阅读说明：本技术 用于制造定子的装置和方法 (Device and method for producing a stator ) 是由 吉川一央 狐塚勝司 藤原慎平 于 2020-10-15 设计创作，主要内容包括：一种用于制造定子的装置和方法,所述装置包括放置台、支承构件和电阻加热装置。放置台构造成将供线圈部段和绝缘体插入该定子芯的槽中的的定子芯放置在该放置台上。定子芯由沿定子芯的轴向方向层叠的钢板形成。线圈部段共同形成定子线圈。绝缘体由在加热时能发泡的材料形成。支承构件构造成沿定子芯的轴向方向对定子芯的齿的远端部分进行支承,以防止在形成定子芯的钢板之间形成间隙。电阻加热装置构造成通过对定子线圈通电来加热绝缘体和定子线圈,从而使绝缘体发泡。(An apparatus and method for manufacturing a stator includes a placing table, a support member, and a resistance heating apparatus. The placing table is configured to place the stator core, on which the coil sections and the insulators are inserted into the slots of the stator core, on the placing table. The stator core is formed of steel plates laminated in an axial direction of the stator core. The coil sections collectively form a stator coil. The insulator is formed of a material that foams when heated. The support member is configured to support distal end portions of the teeth of the stator core in an axial direction of the stator core to prevent formation of gaps between steel plates forming the stator core. The resistance heating device is configured to heat the insulator and the stator coil by energizing the stator coil, thereby foaming the insulator.)

1. A device for manufacturing a stator (1) for a rotating electric machine,

the stator includes:

an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, the stator core having a plurality of teeth (14) each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots (11) each formed between a pair of circumferentially adjacent teeth;

a stator coil formed of a plurality of coil sections (20) inserted into the slots of the stator core; and

a plurality of insulators (30) inserted into the slots of the stator core together with the coil sections, the insulators being made of a material that is foamable when heated,

the device comprises:

a placing table (50) on which the stator core is placed, the stator core having the coil section and the insulator inserted into the slot of the stator core;

a support member (60, 610, 620) configured to support a distal end portion (15) of the teeth of the stator core in an axial direction of the stator core to prevent formation of a gap between the steel plates forming the stator core; and

a resistance heating device (80) configured to heat the insulator and the stator coil by energization of the stator coil, thereby foaming the insulator.

2. The apparatus of claim 1, wherein the support member (60) is configured to support the distal end portions of the teeth of the stator core from a vertically lower side of the distal end portions.

3. The apparatus of claim 1, wherein the support member comprises:

a first support member (610) configured to support the distal end portions of the teeth of the stator core from a first axial side of the stator core; and

a second support member (620) configured to support the distal end portions of the teeth of the stator core from a second axial side of the stator core, the second axial side being opposite to the first axial side in an axial direction of the stator core.

4. A device for manufacturing a stator (1) for a rotating electric machine,

the stator includes:

an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, the stator core having a plurality of teeth (14) each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots (11) each formed between a pair of circumferentially adjacent teeth;

a stator coil formed of a plurality of coil sections (20) inserted into the slots of the stator core; and

an impregnating material that is immersed in the slots of the stator core and cured in the slots to fix the stator coil in the slots,

the device comprises:

a placement table (50) on which the stator core into which the coil section is inserted in the slot of the stator core is placed;

a support member (60, 610, 620) configured to support a distal end portion (15) of the teeth of the stator core in an axial direction of the stator core to prevent formation of a gap between the steel plates forming the stator core;

an impregnation device (100) configured to impregnate the impregnating material in a liquid state into the slots of the stator core; and

a resistance heating device (80) configured to heat the impregnating material and the stator coil by energizing the stator coil, thereby solidifying the impregnating material in the slot.

5. The apparatus of claim 4, wherein the support member (60) is configured to support the distal end portions of the teeth of the stator core from a vertically lower side of the distal end portions.

6. The apparatus of claim 4, wherein the support member comprises:

a first support member (610) configured to support the distal end portions of the teeth of the stator core from a first axial side of the stator core; and

a second support member (620) configured to support the distal end portions of the teeth of the stator core from a second axial side of the stator core, the second axial side being opposite to the first axial side in an axial direction of the stator core.

7. A device for manufacturing a stator (1) for a rotating electric machine,

the stator includes:

an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, the stator core having a plurality of teeth (14) each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots (11) each formed between a pair of circumferentially adjacent teeth;

a stator coil formed of a plurality of coil segments (20) inserted into the slots of the stator core, the stator coil having a plurality of coil protrusions (21) that are portions of the coil segments that protrude from axial end faces of the stator core to the outside of the slots, and a plurality of coil joints (22) at each of which distal end portions of a corresponding pair of the coil protrusions are joined together; and

a package insulator (40) in which at least the coil tab of the stator coil is packaged,

the device comprises:

a metal mold (90) having a groove (91) configured to insert at least the coil terminal of the stator coil into the groove, and a support portion (93) configured to support a distal end portion of the teeth of the stator core in an axial direction of the stator core to prevent a gap from being formed between the steel plates forming the stator core;

a resin supply device (95) configured to supply a liquid thermosetting resin for forming the package insulator into the groove of the metal mold; and

a resistance heating device (85) configured to heat the liquid thermosetting resin and the stator coil by energizing the stator coil with at least the coil tab of the stator coil immersed in the liquid thermosetting resin filled in the groove of the metal mold, thereby solidifying the liquid thermosetting resin to form the package insulator.

8. A method of manufacturing a stator (1) for a rotating electrical machine, the method comprising:

a preparation step (S10) in which an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, the stator core having a plurality of teeth (14) each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, coil section (20) for forming a stator coil, and a plurality of insulators (30) each formed of a material foamable when heated are prepared;

an insulator inserting step (S20) in which the insulators are inserted into the slots of the stator core, respectively;

a coil section insertion step (S30) in which the coil sections are inserted into the slots of the stator core;

a joining step (S70) in which the coil sections are joined to form the stator coil;

a supporting step (S81) in which distal end portions (15) of the teeth of the stator core are supported in an axial direction of the stator core by a support member (60, 610, 620) to prevent formation of gaps between the steel plates forming the stator core; and

a resistance heating step (S84) in which the stator coil is energized to heat the insulator and the stator coil, thereby foaming the insulator.

9. The method of claim 8, wherein the support member comprises a first support member (610) and a second support member (620),

in the supporting step, the distal end portions of the teeth of the stator core are supported from opposite axial sides of the stator core by the first and second support members, respectively.

10. A method of manufacturing a stator (1) for a rotating electrical machine, the method comprising:

a preparation step (S10) in which an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, the stator core having a plurality of teeth (14) each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, coil section (20) for forming a stator coil, and a dipping material each formed between a pair of circumferentially adjacent teeth are prepared, the dipping material being in a liquid state;

a coil section insertion step (S130) in which the coil sections are inserted into the slots of the stator core;

a joining step (S170) in which the coil sections are joined to form the stator coil;

a supporting step (S180) in which distal end portions (15) of the teeth of the stator core are supported in an axial direction of the stator core by a support member (60, 610, 620) to prevent formation of gaps between the steel plates forming the stator core;

an impregnation step (S180) in which the impregnating material in a liquid state is immersed in the slots of the stator core; and

a resistance heating step (S180) in which the stator coil is energized to heat the impregnating material and the stator coil, thereby solidifying the impregnating material in the slots.

11. The method of claim 10, wherein the support member comprises a first support member (610) and a second support member (620),

in the supporting step, the distal end portions of the teeth of the stator core are supported from opposite axial sides of the stator core by the first and second support members, respectively.

12. A method of manufacturing a stator (1) for a rotating electrical machine, the method comprising:

a preparation step (S10) in which an annular stator core (10) formed of a plurality of steel plates (12) laminated in an axial direction of the stator core, each of the teeth extending in a radial direction of the stator core and being arranged at predetermined intervals in a circumferential direction of the stator core, each of the slots being formed between a pair of circumferentially adjacent teeth, a coil section (20) for forming a stator coil, and a liquid thermosetting resin for forming a packing insulator (40) are prepared;

a coil section insertion step (S30, S130) in which the coil section is inserted into the slot of the stator core such that a portion (21) of the coil section protrudes from an axial end face of the stator core to the outside of the slot;

a joining step (S70, S170) in which the coil sections are joined to form the stator coil having a plurality of coil joints (22) at each of which distal end portions of a respective pair of the protruding portions of the coil sections are joined together;

a resin supply step (S93) in which the liquid thermosetting resin for forming the package insulator is supplied into a recess (91) formed in a metal mold (90) in which a support portion (93) is also formed;

an impregnation step (S94) in which at least the coil tabs of the stator coil are immersed in a liquid thermosetting resin filled in the grooves of the metal mold while distal end portions (15) of the teeth of the stator core are placed to be supported by the support portions of the metal mold in an axial direction of the stator core so as to prevent formation of gaps between the steel plates forming the stator core; and

a resistance heating step (S97) in which the stator coil is energized to heat the liquid thermosetting resin and the stator coil, thereby solidifying the liquid thermosetting resin to form the package insulator in which at least the coil tab of the stator coil is packaged.

Technical Field

The present disclosure relates to an apparatus and a method for manufacturing a stator used in a rotary electric machine.

Background

A stator for a rotating electric machine is known (see, for example, japanese patent application publication No. JP2018-143066 a). The stator includes an annular stator core having a plurality of slots formed therein, and a stator coil formed of coil sections (or electrical conductor sections) inserted in the slots of the stator core. Further, the stator further includes a pair of ferrule supports (or insulating members) formed of a non-magnetic material (e.g., resin) and arranged on opposite axial sides of the stator core, respectively. The ferrule holding member is provided for filling a gap between an axial end face of the stator core and a coil end of the stator coil, thereby suppressing displacement of the coil end relative to the stator core.

The stator as described above, known in the art, has pairs of hoop supports arranged on opposite axial sides of the stator core, respectively, increasing the axial dimension of the stator. Therefore, in terms of minimizing the axial dimension of the stator, it is desirable to remove the cuff support from the stator.

However, the inventors of the present application have found through research that removing the ferrule support from the stator during the manufacture of the stator may cause the following problems.

That is, in manufacturing the stator, DRH (direct resistance heating) may be performed in such a manner that: the stator coil (or coil section) is energized to heat the stator coil and other components around the stator coil. However, when performing DRH on the stator from which the cuff supports are removed, the steel plates laminated in the axial direction of the stator core to form the stator core are expanded in the axial direction by repulsive force between portions of the steel plates that are adjacent to each other in the axial direction and magnetized to the same polarity during DRH.

Further, the stator may further include insulators formed of a foamable material and inserted into the slots of the stator core, respectively. In this case, when performing DRH to foam the insulator, if the steel plates forming the stator core are expanded in the axial direction during DRH, a foamable material forming the insulator may intrude between the steel plates, thereby forming a gap between the steel plates.

In addition, the stator may also have an impregnating material (e.g., varnish) impregnated into the slots of the stator core. In this case, when performing DRH to cure (or harden) the impregnation material, if the steel plates forming the stator core are expanded in the axial direction during the DRH, the impregnation material may intrude between the steel plates, thereby forming a gap between the steel plates.

Therefore, in either case, because a gap is formed between the steel plates, NV (noise and vibration) may occur during operation of the rotating electrical machine including the stator.

Disclosure of Invention

The present disclosure has been made in view of the above problems. Accordingly, it is an object of the present disclosure to provide an apparatus and method for manufacturing a stator that does not include a cuff support; by the apparatus and method, it is possible to prevent steel plates, which are laminated in an axial direction of a stator core of a stator to form the stator core, from being expanded in the axial direction when performing DRH on the stator.

According to the present disclosure, there is provided a first apparatus for manufacturing a stator for a rotating electrical machine. The stator includes: an annular stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots each formed between a pair of circumferentially adjacent teeth; a stator coil formed of a plurality of coil sections inserted into slots of a stator core; and a plurality of insulators inserted into the slots of the stator core together with the coil sections, the insulators being formed of a material that foams when heated. The first manufacturing apparatus includes: a placing table on which a stator core having an insulator and a coil section inserted into a slot of the stator core is placed; a support member configured to support distal end portions of teeth of the stator core in an axial direction of the stator core to prevent a gap from being formed between steel plates forming the stator core; and a resistance heating device configured to heat the insulator and the stator coil by energization of the stator coil, thereby causing the insulator to generate foam.

With the configuration of the first manufacturing apparatus according to the present disclosure, during heating of the insulator by the resistance heating apparatus, the distal end portions of the teeth of the stator core may be supported by the support member in the axial direction of the stator core. Therefore, during heating of the insulator by the resistance heating device, the steel plates forming the stator core can be prevented from expanding in the axial direction of the stator core. This can prevent the material of the insulator from entering between the steel plates. As a result, the rotary electric machine including the stator can be prevented from NV during operation.

According to the present disclosure, there is also provided a second apparatus for manufacturing a stator for a rotating electrical machine. The stator includes: an annular stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots each formed between a pair of circumferentially adjacent teeth; a stator coil formed of a plurality of coil sections inserted into slots of a stator core; and an impregnating material that is impregnated into the slots of the stator core and cured in the slots to fix the stator coils in the slots. The second manufacturing apparatus includes: a placing table on which a stator core having a coil section inserted into a slot of the stator core is placed; a support member configured to support distal end portions of teeth of the stator core in an axial direction of the stator core to prevent a gap from being formed between steel plates forming the stator core; an impregnation device configured to impregnate an impregnation material in a liquid state into a groove of a stator core; and a resistance heating device configured to heat the impregnating material and the stator coil by energization of the stator coil, thereby solidifying the impregnating material in the tank.

With the configuration of the second manufacturing apparatus according to the present disclosure, during heating of the impregnating material by the resistance heating apparatus, the distal end portions of the teeth of the stator core may be supported by the support member in the axial direction of the stator core. Therefore, during heating of the impregnation material by the resistance heating device, the steel plates forming the stator core can be prevented from expanding in the axial direction of the stator core. Therefore, the impregnating material can also be prevented from intruding and solidifying between the steel plates. As a result, the rotary electric machine including the stator can be prevented from NV during operation.

According to the present disclosure, there is also provided a third apparatus for manufacturing a stator for a rotating electrical machine. The stator includes: an annular stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots each formed between a pair of circumferentially adjacent teeth; a stator coil formed of a plurality of coil sections inserted into slots of a stator core, the stator coil having a plurality of coil protrusions that are portions of the coil sections that protrude from an axial end face of the stator core to the outside of the slots, and a plurality of coil joints at each of which distal end portions of a corresponding pair of the coil protrusions are joined together; and a package insulator having at least a coil terminal of the stator coil packaged in the package insulator. The third manufacturing apparatus includes: a metal mold having a groove configured to insert at least a coil terminal of the stator coil therein and a support portion configured to support a distal end portion of a tooth of the stator core in an axial direction of the stator core to prevent a gap from being formed between steel plates forming the stator core; a resin supply device configured to supply a liquid thermosetting resin for forming the package insulator into the recess of the metal mold; and a resistance heating device configured to heat the liquid thermosetting resin and the stator coil by energizing the stator coil in a state where at least the coil tab of the stator coil is immersed in the liquid thermosetting resin filled in the groove of the metal mold, thereby solidifying the liquid thermosetting resin to form the sealing insulator.

With the configuration of the third manufacturing apparatus according to the present disclosure, during heating of the liquid thermosetting resin by the resistance heating apparatus, the distal end portions of the teeth of the stator core may be supported in the axial direction of the stator core by the support portions of the metal mold. Therefore, during the heating of the liquid thermosetting resin by the resistance heating means, the steel plate forming the stator core can be prevented from expanding in the axial direction of the stator core. Thereby, it is also possible to prevent the insulator, which has been foamed and solidified in the slots of the stator core, from being detached from the stator core due to the expansion of the steel plate in the axial direction. As a result, no detached portion of the insulator is scattered in the rotating electric machine including the stator.

According to the present disclosure, there is also provided a first method of manufacturing a stator for a rotary electric machine. The first manufacturing method includes: a preparation step of preparing a ring-shaped stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core and a plurality of slots each formed between a pair of circumferentially adjacent teeth, a coil section for forming a stator coil, and a plurality of insulators formed of a material that can be foamed when heated; an insulator inserting step in which insulators are inserted into slots of the stator core, respectively; a coil section insertion step in which the coil sections are inserted into the slots of the stator core; a joining step in which the coil section is joined to form a stator coil; a supporting step in which distal end portions of the teeth of the stator core are supported in an axial direction of the stator core by a support member to prevent formation of gaps between steel plates forming the stator core; and a resistance heating step in which the stator coil is energized to heat the insulator and the stator coil, thereby foaming the insulator.

With the first manufacturing method according to the present disclosure, it is possible to heat the insulator while supporting the distal end portions of the teeth of the stator core in the axial direction of the stator core by the support member. Therefore, in the resistance heating step, the steel sheet forming the stator core can be prevented from expanding in the axial direction of the stator core. This can prevent the material of the insulator from entering between the steel plates. As a result, the rotary electric machine including the stator can be prevented from NV during operation.

According to the present disclosure, there is also provided a second method of manufacturing a stator for a rotary electric machine. The second manufacturing method includes: a preparation step of preparing a ring-shaped stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, a coil section for forming a stator coil, and an impregnating material, each of the grooves being formed between a pair of circumferentially adjacent teeth, the impregnating material being in a liquid state; a coil section insertion step in which the coil sections are inserted into the slots of the stator core; a joining step in which the coil section is joined to form a stator coil; a supporting step in which distal end portions of the teeth of the stator core are supported in an axial direction of the stator core by a support member to prevent formation of gaps between steel plates forming the stator core; an impregnation step in which an impregnating material in a liquid state is immersed in a slot of a stator core; and a resistance heating step in which the stator coil is energized to heat the impregnating material and the stator coil, thereby solidifying the impregnating material in the tank.

With the second manufacturing method according to the present disclosure, the impregnating material can be heated with the distal end portions of the teeth of the stator core supported by the support member in the axial direction of the stator core. Therefore, in the resistance heating step, the steel sheet forming the stator core can be prevented from expanding in the axial direction of the stator core. Therefore, the impregnating material can also be prevented from intruding and solidifying between the steel plates. As a result, the rotary electric machine including the stator can be prevented from NV during operation.

According to the present disclosure, there is also provided a third method of manufacturing a stator for a rotary electric machine. The third manufacturing method includes: a preparation step of preparing an annular stator core formed of a plurality of steel plates laminated in an axial direction of the stator core, the stator core having a plurality of teeth each extending in a radial direction of the stator core and arranged at predetermined intervals in a circumferential direction of the stator core, and a plurality of slots each formed between a pair of circumferentially adjacent teeth, a coil section for forming a stator coil, and a liquid thermosetting resin for forming a package insulator; a coil section insertion step in which the coil section is inserted into a slot of the stator core such that a portion of the coil section protrudes from an axial end face of the stator core to the outside of the slot; a joining step in which coil sections are joined to form a stator coil having a plurality of coil joints at each of which distal end portions of a corresponding pair of the protruding portions of the coil sections are joined together; a resin supplying step in which a liquid thermosetting resin for forming a package insulator is supplied into a recess formed in a metal mold further having a support portion formed therein; an impregnation step in which at least coil joints of the stator coil are immersed in a liquid thermosetting resin filled in grooves of a metal mold, while distal end portions of teeth of the stator core are placed to be supported in an axial direction of the stator core by support portions of the metal mold so as to prevent formation of gaps between steel plates forming the stator core; and a resistance heating step in which the stator coil is energized to heat the liquid thermosetting resin and the stator coil, thereby solidifying the liquid thermosetting resin to form a package insulator in which at least a coil terminal of the stator coil is packaged.

With the third manufacturing method according to the present disclosure, it is possible to heat the liquid thermosetting resin for forming the encapsulating insulator with the distal end portions of the teeth of the stator core being supported by the supporting portions of the metal mold in the axial direction of the stator core. Therefore, in the resistance heating step, the steel sheet forming the stator core can be prevented from expanding in the axial direction of the stator core. Therefore, it is also possible to prevent the insulator, which has been foamed and solidified in the slots of the stator core in the previous insulator heating step, from being detached from the stator core due to the expansion of the steel plate in the axial direction. As a result, no detached portion of the insulator is scattered in the rotating electric machine including the stator.

Drawings

Fig. 1 is a side view of a semi-finished product of a stator manufactured by the manufacturing apparatus and the manufacturing method according to the first embodiment.

Fig. 2 is a perspective view of a semi-finished product of a stator manufactured by the manufacturing apparatus and the manufacturing method according to the first embodiment.

Fig. 3 is a sectional view of a stator manufactured by the manufacturing apparatus and the manufacturing method according to the first embodiment.

Fig. 4 is a flowchart illustrating a manufacturing method according to the first embodiment.

Fig. 5 is a flowchart showing an insulator heating step of the manufacturing method according to the first embodiment.

Fig. 6 is a flowchart showing a package insulator forming step of the manufacturing method according to the first embodiment.

Fig. 7 is a partial sectional view showing the coil protrusion after being deformed to be radially expanded in the radial expansion step of the manufacturing method according to the first embodiment.

Fig. 8 is a perspective view showing a placing table and a supporting member of the manufacturing apparatus according to the first embodiment.

Fig. 9 is a side view showing a placing table and a supporting member of the manufacturing apparatus according to the first embodiment.

Fig. 10 is a plan view along the X direction in fig. 9.

Fig. 11 is a partial sectional view taken along line XI-XI in fig. 10.

Fig. 12 is a perspective view of a portion XII in fig. 11.

Fig. 13 is an enlarged view of a portion XIII in fig. 12.

Fig. 14 is a sectional view showing a placing table, a supporting member, an IH (induction heating) coil, and a DRH (direct resistance heating) device of the manufacturing apparatus according to the first embodiment.

Fig. 15 is a schematic perspective view illustrating the cause of a phenomenon in which steel plates laminated in the axial direction of a stator core of a stator to form the stator core are expanded in the axial direction when DRH is performed on the stator.

Fig. 16 is a schematic cross-sectional view showing the cause of the phenomenon in which the steel plate expands in the axial direction when DRH is performed on the stator.

Fig. 17 is an enlarged view of a portion XVII in fig. 15.

Fig. 18 is a perspective view showing both the metal mold and the resin supply device of the manufacturing device according to the first embodiment.

Fig. 19 is a sectional view showing both a metal mold of a manufacturing apparatus according to the first embodiment and another DRH apparatus.

Fig. 20 is an enlarged view of a portion XX in fig. 19.

Fig. 21 is a sectional view showing a part of a package insulator formed in a package insulator forming step of the manufacturing method according to the first embodiment.

Fig. 22 is a perspective view showing a placement table, a first support member, and a second support member of the manufacturing apparatus according to the second embodiment.

Fig. 23 is a side view showing a placement table, a first support member, and a second support member of the manufacturing apparatus according to the second embodiment.

Fig. 24 is a plan view in the direction XXIV in fig. 23.

Fig. 25 is a sectional view taken along line XXV-XXV in fig. 24.

Fig. 26 is an enlarged view of a portion XXVI in fig. 25.

Fig. 27 is a flowchart showing a manufacturing method according to the third embodiment.

Fig. 28 is a partial sectional view showing a placing table, a supporting member, an IH coil, a DRH apparatus, and a dipping apparatus of a manufacturing apparatus according to a third embodiment.

Detailed Description

Hereinafter, exemplary embodiments will be described with reference to the accompanying drawings. It should be noted that the same components having the same functions throughout the description are denoted by the same reference numerals as much as possible for clarity and understanding, and repeated description of the same components is omitted in order to avoid redundancy.

[ first embodiment ]

The stator 1 manufactured by the manufacturing apparatus and the manufacturing method according to the first embodiment is used in a rotating electrical machine. The rotary electric machine includes a stator 1 and a rotor (not shown) rotatably arranged radially inside the stator 1. Further, the rotating electrical machine may be configured as a motor, a generator, or a motor generator that selectively functions as a motor or a generator.

Fig. 1 and 2 show a semi-finished product of the stator 1, while fig. 3 shows the finally obtained (or finished) stator 1.

As shown in fig. 1 to 3, the stator 1 includes: an annular stator core 10, the stator core 10 having a plurality of slots 11 formed therein; a stator coil formed of a plurality of coil sections (or electrical conductor sections) 20 inserted in the slots 11 of the stator core 10; and a plurality of insulators 30, the plurality of insulators 30 being inserted into the slots 11 together with the coil sections 20. It should be noted that only those portions of the insulator 30 that protrude outside the slots 11 of the stator core 10 are shown in fig. 1.

The stator core 10 includes: an annular back core 13; a plurality of teeth 14, each of the plurality of teeth 14 extending radially inward from the back core 13 and arranged at predetermined intervals in a circumferential direction of the stator core 10 (i.e., a circumferential direction of the back core 13); and slots 11, each slot 11 being formed between a pair of circumferentially adjacent teeth 14.

In the present embodiment, the stator core 10 is formed of a plurality of annular steel plates 12 laminated in the axial direction of the stator core 10 (see fig. 15 and 17). The steel plate 12 may be formed of, for example, magnetic steel. The thickness of the steel sheet 12 is, for example, 0.25 mm.

Each coil section 20 is substantially U-shaped to have a pair of straight portions extending parallel to each other and turn portions connecting ends of the straight portions on the same side. The straight portions are inserted into two corresponding slots 11 of the stator core 10, respectively, such that portions of the straight portions axially protrude from a first axial end surface (i.e., a lower end surface in fig. 1 to 3) 10a of the stator core 10 to the outside of the corresponding slots 11. That is, each coil section 20 has a pair of protruding portions 21 that axially protrude from the first axial end face of the stator core 10 to the outside of the corresponding slot 11. The protruding portion 21 is then bent in the circumferential direction of the stator core 10 so as to extend obliquely with respect to the first axial end face of the stator core 10. Hereinafter, the protruding portion 21 of the coil section 20 is simply referred to as a coil protruding portion 21. All the coil protrusions 21 collectively constitute a first coil end of the stator coil.

In addition, each coil section 20 has a turn portion protruding from the second axial end face (i.e., the upper end face in fig. 1 to 3) of the stator core 10 to the outside of the corresponding slot 11. All turns of the coil section 20 jointly constitute the second coil end of the stator coil.

In the present embodiment, the coil section 20 is obtained by cutting and plastically deforming an electric wire including an electric conductor and an insulating coating. The electrical conductor is formed of an electrically conductive material (e.g., copper) and has a generally rectangular cross-sectional shape. The insulating coating is formed of an electrically insulating material (e.g., enamel) and is arranged to cover an outer surface of the electrical conductor.

Further, the insulating coating is removed from the distal end portion of the coil protrusion 21. Each pair of radially adjacent distal end portions of the coil projections 21 are joined, for example, by welding, to form a joint 22 therebetween (see fig. 19 to 21). Thus, all coil sections 20 are electrically connected together to form a stator coil, which is a star-connected or delta-connected three-phase coil. In addition, the joint formed between the distal end portions 22 of the coil protrusions 21 is hereinafter simply referred to as a coil joint 22.

As shown in fig. 3, in the stator 1 finally obtained, the coil tabs 22 and those portions of the coil protrusions 21 which are immediately adjacent to the coil tabs 22 are encapsulated by the encapsulating insulator 40. The package insulator 40 is formed of, for example, a thermosetting resin. Further, unlike the stator known in the art as described above (see, for example, japanese patent application publication No. JP2018-143066 a), the stator 1 according to the present embodiment does not include a ferrule support.

Next, a manufacturing apparatus and a manufacturing method according to the present embodiment will be described with reference to fig. 4 to 21.

Fig. 4 is a flowchart showing an outline of the manufacturing method according to the present embodiment.

As shown in fig. 4, the manufacturing method includes a preparation step S10, an insulator insertion step S20, a coil section insertion step S30, a radial expansion step S40, a lead forming step S50, a bending step S60, a soldering step S70, an insulator heating step S80, and a package insulator forming step S90.

First, in a preparation step S10, the stator core 10, the coil sections 20 for forming the stator coil, and the insulator 30 are prepared.

In the insulator inserting step S20, the insulators 30 are inserted into the corresponding slots 11 of the stator core 10, respectively. Accordingly, the insulators 30 are respectively located inside the inner walls of the stator core 10 that define the corresponding slots 11. Further, in the present embodiment, the insulator 30 is formed of a curable and foamable resin that foams and cures, for example, upon heating.

In the coil section inserting step S30, the coil sections 20 are inserted into the respective slots 11 of the stator core 10. Therefore, in each slot 11 of the stator core 10, between the inner wall of the stator core 10 defining the slot 11 and the corresponding coil section 20 inserted in the slot 11, a corresponding insulator 30 inserted in the slot 11 is interposed.

More specifically, in this step, for each of the substantially U-shaped coil sections 20, the two straight portions of the coil section 20 are inserted into two corresponding slots 11 of the stator core 10, respectively, the slots 11 being located one pole pitch away from each other. Therefore, portions of the straight portions axially protrude from the first axial end surface (i.e., the lower end surface in fig. 1 to 3) of the stator core 10 to the outside of the corresponding slots 11. Each of the straight portions constitutes one of the coil protrusions 21. Further, in each slot 11 of the stator core 10, the straight portions of the coil sections 20 are arranged in radial alignment with each other (see fig. 7). Therefore, for each slot 11 of the stator core 10, those coil protrusions 21 that protrude outward from the slot 11 are also arranged in radial alignment with each other.

In the radial expansion step S40, the coil protrusion 21 is deformed to radially expand. Therefore, as shown in fig. 7, between each pair of radially adjacent coil protrusions 21, a predetermined gap is formed.

In the lead wire forming step S50, the lead wires 23 (see fig. 14) of the three-phase stator coil are formed into a predetermined shape. More specifically, each lead wire 23 is formed by plastically deforming a given one of the coil protrusions 21. Further, lead wires 23 are formed at predetermined positions where the above-described lead wires 23 may be connected to ends of power supply wires (not shown) through which three-phase AC power is supplied to the stator coils, respectively.

In the bending step S60, the coil protrusion 21 is bent in the circumferential direction of the stator core 10 so as to extend obliquely with respect to the first axial end face of the stator core 10. Thus, the distal end portion (i.e., the exposed portion) of each coil protrusion 21 is positioned radially adjacent to or radially against the distal end portion (i.e., the exposed portion) of another coil protrusion 21.

In the welding step S70, each pair of radially adjacent or radially abutting distal end portions (i.e., exposed portions) of the coil protrusions 21 is welded to form a weld point (i.e., the coil joint 22) therebetween. Thus, all coil sections 20 are electrically connected together to form a three-phase stator coil.

In the insulator heating step S80, the insulator 30 is heated by both IH (induction heating) and DRH (direct resistance heating). As described above, in the present embodiment, the insulator 30 is formed of a curable and foamable resin. Therefore, after heating in this step, the insulator 30 is foamed and cured. Therefore, the empty space in the slots 11 of the stator core 10 is filled with the insulator 30, thereby fixing the coil section 20 in the slots 11.

The insulator heating step S80 is described in more detail below with reference to fig. 5 and 8 to 17.

Fig. 5 is a flowchart showing an outline of the insulator heating step S80. As shown in fig. 5, the insulator heating step S80 includes a product mounting step S81, an IH coil placing step S82, a clamping step S83, an IH and DRH step S84, a loosening step S85, an IH coil removing step S86, and a product removing step S87.

In the product mounting step S81, the semi-finished product of the stator 1 obtained by performing the steps S10 to S70 of the manufacturing method as described above is mounted to the insulator heating device.

Specifically, as shown in fig. 8 to 14, the insulator heating apparatus constituting a part of the manufacturing apparatus for manufacturing the stator 1 according to the present embodiment includes a placing table 50, a supporting member 60, an IH coil 70, and a DRH apparatus 80.

The standing board 50 is substantially annular in shape. In the product mounting step S81, the radially outer portion of the stator core 10 is placed on the placing table 50. More specifically, as shown in fig. 11 and 12, the vertically lower surface of the radially outer portion of the stator core 10 is placed on the placing table 50.

The support member 60 has an annular base portion 61 and a cylindrical portion 62 axially extending from a radially inner peripheral portion of the base portion 61. As shown in fig. 12 and 13, the cylindrical portion 62 of the support member 60 is configured to support the distal end portions 15 (i.e., the radially inner end portions in the present embodiment) of the teeth 14 of the stator core 10 in the axial direction of the stator core 10. Hereinafter, the distal end portion 15 of the tooth 14 is simply referred to as a tooth end portion 15. More specifically, the cylindrical portion 62 of the support member 60 supports the tooth end portion 15, with a vertical upper end surface 63 of the cylindrical portion 62 abutting against a vertical lower surface 151 of the tooth end portion 15.

Therefore, the support member 60 can support the tooth end portions 15 in the axial direction of the stator core 10 to prevent a gap from being formed between the steel plates 12 forming the stator core 10. In addition, the product mounting step S81 in the present embodiment corresponds to a "supporting step".

In the IH coil placing step S82, as shown in fig. 14, the IH coils 70 are placed radially outside and radially inside the stator core 10.

More specifically, in this step, the IH coil 70 is moved downward from the vertically upper side of the stator core 10 to a position where the IH coil 70 faces radially toward the stator core 10 from both the radially outer side and the radially inner side of the stator core 10. Here, the IH coil 70 is provided to heat the stator core 10 by electromagnetic induction, thereby heating the insulator 30 inserted into the slot 11 of the stator core 10 to be foamed.

In the clamping step S83, as shown in fig. 14, the lead wires 23 of the stator coil are clamped by the respective terminals 81 of the DRH device 80. Here, the DRH device 80 is provided to heat the stator coil by energization of the stator coil (or supply of current to the stator coil), thereby heating the insulator 30 inserted into the slot 11 of the stator core 10 together with the coil section 20 to foaming.

In the IH and DRH step S84, IH (induction heating) and DRH (direct resistance heating) are performed on the semi-finished product of the stator 1.

More specifically, in this step, IH is performed by energizing the IH coil 70, thereby heating the stator core 10 by electromagnetic induction; therefore, the insulator 30 is also heated by the heat transferred from the stator core 10. Meanwhile, DRH is performed by energizing the stator coil so that the stator coil is heated due to its resistance to current; therefore, the insulator 30 is also heated by the heat transferred from the stator coil.

Therefore, after being heated by both IH and DRH, the insulator 30 foams to fill the vacant spaces in the slots 11 of the stator core 10, thereby fixing the stator coil (i.e., the coil section 20) in the slots 11.

As described above, in the present embodiment, the insulator 30 is heated by both IH and DRH, thereby reducing the time required to raise the temperature of the insulator 30 to the foaming temperature of the insulator 30, thereby improving productivity. It should be noted, however, that the insulator 30 may alternatively be heated by only one of IH and DRH.

Further, as described previously, the stator 1 according to the present embodiment does not include the ferrule support. Therefore, if the tooth end portions 15 are not supported by the support member 60 during DRH, a phenomenon may occur in which the steel plates 12 forming the stator core 10 are spread in the axial direction of the stator core 10. The reason for this phenomenon will be described below with reference to fig. 15 to 17.

In fig. 15, the symbol "x" marked on the coil section 20 inserted into the corresponding slot 11 of the stator core 10 indicates that, during DRH, current flows through the coil section 20 in the direction from the upper side to the lower side in fig. 15. Further, in fig. 16, a symbol "x" marked on the coil section 20 indicates that, during DRH, current flows through the coil section 20 in a direction into the plane of the paper.

Energizing the coil section 20 in the direction as described above will generate a magnetic field in the direction indicated by arrow H in fig. 16. The magnetic field magnetizes the tooth end 15 located on a first circumferential side of the coil section 20 marked with the "x" symbol to the N-pole, while magnetizing the tooth end 15 located on a second circumferential side of the coil section 20 marked with the "x" symbol to the S-pole. Therefore, as shown in fig. 17, at each tooth end 15 of the stator core 10, all the steel plates 12 forming the stator core 10 will have the same polarity and thus will repel each other. As a result, the steel plates 12 can be expanded in the axial direction of the stator core 10 to form a gap between the steel plates 12.

In order to prevent the occurrence of the above phenomenon, in the present embodiment, the tooth end portion 15 is supported in the axial direction of the stator core 10 by the support member 60 during DRH. Therefore, during DRH, the steel plates 12 forming the stator core 10 are prevented from expanding in the axial direction of the stator core 10. As a result, the material of the insulator 30 (i.e., the curable and foamable resin) can be prevented from entering between the steel plates 12.

After the IH and DRH steps S84 are completed, the lead wires 23 of the stator coil are released from the corresponding terminals 81 of the DRH device 80 in a release step S85.

In the IH coil removing step S86, the IH coil 70 is removed from the stator core 10. More specifically, the IH coil 70 moves upward, returning to its original position.

In the product removing step S87, the semi-finished product of the stator 1 is removed from the insulator heating device.

After completing all the steps S81 to S87 shown in fig. 5, the insulator heating step S80 is terminated.

Referring again to fig. 4, in the encapsulation insulator forming step S90, the coil tab 22 and those portions of the coil protrusion 21 that are immediately adjacent to the coil tab 22 are encapsulated by the encapsulation insulator 40.

The package insulator forming step S90 will be described in more detail below with reference to fig. 6 and 18 to 21.

Fig. 6 is a flowchart showing an outline of the package insulator forming step S90. As shown in fig. 6, the package insulator forming step S90 includes a product mounting step S91, a metal mold mounting step S92, a resin injection step S93, a product dipping step S94, an IH coil placing step S95, a clamping step S96, IH and DRH steps S97, a releasing step S98, an IH coil removing step S99, a metal mold stripping step S100, a metal mold removing step S101, and a product removing step S102.

In the product mounting step S91, the semi-finished product of the stator 1 obtained by performing the steps S10 to S80 of the manufacturing method as described above is mounted to the package insulator forming device. Further, the package insulator forming device also constitutes a portion of the manufacturing device according to the present embodiment for manufacturing the stator 1.

In the metal mold mounting step S92, the metal mold 90 is mounted to the package insulator forming device.

As shown in fig. 18, the metal mold 90 is substantially disc-shaped. The metal mold 90 has an annular groove 91 formed in a vertical surface thereof. The groove 91 is shaped and sized to allow the coil tab 22 and those portions of the coil protrusion 21 immediately adjacent to the coil tab 22 to be inserted into the groove 91. Further, the upper surface of the metal mold 90 is shaped and sized to allow the stator core 10 to be placed on the upper surface. The upper surface of the metal mold 90 includes a first portion 92 located radially outside the groove 91 and a second portion 93 located radially inside the groove 91. Hereinafter, the first portion and the second portion of the upper surface of the metal mold 90 are simply referred to as a radially outer upper surface 92 and a radially inner upper surface 93, respectively.

In the resin injection step S93, a liquid thermosetting resin for forming the package insulator 40 is injected into the recess 91 of the metal mold 90. More specifically, as shown by an arrow R in fig. 18, the liquid thermosetting resin supplied from the resin supply device 95 is injected into the groove 91 of the metal mold 90.

In the product dipping step S94, the coil tab 22 and those portions of the coil protrusion 21 that are immediately adjacent to the coil tab 22 are dipped in the liquid thermosetting resin filled in the groove 91 of the metal mold 90.

Specifically, in this step, as shown in fig. 19 and 20, the stator core 10 is placed on the upper surface of the metal mold 90 such that the radially outer portion of the stator core 10 is supported by the radially outer side upper surface 92 of the metal mold 90, and the tooth end portions 15 of the stator core 10 are supported by the radially inner side upper surface 93 of the metal mold 90. More specifically, the radially inner upper surface 93 of the metal mold 90 supports the tooth end 15 of the stator core 10, with the vertical lower surface 151 of the tooth end 15 abutting against the radially inner upper surface 93. Therefore, the radially inner upper surface 93 of the metal mold 90 can support the tooth end portions 15 from the lower side thereof in the axial direction of the stator core 10 to prevent formation of gaps between the steel plates 12 forming the stator core 10. That is, the radially inner upper surface 93 of the metal mold 90 serves as a support portion of the metal mold 90 so as to prevent a gap from being formed between the steel plates 12.

In the IH coil placing step S95, as shown in fig. 19 and 20, the IH coil 75 is placed on the lower surface of the metal mold 90. Here, the IH coil 75 is provided to heat the metal mold 90 by electromagnetic induction, thereby heating the liquid thermosetting resin filled in the groove 91 of the metal mold 90 for forming the package insulator 40 to be solidified (or hardened).

In the clamping step S96, as shown in fig. 19, the lead wires 23 of the stator coil are clamped by the respective terminals 86 of the DRH device 85. Here, the DRH device 85 is provided to heat the stator coil by energization of the stator coil (or supply of current to the stator coil), thereby heating the liquid thermosetting resin into which the coil tab 22 and those portions of the coil protrusion 21 which are in close proximity to the coil tab 22 are immersed to solidify (or harden).

In the IH and DRH step S97, IH (induction heating) and DRH (direct resistance heating) are performed on the semi-finished product of the stator 1.

More specifically, in this step, IH is performed by energizing the IH coil 75, thereby heating the metal mold 90 by electromagnetic induction; therefore, the liquid thermosetting resin for forming the package insulator 40 is also heated by the heat transferred from the metal mold 90. Meanwhile, DRH is performed by energizing the stator coil so that the stator coil is heated due to its resistance to current; therefore, the liquid thermosetting resin used to form the encapsulating insulator 40 is also heated by the heat transferred from the stator coil.

Thus, upon heating by both IH and DRH, the liquid thermosetting resin is solidified (or hardened) to form the package insulator 40; in the encapsulating insulator 40, the coil tab 22 and those portions of the coil protrusion 21 which are adjacent to the coil tab 22 are encapsulated.

As described above, in the present embodiment, the liquid thermosetting resin for forming the encapsulating insulator 40 is heated by both IH and DRH, thereby reducing the time required for solidifying (or hardening) the liquid thermosetting resin to form the encapsulating insulator 40, thereby improving productivity. However, it should be noted that the liquid thermosetting resin may alternatively be heated by only one of IH and DRH.

Further, as described previously, the stator 1 according to the present embodiment does not include the ferrule support. Therefore, if the tooth end portions 15 are not supported by the radially inner upper surface 93 (i.e., the support portion) of the metal mold 90 during DRH, a phenomenon may occur in which the steel plates 12 forming the stator core 10 are expanded in the axial direction of the stator core 10 by repulsive force between portions of the steel plates 12 that are positioned adjacent to each other in the axial direction and magnetized to the same polarity during DRH.

In order to prevent the occurrence of the above phenomenon, in the present embodiment, the tooth end portion 15 is supported by the radially inner upper surface 93 (i.e., the supporting portion) of the metal mold 90 in the axial direction of the stator core 10 during DRH. Therefore, during DRH, the steel plates 12 forming the stator core 10 are prevented from expanding in the axial direction of the stator core 10. As a result, it is possible to prevent the insulator 30, which has been foamed and cured in the previous insulator heating step S80, from being detached from the stator core 10 due to the expansion of the steel plates 12 in the axial direction.

After the IH and DRH steps S97 are completed, the lead wires 23 of the stator coils are loosened from the respective terminals 86 of the DRH device 85 in a loosening step S98.

In the IH coil removing step S99, the IH coil 75 is removed from the metal mold 90.

In the metal mold peeling step S100, the metal mold 90 is peeled from the package insulator 40. Therefore, as shown in fig. 21, in the stator 1, an encapsulating insulator 40 is formed, in which the coil tabs 22 and those portions of the coil protrusions 21 that are adjacent to the coil tabs 22 are encapsulated in the encapsulating insulator 40.

In the metal mold removing step S101, the metal mold 90 is removed from the package insulator forming device.

In the product removal step S102, the finished stator 1 is removed from the package insulator forming device. Then, the package insulator forming step S90 is terminated.

As a result, upon completion of all steps S10 to S90, the stator 1 as shown in fig. 3 is finally obtained.

According to the present embodiment, the following advantageous effects can be achieved.

The apparatus for manufacturing the stator 1 according to the present embodiment includes a placing table 50, a supporting member 60, and a DRH apparatus 80. The placement stage 50 is configured to place the stator core 10 having the coil section 20 and the insulator 30 inserted into the slot 11 of the coil section 20 on the placement stage 50. The support member 60 is configured to support the tooth end portions 15 of the stator core 10 in the axial direction of the stator core 10 to prevent gaps from being formed between the steel plates 12 forming the stator core 10. The DRH device 80 is configured to heat the insulator 30 and the stator coil by energization of the stator coil, thereby foaming the insulator 30.

With the above configuration, the tooth end portions 15 can be supported in the axial direction of the stator core 10 by the support member 60 during heating of the insulator 30 by the DRH apparatus 80. Therefore, during heating of the insulator 30 by the DRH apparatus 80, the steel plates 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10. Therefore, the material of the insulator 30 (i.e., the curable and foamable resin) can also be prevented from entering between the steel plates 12. As a result, NV (noise and vibration) can be prevented from occurring during operation of the rotary electric machine including the stator 1.

Further, in the present embodiment, the support member 60 is configured to support the tooth end 15 of the stator core 10 from the vertically lower side of the tooth end 15.

When the stator core 10 is placed such that the axial direction of the stator core 10 coincides with the vertical direction, those steel plates 12 of the stator core 10 that are located on the vertically lower side are easily deformed by their own weight, in addition to being affected by the magnetic field generated during heating of the insulator 30 by the DRH apparatus 80. However, in the present embodiment, in the case where the tooth end portions 15 of the stator core 10 are supported from the vertically lower side by the support members 60, it is still possible to prevent the steel plates 12 forming the stator core 10 from expanding in the axial direction of the stator core 10 during heating of the insulator 30 by the DRH apparatus 80.

The apparatus for manufacturing the stator 1 according to the present embodiment further includes a metal mold 90, a resin supply device 95, and a DRH device 85. The metal mold 90 has a groove 91 and a support portion (i.e., a radially inner upper surface) 93. The groove 91 is configured such that at least the coil tab 22 of the stator coil is inserted into the groove 91. The support portion 93 is configured to support the tooth end portion 15 of the stator core 10 in the axial direction of the stator core 10 to prevent a gap from being formed between the steel plates 12 forming the stator core 10. The resin supply device 95 is configured to supply a liquid thermosetting resin for forming the package insulator 40 into the groove 91 of the metal mold 90. The DRH device 85 is configured to heat the liquid thermosetting resin and the stator coil by energization of the stator coil, with at least the coil tab 22 of the stator coil immersed in the liquid thermosetting resin filled in the groove 91 of the metal mold 90, thereby solidifying the liquid thermosetting resin to form the package insulator 40.

With the above configuration, it is possible to prevent the steel plates 12 forming the stator core 10 from expanding in the axial direction of the stator core 10 in the package insulator forming step S90. Therefore, it is also possible to prevent the insulator 30, which has been foamed and cured in the previous insulator heating step S80, from being detached from the stator core 10 due to the expansion of the steel plates 12 in the axial direction. As a result, the detached portion of the insulator 30 is not scattered in the rotating electric machine including the stator 1.

The manufacturing method of the stator 1 according to the present embodiment includes the insulator heating step S80. Further, the insulator heating step S80 includes a product mounting step S81 (i.e., a supporting step) and IH and DRH steps S84. In the product mounting step S81, the tooth end portions 15 of the stator core 10 are supported in the axial direction of the stator core 10 by the support members 60 to prevent gaps from being formed between the steel plates 12 forming the stator core 10. In IH and DRH step S84, the stator coil is energized to heat the insulator 30 and the stator coil, thereby foaming the insulator 30.

With the above method, the insulator 30 can be heated while supporting the tooth end portions 15 in the axial direction of the stator core 10 by the support member 60. Therefore, in the IH and DRH step S84, the steel sheets 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10. Therefore, the material of the insulator 30 (i.e., the curable and foamable resin) can also be prevented from entering between the steel plates 12. As a result, NV can be prevented from occurring during operation of the rotary electric machine including the stator 1.

The manufacturing method of the stator 1 according to the present embodiment further includes a package insulator forming step S90. Further, the package insulator forming step S90 includes a resin injection step S93 (i.e., a resin supply step), a product dipping step S94, and IH and DRH steps S97. In the resin injection step S93, the liquid thermosetting resin supplied from the resin supply device 95 is injected into the recess 91 of the metal mold 90. In the product dipping step S94, at least the coil tabs 22 of the stator coil are dipped in the liquid thermosetting resin filled in the grooves 91 of the metal mold 90, and the tooth end portions 15 of the stator core 10 are placed so as to be supported in the axial direction of the stator core 10 by the supporting portions (i.e., the radially inner upper surfaces 93) of the metal mold 90, so as to prevent a gap from being formed between the steel plates 12 forming the stator core 10. In IH and DRH step S97, the stator coil is energized to heat the liquid thermosetting resin and the stator coil, thereby solidifying the liquid thermosetting resin to form the package insulator 40.

With the above method, the liquid thermosetting resin for forming the encapsulating insulator 40 can be heated while the tooth end portions 15 are supported in the axial direction of the stator core 10 by the supporting portions of the metal mold 90. Therefore, in the IH and DRH step S97, the steel sheets 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10. Therefore, it is also possible to prevent the insulator 30, which has been foamed and cured in the previous insulator heating step S80, from being detached from the stator core 10 due to the expansion of the steel plates 12 in the axial direction. As a result, the detached portion of the insulator 30 is not scattered in the rotating electric machine including the stator 1.

[ second embodiment ]

The manufacturing apparatus for manufacturing the stator 1 according to the second embodiment has a similar configuration to that of the manufacturing apparatus according to the first embodiment. Therefore, only the differences between the manufacturing apparatus according to the second embodiment and the manufacturing apparatus according to the first embodiment will be described below.

Fig. 22 to 26 show the configuration of a part of an insulator heating apparatus constituting a manufacturing apparatus according to a second embodiment.

As shown in fig. 22 to 26, in the present embodiment, the insulator heating apparatus includes a pair of a first support member 610 and a second support member 620 instead of the support member 60 in the first embodiment.

The first support member 610 has an annular base portion 611 and a cylindrical portion 612 extending axially upward from a radially inner peripheral portion of the base portion 611. As shown in fig. 25 and 26, the cylindrical portion 612 of the first support member 610 is configured to support the tooth end portion 15 of the stator core 10 from the first axial side (i.e., the lower side in fig. 25 and 26) of the stator core 10. More specifically, the cylindrical portion 612 of the first support member 610 supports the tooth end portion 15 with the vertical upper end surface 613 of the cylindrical portion 612 abutting against the vertical lower surface 151 of the tooth end portion 15. Therefore, the first support member 610 can support the tooth end portions 15 from the first axial side of the stator core 10 to prevent a gap from being formed between the steel plates 12 forming the stator core 10.

On the other hand, the second support member 620 has an annular base 621 and a cylindrical portion 622 axially extending downward from a radially inner peripheral portion of the base 621. As shown in fig. 25 and 26, the cylindrical portion 622 of the second support member 620 is configured to support the tooth end portion 15 of the stator core 10 from the second axial side (i.e., the upper side in fig. 25 and 26) of the stator core 10. More specifically, the cylindrical portion 622 of the second support member 620 supports the tooth end 15 with the vertical lower end surface 623 of the cylindrical portion 622 abutting against the vertical upper surface 152 of the tooth end 15. Therefore, the second support member 620 can support the tooth end portions 15 from the second axial side of the stator core 10 to prevent a gap from being formed between the steel plates 12 forming the stator core 10.

Further, as shown in fig. 25 and 26, in the present embodiment, the radially inner portion of the second coil end portion 24 of the stator coil, which is located on the second axial side of the stator core 10, protrudes radially inward from the radially inner peripheral surface of the stator core 10. Thus, the cylindrical portion 622 of the second support member 620 is configured such that the radially outer peripheral surface 624 of the cylindrical portion 622 tapers upward. That is, the diameter of the radially outer peripheral surface 624 of the cylindrical portion 622 gradually increases in the axial direction from the base 621 side (i.e., from the upper side). Further, as shown by an arrow M in fig. 25, the cylindrical portion 622 of the second support member 620 is configured to be able to change its diameter. With the above configuration, the vertical lower end face 623 of the cylindrical portion 622 of the second support member 620 abuts against the vertical upper surface 152 of the tooth end portion 15 of the stator core 10 in the following manner.

First, the cylindrical portion 622 of the second support member 620 is set to a small diameter state in which the maximum outer diameter of the cylindrical portion 622 is smaller than the inner diameter of the second coil end portion 24 of the stator coil. Then, the cylindrical portion 622 in a small diameter state is inserted into the inside of the second coil end portion 24 of the stator coil. Thereafter, the cylindrical portion 622 is switched to a large diameter state in which the maximum outer diameter of the cylindrical portion 622 is slightly larger than the inner diameter of the stator core 10. Thus, the vertical lower end surface 623 of the cylindrical portion 622 abuts against the vertical upper surface 152 of the tooth end portion 15. As a result, the second support member 620 can support the tooth end 15 from the second axial side of the stator core 10.

The IH and DRH steps S84 are performed as described in the first embodiment while the tooth end 15 is supported from the first axial side and the second axial side of the stator core 10 by the first support member 610 and the second support member 620, respectively.

According to the present embodiment, the following advantageous effects can be further achieved.

The apparatus for manufacturing the stator 1 according to the present embodiment includes the first support member 610 and the second support member 620, the first support member 610 being configured to support the tooth end portion 15 from the first axial side of the stator core 10, the second support member 620 being configured to support the tooth end portion 15 from the second axial side of the stator core 10.

With the above configuration, the tooth end portions 15 can be supported from both axial sides of the stator core 10 during heating of the insulator 30 by the DRH apparatus 80. Therefore, during heating of the insulator 30 by the DRH apparatus 80, the steel plates 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10 over the entire axial range of the stator core 10. Therefore, it is also possible to prevent the material (i.e., curable and foamable resin) of the insulator 30 from intruding between the steel plates 12 over the entire axial range of the stator core 10. As a result, NV can be more reliably prevented from occurring during operation of the rotary electric machine including the stator 1.

The manufacturing method of the stator 1 according to the present embodiment includes the insulator heating step S80. Further, the insulator heating step S80 includes a product mounting step S81 (i.e., a supporting step) and IH and DRH steps S84. In the product mounting step S81, the tooth end portions 15 of the stator core 10 are supported from the first and second axial sides of the stator core 10 by the first and second support members 610 and 620, respectively, to prevent gaps from being formed between the steel plates 12 forming the stator core 10. In IH and DRH step S84, the stator coil is energized to heat the insulator 30 and the stator coil, thereby foaming the insulator 30.

With the above method, the insulator 30 can be heated with the tooth end portions 15 supported from the first axial side and the second axial side of the stator core 10 by the first support member 610 and the second support member 620, respectively. Therefore, in the IH and DRH step S84, the steel sheets 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10 over the entire axial range of the stator core 10. Therefore, it is also possible to prevent the material (i.e., curable and foamable resin) of the insulator 30 from intruding between the steel plates 12 over the entire axial range of the stator core 10. As a result, NV can be more reliably prevented from occurring during operation of the rotary electric machine including the stator 1.

[ third embodiment ]

In the first embodiment as described above, the insulator 30 is formed of a curable and foamable resin. Further, the insulator 30 is heated to be foamed in the insulator heating step S80, filling the vacant space in the slots 11 of the stator core 10, thereby fixing the stator coil (i.e., the coil section 20) in the slots 11.

In contrast, in the third embodiment, the insulator 30 is formed of, for example, insulating paper, rather than being formed of curable and foamable resin. Further, the stator coil (i.e., the coil section 20) is fixed in the slot 11 of the stator core 10 by immersing an impregnating material in the slot 11 and heating the impregnating material to be cured (or hardened) in the slot 11

Fig. 27 is a flowchart showing an outline of a method for manufacturing the stator 1 according to the third embodiment.

As shown in fig. 27, the manufacturing method according to the third embodiment includes a preparation step S110, an insulator insertion step S120, a coil section insertion step S130, a radial expansion step S140, a lead forming step S150, a bending step S160, a soldering step S170, a dipping and heating step S180, and a package insulator forming step S190.

First, in a preparation step S110, the stator core 10, the coil sections 20 for forming the stator coil, and the insulator 30 are prepared.

In the insulator inserting step S120, the insulators 30 are inserted into the corresponding slots 11 of the stator core 10, respectively. Accordingly, the insulators 30 are respectively located inside the inner walls of the stator cores 10 defining the corresponding slots 11. As described above, in the third embodiment, the insulator 30 is formed of, for example, insulating paper.

It should be noted that the stator 1 may alternatively be configured not to include the insulator 30; therefore, the manufacturing method according to the third embodiment may omit the insulator insertion step S120.

Steps S130 to S170 of the manufacturing method according to the third embodiment are the same as steps S30 to S70 of the manufacturing method according to the first embodiment, respectively. Therefore, the description of steps S130 to S170 will be omitted below.

In the dipping and heating step S180, the dipping material is dipped in the slots 11 of the stator core 10, and heated by both IH (induction heating) and DRH (direct resistance heating) to be cured in the slots 11. Furthermore, the impregnating material may be realized by, for example, a varnish.

Fig. 28 shows the configuration of the impregnation and heating device for performing the impregnation and heating step S180.

As shown in fig. 28, the dipping and heating apparatus constituting a part of the apparatus for manufacturing the stator 1 according to the third embodiment includes a placing table 50, a supporting member 60, an IH coil 70 and a DRH apparatus 80, and a dipping apparatus 100.

The placing table 50, the supporting member 60, the IH coil 70, and the DRH apparatus 80 of the dipping and heating apparatus according to the third embodiment are respectively the same as those of the insulator heating apparatus according to the first embodiment. Therefore, the description of the placing table 50, the supporting member 60, the IH coil 70, and the DRH apparatus 80 will not be repeated below.

The impregnation device 100 is configured to impregnate an impregnation material in a liquid state into the slots 11 of the stator core 10. More specifically, in the present embodiment, as shown in fig. 28, the impregnation device 100 is configured to impregnate an impregnation material into the slots 11 of the stator core 10 from the vertically upper side of the stator core 10 in the axial direction of the stator core 10.

It should be noted that the configuration of the impregnation device 100 is not limited to the above. For example, the impregnation device 100 may alternatively be configured to immerse the impregnation material in the slots 11 of the stator core 10 from the radially inner side of the stator core 10. As another alternative, the stator core 10 having the coil sections 20 inserted into the slots 11 of the stator core 10 may be immersed in a liquid-impregnated material filled in a container.

After the impregnating material is impregnated into the slots 11 of the stator core 10, the impregnating material is heated by both IH and DRH to be cured in the slots 11. Thus, the stator coil (i.e., the coil section 20) is fixed in the slots 11 of the stator core 10 by the impregnating material.

As described above, in the present embodiment, the impregnation material is heated by both IH and DRH, thereby reducing the time required to cure the impregnation material, thereby improving productivity. However, it should be noted that the impregnating material may alternatively be heated by only one of IH and DRH.

In the present embodiment, during heating of the impregnating material by the DRH, the tooth end portions 15 of the stator core 10 are supported in the axial direction of the stator core 10 by the support member 60. Therefore, during DRH, the steel plates 12 forming the stator core 10 are prevented from expanding in the axial direction of the stator core 10. As a result, the impregnating material can be prevented from entering between the steel plates 12 and being cured.

Referring again to fig. 27, in the encapsulation insulator forming step S190, the coil tab 22 and those portions of the coil protrusion 21 that are immediately adjacent to the coil tab 22 are encapsulated by the encapsulation insulator 40. The package insulator forming step S190 is the same as the package insulator forming step S90 described in the first embodiment. Therefore, detailed description of the package insulator forming step S190 will be omitted below.

According to the third embodiment, the following advantageous effects can be achieved.

The apparatus for manufacturing the stator 1 according to the present embodiment includes a placing table 50, a supporting member 60, a dipping apparatus 100, and a DRH apparatus 80. The placement stage 50 is configured to place the stator core 10 having the coil section 20 and the insulator 30 inserted into the slot 11 of the coil section 20 on the placement stage 50. The support member 60 is configured to support the tooth end portions 15 of the stator core 10 in the axial direction of the stator core 10 to prevent gaps from being formed between the steel plates 12 forming the stator core 10. The impregnation device 100 is configured to impregnate an impregnation material in a liquid state into the slots 11 of the stator core 10. The DRH device 80 is configured to heat the impregnating material and the stator coil by energization of the stator coil, thereby solidifying the impregnating material in the tank 11.

With the above configuration, the tooth end portions 15 can be supported in the axial direction of the stator core 10 by the support member 60 during heating of the impregnated material by the DRH apparatus 80. Therefore, during heating of the impregnation material by the DRH apparatus 80, the steel sheets 12 forming the stator core 10 may be prevented from expanding in the axial direction of the stator core 10. Therefore, the impregnating material can also be prevented from intruding and solidifying between the steel plates 12. As a result, NV can be prevented from occurring during operation of the rotary electric machine including the stator 1.

The manufacturing method of the stator 1 according to the present embodiment includes the dipping and heating step S180. In the dipping and heating step S180, the tooth end portions 15 of the stator core 10 are supported in the axial direction of the stator core 10 by the support members 60 to prevent gaps from being formed between the steel plates 12 forming the stator core 10. Further, the impregnating material in a liquid state is immersed in the slots 11 of the stator core 10. Further, the stator coil is energized to heat the impregnating material and the stator coil, thereby solidifying the impregnating material in the slot 11. That is, in the present embodiment, the dipping and heating step S180 includes a supporting step, a dipping step, and a resistance heating step.

With the above method, the impregnating material can be heated while supporting the tooth end portions 15 in the axial direction of the stator core 10 by the support member 60. Therefore, in the dipping and heating step S180, the steel plates 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10. Therefore, the impregnating material can also be prevented from intruding and solidifying between the steel plates 12. As a result, NV can be prevented from occurring during operation of the rotary electric machine including the stator 1.

While the particular embodiments described above have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications and improvements may be made without departing from the spirit of the disclosure.

For example, in the first and third embodiments, in the insulator heating step S80 or the dipping and heating step S180, the tooth end 15 of the stator core 10 is supported by the support member 60. However, in steps S20 to S70 or steps S120 to S170, the tooth end 15 may also be supported by the support member 60. In these cases, it is preferable that the support member 60 supports the tooth end portions 15 from the first axial side of the stator core 10, and the insulators 30 and the coil section 20 are inserted into the slots 11 of the stator core 10 from the second axial side of the stator core 10. Therefore, during the insertion of the insulator 30 into the slots 11 of the stator core 10, the steel plates 12 forming the stator core 10 can be prevented from expanding in the axial direction of the stator core 10 by the frictional force between the insulator 30 and the inner wall of the stator core 10 defining the slots 11. Similarly, during the insertion of the coil section 20 into the slot 11 of the stator core 10, the steel plate 12 can be prevented from expanding in the axial direction of the stator core 10 by the frictional force between the coil section 20 and the inner surface of the insulator 30 facing the coil section 20. Further, the steel plate 12 can be prevented from deforming vertically downward under its own weight.

In the second embodiment, in the insulator heating step S80, the tooth end portions 15 of the stator core 10 are supported from the first axial side and the second axial side of the stator core 10 by the first supporting member 610 and the second supporting member 620, respectively. Similarly, in the package insulator forming step S90, the second support member 620 may be used to support the vertical upper surface 152 of the tooth end 15, while the vertical lower surface 151 of the tooth end 15 is supported by the radially inner upper surface 93 (i.e., the support portion) of the metal mold 90. In this case, during heating of the thermosetting resin (i.e., the material of the encapsulating insulator 30) by the DRH, the steel plates 12 forming the stator core 10 can be prevented from spreading in the axial direction of the stator core 10 over the entire axial range of the stator core 10.

In the third embodiment, in the dipping and heating step S180, the tooth end portions 15 of the stator core 10 are supported from the first axial side (i.e., the vertically lower side) of the stator core 10 by the single support member 60. Alternatively, as in the second embodiment, in the dipping and heating step S180, the tooth end portions 15 may be supported from the first and second axial sides of the stator core 10 by the first and second support members 610 and 620, respectively.

In the embodiment described above, during the manufacture of the stator 1, the stator core 10 is placed such that the axial direction of the stator core 10 coincides with the vertical direction. However, the stator core 10 may alternatively be placed such that the axial direction of the stator core 10 is, for example, perpendicular to the vertical direction (i.e., coincides with the horizontal direction). In this case, the support member 60 described in the first embodiment will support the tooth end 15 from the side of the stator core 10 in the horizontal direction. On the other hand, the first support member 610 and the second support member 620 described in the second embodiment will support the tooth end 15 from the opposite sides of the stator core 10 in the horizontal direction, respectively.