between the upper guide 57d and the lower guide 57c, the center is deepest and a stepped receiving surface 57b is formed as a recess.

  At the tip of the base 56a of the punch 56, a step-like pressing surface 56b corresponding to the receiving surface 57b having a width that can be inserted into the guide width between the upper guide 57d and the lower guide 57c is provided. It has become.

  The coil end planned portion 43 of the insulation covered rectangular wire 30 is fitted between the upper guide 57d and the lower guide 57c so that the length direction thereof is along the inner wall (see FIGS. 9A and 9B). In this state, the convex portion of the punch 56 is fitted into the concave portion of the die 57, and the corner portions C1 to C6 are formed with the coil end planned portion 43 sandwiched between the receiving surface 57b and the pressing surface 56b (FIG. 10A). (See (b)).

  Since the corners C1 to C6 of the insulating covered rectangular wire 30 are formed while being fitted between the upper guide 57d and the lower guide 57c, the bulge of the side surface of the insulating covering rectangular wire 30 It is suppressed by being pressed by the inner wall of the lower guide 57c.

  According to this embodiment, when the insulation-coated conductor wire is bent, the deformation-suppressing member presses the force of the insulation-coated conductor wire to deform in a direction different from the bending direction, and the deformation can be suppressed.

  Since the coil end formed in this way is a rectangle with the original cross-sectional shape, the conductor space factor can be improved without generating an extra gap when the coil ends are overlapped with each other. In addition, the dimensional accuracy of the inner and outer diameters of the coil subassembly can be increased.

  In addition, since deformation in a direction different from the bending direction of the insulation-coated conductor wire is suppressed, a thin-coated portion of the insulation-coated conductor wire does not occur, sufficient insulation can be secured, and a structure that can withstand high voltages It can be.

  In addition, in the step-shaped forming process for forming the coil end planned portion of the insulation-coated conductor wire in a staircase shape, the guide has a deepest step at the center and a step-shaped receiving surface that is approximately the same width as the width of the insulation-coated conductor wire on both sides. The length of the insulation-coated conductor wire is aligned with the guide of the die using a die having a concave portion provided with a punch and a punch having a convex portion having a stepped pressing surface corresponding to the receiving surface at the tip. In such a state, the convex portion of the punch is inserted into the concave portion of the die so that the insulating coated conductor wire is formed in a step shape, so that both side surfaces of the insulating coated conductor wire and the inner wall of the die guide are in contact with each other, A force for expanding both side surfaces of the insulating coated conductor wire is pressed against the inner wall of the guide of the die, and the swelling of the insulating coated conductor wire can be suppressed.

(Crank bending process)
In the present embodiment, a crank bending process is performed on the insulating coated rectangular wire 30 after the step-shaped forming process described above.

  FIG. 11 is a diagram for explaining a crank bending process in the coil end forming method of the stator coil according to the present embodiment, and FIG. 11A is a diagram showing the insulating coated rectangular wire 30 in a state where the crank bending process is performed. (B) is a side view of (a) seen from the direction F, and (c) is a schematic side view for explaining the processing of the crank bending process.

  The crank bending step is a step of crank bending the coil end planned portion 43 of the insulation covered rectangular wire 30 that has undergone the step-like forming step (see FIGS. 3 and 11B). Can be formed.

  Hereinafter, the outline of the crank bending process will be described with reference to FIG.

  In the crank bending process of the present embodiment, a die 58, a punch 59, and a punch 60 are used to provide a receiving surface with a step on the die 58, and the coil end planned portion 43 of the insulating coated rectangular wire 30 is received. Prepared between the surface and the punch 59 and the punch 60, with the insulating coating flat wire 30 fixed by the shallow receiving surface and the punch 59, the punch 60 is pressed against the deep receiving surface to bend the coil end planned portion 43. Step 3A is formed.

  By the way, in this embodiment, when forming the level | step difference 3A in the insulation coating flat wire 30, it can prevent that the side surface inside the level | step difference 3A swells. The configuration for this will be described with reference to FIGS. 12, 13, and 14. FIG.

  12 is a diagram showing details of the crank bending process shown in FIG. 11, (a) is a plan view showing a first state in which the crank bending process is performed, and (b) is a direction of (a). It is the side view seen from G. 13 is a diagram showing details of the crank bending process shown in FIG. 11, and FIG. 13 (a) is a plan view showing a second state following FIG. 12 in a state in which the crank bending process is performed. (B) is the side view which looked at (a) from direction H. Further, FIG. 14 is an enlarged view of a portion J in FIG.

  The die 58 has two receiving surfaces 58a and 58b that are stepped from each other, and guides 58c and 58d are provided between the shallow receiving surface 58a and the deep receiving surface 58b. The guide width between the guide 58c and the guide 58d is set to be about 0.05 mm wider than the width of the insulating covered rectangular wire 30.

  The coil end planned portion 43 of the insulation covered rectangular wire 30 is such that the length direction thereof extends from the receiving surface 58a to the receiving surface 58b, and the substantially central portion of the crown 1 is fitted between the guide 58c and the guide 58d (see FIG. 12 (a) and 12 (b)), in this state, the shallow receiving surface 58a and the punch 59 hold one end of the insulating coated flat wire 30 and the punch 60 holds the other end of the insulating covering flat wire 30 to the deep receiving surface 58b. To form a step 3A (see FIGS. 13A and 13B).

  Since the step 3A of the insulating covered rectangular wire 30 is formed while being fitted between the guide 58c and the guide 58d, the swelling of the side surface of the insulating covering rectangular wire 30 is suppressed by the inner wall of the guide 58c and the inner wall of the guide 58d. And suppressed (see FIG. 14).

  According to this embodiment, when the insulation-coated conductor wire is bent, the deformation-suppressing member presses the force of the insulation-coated conductor wire to deform in a direction different from the bending direction, and the deformation can be suppressed.

  Since the coil end formed in this way is a rectangle with the original cross-sectional shape, the conductor space factor can be improved without generating an extra gap when the coil ends are overlapped with each other. In addition, the dimensional accuracy of the inner and outer diameters of the coil subassembly can be increased.

  In addition, since deformation in a direction different from the bending direction of the insulation-coated conductor wire is suppressed, a thin-coated portion of the insulation-coated conductor wire does not occur, sufficient insulation can be secured, and a structure that can withstand high voltages It can be.

  Also, in a crank bending process in which the coil end planned portion of the insulation coated conductor wire is formed in a crank shape, a die having a step on the receiving surface and provided with a guide having a width substantially the same as the width of the insulation coating conductor wire is used. The insulation-coated conductor wire is fitted into the guide, and the other end of the insulation-coated conductor wire is connected to the die by the second punch while the one end of the insulation-coated conductor wire is held by the shallow receiving surface of the die and the first punch. Since the guide is brought into contact with the side surface of the insulated conductor wire when the crank is bent, the guide is brought into contact with the side surface of the insulated conductor wire and the inner wall of the die guide is in contact. The force that the both side surfaces of the insulation coated conductor wire try to swell is pressed against the inner wall of the die guide, and the swell can be suppressed.

  The present invention can be applied to a generator motor for driving a vehicle, and is effective, for example, in improving the performance of a so-called hybrid car having both an internal combustion engine and an electric motor.

It is a fragmentary perspective view which shows a part of one insulation coating flat wire. It is a fragmentary perspective view which shows the coil end which is an aggregate | assembly of a step-like coil end part. It is a model circumferential direction expansion | deployment top view of a step-like coil end part. It is a figure explaining the right angle bending process among the coil end shaping | molding methods of the stator coil of this embodiment, (a) is a figure which shows the insulation coating rectangular wire in the state to which the right angle bending process was given, (b) FIG. 5 is a schematic plan view for explaining processing in a right-angle bending process. It is a figure which shows the detail of the right angle bending process shown in FIG. 4, (a) is a top view which shows the 1st state which implements a right angle bending process, (b) looked at (a) from the direction A. It is a side view. It is a figure which shows the detail of the right angle bending process shown in FIG. 4, (a) is the state which implements a right angle bending process, Comprising: It is a top view which shows the 2nd state following FIG. 5, (b) is ( It is the side view which looked at a) from direction B. FIG. 5 is a diagram showing details of the right-angle bending process shown in FIG. 4, (a) is a plan view showing a third state following FIG. 6 in a state in which the right-angle bending process is performed, and (b) is ( It is the side view which looked at a) from direction C. It is a figure explaining the step-shaped shaping | molding process among the coil end shaping | molding methods of the stator coil of this embodiment, (a) is a figure which shows the insulation coating rectangular wire in the state to which the step-shaped shaping | molding process was performed, b) is a schematic plan view for explaining processing in a step-like forming step. It is a figure which shows the detail of the step shape forming process shown in FIG. 8, (a) is a top view which shows the 1st state which implements a step shape forming process, (b) is (a) from direction D. FIG. It is a figure which shows the detail of the step-shaped shaping | molding process shown in FIG. 8, (a) is a top view which is the state which implements a step-shaped shaping | molding process, and shows the 2nd state following FIG. 9, (b) FIG. 3A is a side view when (a) is viewed from a direction E. FIG. It is a figure explaining the crank bending process among the coil end shaping | molding methods of the stator coil of this embodiment, (a) is a figure which shows the insulation coating rectangular wire in the state to which the crank bending process was given, (b) (A) is the side view which looked from the direction F, (c) is a schematic side view explaining the process of a crank bending process. It is a figure which shows the detail of the crank bending process shown in FIG. 11, (a) is a top view which shows the 1st state which implements a crank bending process, (b) looked at (a) from the direction G. It is a side view. It is a figure which shows the detail of the crank bending process shown in FIG. 11, (a) is the state which implements a crank bending process, Comprising: It is a top view which shows the 2nd state following FIG. 12, (b) is ( It is the side view which looked at from a direction H. It is the figure which expanded the part J of FIG.13 (b). It is a figure which shows an example of the shape of a stator coil, (a) is a side view of the coil end part made into step shape, (b) is sectional drawing of a coil, (c) is K- of (a). It is sectional drawing of the coil in K part.

Explanation of symbols

C1-C7 corner C1 corner (innermost corner)
C7 corner (outermost corner)
DESCRIPTION OF SYMBOLS 1-4 Circumferential line part 1 Head top part 6-8 Axial line part 3A Level | step difference 11 Stator 12 Stator core 14 Slot 15 Slot 20 Stator coil 30 Insulation covering rectangular wire 40 Slot accommodating part 42 Coil end part (step-like coil end part)
43 Coil end planned portion 52, 53, 57, 58 Die 54, 55, 56, 59, 60 Punch 52a, 54a Upper divided block 52b, 54b, 56a, 57a Base 52c Lower divided block 52d, 54d Guide groove 56b Press surface 57b, 58a, 58b Receiving surface 57c Lower guide 57d Upper guide 58c, 58d Guide

Claims (5)

In the coil end molding method of the stator coil, the coil end portion of the insulation coated conductor wire formed by insulation coating of the rectangular wire is bent to form the coil end portion of the stator coil into a predetermined shape.
When bending the coil end planned portion of the insulating coated conductor wire, the insulating coated conductor wire is fitted into a die and a punch, and guides are provided on both side surfaces of the insulating coated conductor wire in a direction crossing the bending direction. A method for forming a coil end of a stator coil, wherein a surface is brought into contact to suppress the bulging deformation of the insulating coated conductor wire. A right-angle bending step of bending the coil end planned portion of the insulation-coated conductor wire at a right angle;
The right-angled step, using a die guide grooves of substantially the same width as the width of the insulation coated conductor wire is provided, in the guide state is fitted to the insulation coated conductor wire into the groove of the die, the punch 2. The coil end forming method for a stator coil according to claim 1, wherein the insulation coated conductor wire is bent at a right angle by moving the wire toward the die side.   In the right angle bending step, the die is formed by connecting a plurality of divided blocks capable of dividing the guide groove in the width direction as the die, and after bending the insulating coated conductor wire, the die is divided into the divided blocks. 3. The coil end molding method for a stator coil according to claim 2, wherein the insulation coated conductor wire that is disassembled and taken in the guide groove is taken out. A step-shaped forming step of forming the coil end planned portion of the insulation-coated conductor wire in a step shape;
The step-shaped forming step includes a die having a deepest step at the center and a recess provided with guides having substantially the same width as the width of the insulation-coated conductor wire on both sides, and the receiving surface at the tip. A punch having a convex portion having a stepped pressing surface according to the length of the insulating coated conductor wire along the guide of the die and the convex portion of the punch. The stator coil coil end forming method according to any one of claims 1 to 3, wherein the insulating coated conductor wire is formed in a step shape by being inserted into a concave portion of a die. A crank bending step of forming a predetermined coil end portion of the insulation-coated conductor wire in a crank shape;
In the crank bending step, the insulating coated conductor wire is fitted into the guide using a die having a receiving surface having a step and a guide having a width substantially the same as the width of the insulating coated conductor wire. In a state where one end of the insulated conductor wire is pressed by the shallow receiving surface of the die and the first punch, the other end of the insulated conductor wire is pressed against the deep receiving surface of the die by the second punch. 5. The coil end forming method of a stator coil according to claim 1, wherein the guide is brought into contact with a side surface of the insulation-coated conductor wire when the crank is bent.

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