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 北角泰典 吉川一央 武田洋明 下谷纯一 恩田一志 于 2020-09-11 设计创作，主要内容包括：一种用于制造定子的装置,包括：支承构件,上述支承构件构造成对定子芯进行支承；至少一个加工夹具,上述加工夹具具有圆筒部和多个突出部；以及操作单元。操作单元构造成在每个线圈突出部被插入加工夹具的一个周向相邻成对的突出部之间,并且定子芯的轴向端面位于加工夹具的突出部附近的状态下,同时或交替地执行第一操作和第二操作。第一操作是使定子芯和加工夹具沿定子芯的周向方向相对地旋转的操作。第二操作是使定子芯和加工夹具沿定子芯的轴向方向以彼此远离的方式相对地移动的操作。(An apparatus for manufacturing a stator, comprising: a support member configured to support the stator core; at least one machining jig having a cylindrical portion and a plurality of protruding portions; and an operation unit. The operation unit is configured to simultaneously or alternately perform the first operation and the second operation in a state where each of the coil protrusions is inserted between one circumferentially adjacent pair of protrusions of the machining jig, and the axial end face of the stator core is located in the vicinity of the protrusion of the machining jig. The first operation is an operation of relatively rotating the stator core and the machining jig in the circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the machining jig away from each other in the axial direction of the stator core.)

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

the stator includes: an annular stator core (10), the stator core (10) having a plurality of slots (11) formed therein; and a stator coil formed with a plurality of coil sections (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 sections that protrude from an axial end face (10a) of the stator core to the outside of the slots,

the device comprises:

a support member (50) configured to support the stator core by the coil sections inserted into the slots of the stator core;

at least one machining jig (60, 601-604) configured to be arranged coaxially with the stator core, the at least one machining jig having a cylindrical portion (61, 611-614) arranged radially outside or radially inside the coil protrusion and a plurality of protruding portions (62) each protruding radially from the cylindrical portion and arranged at predetermined intervals in a circumferential direction of the cylindrical portion; and

an operation unit (70) configured to perform a first operation and a second operation simultaneously or alternately in a state where each of the coil protrusions is inserted between one circumferentially adjacent pair of the protrusions of at least one of the machining jigs and the axial end face of the stator core is positioned a predetermined distance (D) from the protrusion of at least one of the machining jigs in an axial direction of the stator core, wherein the first operation is an operation of relatively rotating the stator core and at least one of the machining jigs in the circumferential direction of the stator core, and the second operation is an operation of relatively moving the stator core and at least one of the machining jigs away from each other in the axial direction of the stator core.

2. The apparatus of claim 1,

the operation unit is configured to perform the first operation and the second operation simultaneously or alternately in accordance with the predetermined interval between the protruding portions of at least one of the machining jigs in the circumferential direction of the cylindrical portion.

3. The apparatus of claim 1 or 2,

the operation unit is configured to further perform a third operation after performing the first operation and the second operation, the third operation being an operation of relatively moving the stator core and at least one of the machining jigs in the axial direction of the stator core in a manner toward each other, wherein each of the protrusions of the at least one of the machining jigs is held in contact with a distal end portion (22) of a corresponding one of the coil protrusions or a portion of the corresponding coil protrusion immediately adjacent to the distal end portion.

4. The apparatus according to any one of claims 1 to 3, wherein the protruding portion of at least one of the machining jigs is formed as axially extending walls (64, 641-644) each extending in an axial direction of the cylindrical portion and arranged at predetermined intervals in the circumferential direction of the cylindrical portion,

at least one of the machining jigs is configured to allow each of the coil protrusions to be inserted into a corresponding one of grooves (65, 651-654) formed between the axially extending walls.

5. The apparatus according to any one of claims 1 to 3, wherein the protruding portion of at least one of the machining jigs is formed as pins (67, 671 to 674) each protruding radially from a stator-core-side end portion of the cylindrical portion and arranged at a predetermined interval in the circumferential direction of the cylindrical portion,

at least one of the machining jigs is configured to allow each of the coil protrusions to be inserted between one of the circumferentially adjacent pairs of the pins.

6. The apparatus according to any one of claims 1 to 5, wherein at least one of the working jigs includes a first working jig (601) having a first cylindrical portion (611) and a plurality of first protruding portions (62, 641, 671) each protruding radially outward from the first cylindrical portion and arranged at predetermined intervals in a circumferential direction of the first cylindrical portion, and a second working jig (602) having a second cylindrical portion (612) and a plurality of second protruding portions (62, 642, 672) respectively protruding radially inward from the second cylindrical portion and arranged at predetermined intervals in a circumferential direction of the second cylindrical portion, the first cylindrical portion being arranged radially inward of the second cylindrical portion and arranged coaxially with the second cylindrical portion, the first protruding portion and the second protruding portion are radially interposed between the first cylindrical portion and the second cylindrical portion,

the coil protrusions are arranged in a plurality of layers in a radial direction of the stator core, the plurality of layers including at least a first layer and a second layer, the first layer being located adjacent to and radially inward of the second layer,

the operation unit is configured to simultaneously perform the first operation and the second operation on both the coil protrusions arranged at the first layer and the coil protrusions arranged at the second layer, the coil protrusions arranged at the first layer and the coil protrusions arranged at the second layer being inserted between the first protrusions of the first machining jig and between the second protrusions of the second machining jig, respectively.

7. A method of manufacturing a stator (1) for a rotating electrical machine,

the stator includes: an annular stator core (10), the stator core (10) having a plurality of slots (11) formed therein; and a stator coil formed with a plurality of coil sections (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 sections that protrude from an axial end face (10a) of the stator core to the outside of the slots,

the method comprises the following steps:

a step (S61) of supporting the stator core by a support member (50), the coil sections of the stator core being inserted into the slots of the stator core such that the coil protrusions protrude from the axial end faces of the stator core in an axial direction of the stator core;

a step (S62) of arranging at least one machining jig (60, 601-604) coaxially with the stator core, the at least one machining jig having a cylindrical portion (61, 611-614) and a plurality of protruding portions (62) each protruding radially from the cylindrical portion and arranged at predetermined intervals in a circumferential direction of the cylindrical portion;

a step (S63) of relatively moving the stator core and at least one of the machining jigs in the axial direction of the stator core in a manner to face each other so that the cylindrical portion of at least one of the machining jigs is located radially outward or radially inward of the coil protrusions, each of the coil protrusions is inserted between one circumferentially adjacent pair of the protrusions of at least one of the machining jigs, and the axial end face of the stator core is located at a predetermined distance (D) from the protrusion of at least one of the machining jigs in the axial direction of the stator core;

a step (S64) of simultaneously or alternately performing a first operation and a second operation, the first operation being an operation of relatively rotating the stator core and at least one of the machining jigs in a circumferential direction of the stator core, the second operation being an operation of relatively moving the stator core and at least one of the machining jigs in the axial direction of the stator core in a manner away from each other; and

a step (S65) of performing a third operation after the steps of performing the first operation and the second operation, the third operation being an operation of relatively moving the stator core and at least one of the machining jigs in the axial direction of the stator core in a manner toward each other, wherein each of the protrusions of at least one of the machining jigs is held in contact with a distal end portion (22) of a corresponding one of the coil protrusions or with a portion of the corresponding coil protrusion immediately adjacent to the distal end portion.

Technical Field

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

Background

An apparatus for manufacturing a stator used in a rotating electrical machine is known (see, for example, japanese patent application publication No. JP 2018170910A). The stator includes a ring-shaped stator core having a plurality of slots formed therein, and a stator coil formed with coil sections (or electrical conductor sections) inserted in the slots of the stator core. The manufacturing apparatus is configured to bend a coil protrusion, which is a portion of the coil section that protrudes from an axial end face of the stator core to the outside of the slot, in a circumferential direction of the stator core. Specifically, the manufacturing apparatus includes an inner bending die and an outer bending die, each of which has a plurality of engaging claws formed therein. In manufacturing the stator, the inner bending die is placed so that the engaging claws thereof engage with the distal end portions of those coil protrusions located radially inward, respectively, and the outer bending die is placed so that the engaging claws thereof engage with the distal end portions of those coil protrusions located radially outward, respectively. Then, the inner bending die and the outer bending die are axially moved toward the stator core while being respectively rotated toward opposite sides in the circumferential direction of the stator core. Therefore, the coil protrusion on the radially inner side and the coil protrusion on the radially outer side are bent toward the opposite sides in the circumferential direction of the stator core, respectively. Thereafter, each radially adjacent pair of distal end portions of the coil protrusions are joined, for example, by welding, to form the stator coil.

Disclosure of Invention

However, the inventors of the present application found through research that the manufacturing method known in the art as described above may involve the following problems.

That is, the known manufacturing apparatus is configured to bend the coil protrusion by applying a load to the distal end portion of the coil protrusion. Therefore, the radius of curvature of the coil protrusion may become large. As a result, it is possible to increase the height of the coil end of the stator coil, including the coil protrusion, thereby increasing the axial dimension of the entire stator.

Further, the known manufacturing apparatus is configured such that the radius of curvature of the coil protrusion cannot be controlled during bending of the coil protrusion in the circumferential direction of the stator core. Therefore, the radius of curvature of the coil protrusion may vary, so that the position of the distal end portion of the coil protrusion is unstable. As a result, in the subsequent joining step, it is difficult to join each radially adjacent pair of distal end portions of the coil protrusion.

The present disclosure has been made in view of the above problems. Accordingly, it is an object of the present disclosure to provide both an apparatus and a method for manufacturing a stator, by which a radius of curvature of a stator coil protrusion can be controlled, thereby minimizing the size of the entire stator.

According to the present disclosure, there is provided an apparatus for manufacturing a stator for a rotating electrical machine. The stator includes an annular stator core having a plurality of slots formed therein and a stator coil formed with a plurality of coil sections inserted into the slots of the stator core. The stator coil has a plurality of coil protrusions that are portions of the coil sections that protrude from the axial end faces of the stator core to the outside of the slot. The apparatus includes a support member, at least one machining jig, and an operation unit. The support member is configured to support the stator core by the coil sections inserted into the slots of the stator core. At least one machining jig is configured to be arranged coaxially with the stator core. At least one of the machining jigs has a cylindrical portion arranged radially outside or radially inside the coil protruding portions, and a plurality of protruding portions each protruding radially from the cylindrical portion and arranged at predetermined intervals in a circumferential direction of the cylindrical portion. The operation unit is configured to simultaneously or alternately perform the first operation and the second operation in a state where each coil protrusion is inserted between one circumferentially adjacent pair of protrusions of the at least one machining jig, and the axial end face of the stator core is positioned a predetermined distance from the protrusion of the at least one machining jig in the axial direction of the stator core. The first operation is an operation of relatively rotating the stator core and at least one machining jig in the circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the at least one machining jig away from each other in the axial direction of the stator core.

With the above configuration, the protrusion of the at least one machining jig will apply a load to a portion of the coil protrusion located near the stator core, thereby bending the coil protrusion in the circumferential direction. Therefore, the radius of curvature of the coil protrusion can be reduced. As a result, it is possible to reduce the height of the coil end of the stator coil, which includes the coil protrusion, thereby reducing the axial dimension of the entire stator.

Further, with the above configuration, the operation unit will perform the first operation and the second operation simultaneously or alternately, so that the radius of curvature of the coil protrusion can be controlled. Therefore, it is possible to suppress variation in the radius of curvature of the coil protrusion, thereby improving the positional accuracy of the distal end portion of the coil protrusion. As a result, in the subsequent joining step, each corresponding pair of distal end portions of the coil protrusions can be easily joined.

According to the present disclosure, there is also provided a method of manufacturing a stator for a rotary electric machine. The stator includes an annular stator core having a plurality of slots formed therein and a stator coil formed with a plurality of coil sections inserted into the slots of the stator core. The stator coil has a plurality of coil protrusions that are portions of the coil sections that protrude from the axial end faces of the stator core to the outside of the slot. The method comprises the following steps: a step of supporting a stator core by a support member, the coil sections of the stator core being inserted into slots of the stator core such that coil protrusions protrude from axial end faces of the stator core in an axial direction of the stator core; a step of arranging at least one machining jig coaxially with the stator core, the at least one machining jig having a cylindrical portion and a plurality of protruding portions each protruding radially from the cylindrical portion and arranged at predetermined intervals in a circumferential direction of the cylindrical portion; a step of relatively moving the stator core and the at least one machining jig toward each other in the axial direction of the stator core so that (a) the cylindrical portion of the at least one machining jig is located radially outward or radially inward of the coil protrusions, (b) each coil protrusion is inserted between one circumferentially adjacent pair of protrusions of the at least one machining jig, and (c) the axial end face of the stator core is located at a predetermined distance from the protrusions of the at least one machining jig in the axial direction of the stator core; a step of simultaneously or alternately performing a first operation and a second operation, the first operation being an operation of relatively rotating the stator core and the at least one machining jig in a circumferential direction of the stator core, the second operation being an operation of relatively moving the stator core and the at least one machining jig in an axial direction of the stator core in a manner away from each other; and an operation of performing a third operation after the steps of performing the first operation and the second operation, the third operation relatively moving the stator core and the at least one machining jig toward each other in the axial direction of the stator core, wherein each of the projections of the at least one machining jig is held in contact with a distal end portion of a corresponding one of the coil projections or a portion of the corresponding coil projection immediately adjacent to the distal end portion.

By the above method, the height of the coil end of the stator coil can be reduced, thereby reducing the axial dimension of the entire stator. Further, it is also possible to improve the positional accuracy of the distal end portions of the coil protrusions, thereby making it possible to easily join each corresponding pair of distal end portions of the coil protrusions in a subsequent joining step.

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 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 structural diagram of a manufacturing apparatus according to the first embodiment.

Fig. 5 is a perspective view of a machining jig of the manufacturing apparatus according to the first embodiment.

Fig. 6 is a plan view of a machining jig of the manufacturing apparatus according to the first embodiment.

Fig. 7 is a flowchart illustrating a manufacturing method according to the first embodiment.

Fig. 8 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. 9 is a flowchart showing a bending step of the manufacturing method according to the first embodiment.

Fig. 10 is a first explanatory diagram showing a bending step of the manufacturing method according to the first embodiment.

Fig. 11 is a second explanatory diagram showing a bending step of the manufacturing method according to the first embodiment.

Fig. 12 is a third explanatory view showing a bending step of the manufacturing method according to the first embodiment.

Fig. 13 is a fourth explanatory diagram showing a bending step of the manufacturing method according to the first embodiment.

Fig. 14 is a perspective view of a machining jig of the manufacturing apparatus according to the second embodiment.

Fig. 15 is a first explanatory view showing a bending step of the manufacturing method according to the second embodiment.

Fig. 16 is a second explanatory diagram showing a bending step of the manufacturing method according to the second embodiment.

Fig. 17 is a third explanatory diagram showing a bending step of the manufacturing method according to the second embodiment.

Fig. 18 is a fourth explanatory diagram showing a bending step of the manufacturing method according to the second embodiment.

Fig. 19 is a perspective view of a machining jig of a manufacturing apparatus according to a third embodiment.

Fig. 20 is a plan view of a machining jig of a manufacturing apparatus according to a third embodiment.

Fig. 21 is a perspective view of a machining jig of a manufacturing apparatus according to a fourth embodiment.

Fig. 22 is a plan view of a machining jig of a manufacturing apparatus according to a fourth embodiment.

Fig. 23 is a perspective view of a machining jig of a manufacturing apparatus according to a fifth embodiment.

Fig. 24 is a perspective view of a machining jig of a manufacturing apparatus according to a sixth 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 disposed radially inside or radially outside the stator. 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 shows a semi-finished product of the stator 1, while fig. 2 and 3 show 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 with 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 circumferentially adjacent pair of teeth 14. In the present embodiment, the stator core 10 is formed by laminating a plurality of annular magnetic steel plates in the axial direction thereof.

Each coil section 20 is substantially U-shaped to have a pair of straight portions extending parallel to each other and a turn portion connecting end portions 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 10a (i.e., a lower end surface in fig. 1 to 3) 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 10a 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 10a of the stator core 10. Hereinafter, the protrusion 21 of the coil section 20 is simply referred to as a coil protrusion 21. All the coil protrusions 21 collectively constitute the coil end 25 of the stator coil.

In addition, each coil section 20 has a turn portion protruding from the second axial end face 10b (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 other 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, as shown in fig. 1, the insulating coating is removed from the distal end portion 22 of the coil protrusion 21. Thus, the distal end portion 22 of the coil protrusion 21 constitutes an exposed portion 22 of the electrical conductor exposed from the insulating coating.

Further, each radially adjacent pair of distal end portions (i.e., exposed portions) 22 of the coil protrusion 21 is joined, for example, by welding, to form a joint (e.g., a weld) between the distal end portions. 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.

As shown in fig. 2 and 3, in the stator 1 finally obtained, the coil tabs and those portions of the coil protrusions 21 adjacent to the coil tabs are encapsulated by the encapsulating insulator 40. The package insulator 40 is formed of, for example, a thermosetting resin.

Next, an apparatus for manufacturing the stator 1 according to the present embodiment is described with reference to fig. 4 to 6.

The manufacturing apparatus is designed in the bending step of the method for manufacturing the stator 1 according to the present embodiment. As described in more detail below, in the bending step, the coil protrusion 21 axially protruding from the first axial end face 10a of the stator core 10 to the outside of the slot 11 is bent in the circumferential direction of the stator core 10 so as to extend obliquely with respect to the first axial end face 10a (see fig. 1 and 11).

As shown in fig. 4 to 6, the manufacturing apparatus includes a support member 50, a plurality of machining jigs 60, and an operation unit 70. It should be noted that only one machining jig 60 is shown in fig. 4 to 6 for the sake of simplicity.

The support member 50 is configured to support the stator core 10, the stator core 10 having the coil section 20 inserted in the slots 11 of the stator core 10. The coil protrusions 21 axially protruding to the outside of the slots 11 of the stator core 10 supported by the support member 50 are arranged to be aligned with each other in the circumferential direction of the stator core 10.

Further, although not shown in fig. 4, the straight portions of the substantially U-shaped coil section 20 are radially arranged in multiple layers in the slots 11 of the stator core 10. Therefore, the coil protrusions 21 axially protruding to the outside of the slots 11 of the stator core 10 are also radially arranged in multiple layers.

Each machining jig 60 has: a cylindrical portion 61; a plurality of projecting portions 62, each of the projecting portions 62 projecting radially from the cylindrical portion 61; and a base portion 63, the base portion 63 being disposed radially inward of the cylindrical portion 61. In the bending step, each machining jig 60 is arranged coaxially with the stator core 10.

The inner diameter or the outer diameter of the cylindrical portion 61 is set according to the diameter of the inner circle or the outer circle of the coil protrusion 21. Since the coil protrusions 21 are radially arranged in a plurality of layers, the machining jig 60 is configured such that the inner diameter or the outer diameter of each cylindrical portion 61 is different from each other.

Further, among the plurality of machining jigs 60, the radially innermost machining jig 60 is configured such that the cylindrical portion 61 thereof can be arranged radially inward of all the coil protrusions 21. In contrast, the radially outermost machining jig 60 is configured such that the cylindrical portion 61 thereof can be arranged radially outward of all the coil protrusions 21. Furthermore, each of its remaining (or radially intermediate) machining jigs 60 is configured such that its cylindrical portion 61 can be arranged between one radially adjacent pair of layers of the coil protrusion 21.

In addition, each of the machining jigs 60 may be configured such that all of the protruding portions 62 thereof protrude radially outward or radially inward from the cylindrical portion 61. For example, the machining jig 60 shown in fig. 4 to 6 is configured such that all the protruding portions 62 protrude radially outward from the cylindrical portion 61. However, the machining jig 60 may alternatively be configured such that all the protruding portions 62 protrude radially inward from the cylindrical portion 61.

In the present embodiment, each of the machining jigs 60 has its protruding portion 62 formed as axially extending walls 64, each of the axially extending walls 64 extending in the axial direction of the cylindrical portion 61 and arranged at predetermined intervals in the circumferential direction of the cylindrical portion 61 (or the circumferential direction of the stator core 10). A groove 65 is formed between each circumferentially adjacent pair of axially extending walls 64 (i.e., projections 62). The circumferential width of each groove 65 formed between the axially extending walls 64 is set to be larger than the circumferential width of each coil protrusion 21. Therefore, for each groove 65, a corresponding one of the coil protrusions 21 may be inserted in the groove 65. More specifically, as the machining jig 60 is moved in the axial direction indicated by the arrow a in fig. 4, the respective coil protrusions 21 are inserted into the grooves 65 formed between the axially extending walls 64, respectively. In addition, during insertion, the circumferential side surfaces (i.e., the side surfaces facing in the circumferential direction) of the axially extending walls 64 may be in contact with the circumferential side surfaces of the respective coil protrusions 21.

Further, in each of the machining jigs 60, the base portion 63 is positioned radially inside the cylindrical portion 61, and is fixed to one axial end (i.e., the lower end in fig. 4 and 5). Further, the base 63 is mechanically connected to the operation unit 70.

The operation unit 70 is configured to be able to move the machining jig 60 in both the circumferential direction and the axial direction of the stator core 10. It should be noted that the operating unit 70 may alternatively be configured to be able to move the stator core 10 supported by the support member 50 in both the circumferential direction and the axial direction of the stator core 10, instead of moving the machining jig 60, or simultaneously moving the machining jig 60.

Hereinafter, the operation of the operation unit 70 for relatively rotating the stator core 10 and the machining jig 60 in the circumferential direction of the stator core 10 is referred to as a first operation, and the operation of the operation unit 70 for relatively moving the stator core 10 and the machining jig 60 away from each other in the axial direction of the stator core 10 is referred to as a second operation. Further, the operation of the operation unit 70 for relatively moving the stator core 10 and the machining jig 60 toward each other in the axial direction of the stator core 10 is referred to as a third operation. The first operation, the second operation, and the third operation performed by the operation unit 70 will be described in detail later.

Next, a manufacturing method of the stator 1 according to the present embodiment will be described with reference to fig. 7 to 13.

Fig. 7 is a flowchart showing an outline of the manufacturing method according to the present embodiment.

As shown in fig. 7, 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 with 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 project from the first axial end face 10a (i.e., the lower end face 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. 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. 8, between each of the radially adjacent pairs of the coil protrusions 21, a predetermined gap S is formed.

In the lead wire forming step S50, the lead wires 23 (shown in fig. 2) 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 10a of the stator core 10.

The bending step S60 is described in detail below with reference to fig. 9 to 13.

Fig. 9 is a flowchart showing an outline of the bending step S60. Fig. 10 to 13 are schematic views in the radial direction of the stator core 10, showing only three circumferentially adjacent coil protrusions 21 of all the coil protrusions 21 and a part of one machining jig 60 corresponding to the three coil protrusions 21. In addition, in the present embodiment, in the bending step S60, each of the machining jigs 60 is moved relative to the stator core 10 by the operation unit 70.

As shown in fig. 9, the bending step S60 includes a stator core supporting step S61, a machining jig arranging step S62, a machining jig moving step S63, a first and second operation performing step S64, and a third operation performing step S65.

In the stator core supporting step S61, the stator core 10 is supported by the support member 50 (see fig. 4).

In the machining jig arranging step S62, each machining jig 60 is arranged coaxially with the stator core 10.

In the machining jig moving step S63, as shown by arrow a in fig. 4, each machining jig 60 is axially moved toward the stator core 10 so that the first axial end face 10a of the stator core 10 and the stator core-side axial end portion of the machining jig 60 become close to each other (see fig. 10). Therefore, for each of the machining jigs 60, the cylindrical portion 61 of the machining jig 60 is located radially outward of all the coil protrusion portions 21, radially inward of all the coil protrusion portions 21, or between two radially adjacent layers of the coil protrusion portions 21. Further, as shown in fig. 10, in each of the grooves 65 formed between the axially extending walls 64 of the machining jig 60, a corresponding one of the coil protrusions 21 is inserted. In this state, as shown in fig. 10, the stator core side end portion 66 of the axially extending wall 64 of the machining jig 60 is positioned at a predetermined distance D from the first axial end face 10a of the stator core 10. The distance D is predetermined to allow the coil protrusion 21 to bend between the axially extending walls 64 of the machining fixture 60. Therefore, when the operation unit 70 performs the first operation to rotate the machining jig 60 in the circumferential direction of the stator core 10, each coil protrusion 21 is bent, with the bending start point being located between the first axial end surface 10a of the stator core 10 and the position where the coil protrusion 21 abuts against the stator core-side end portion 66 of the corresponding one of the axially extending walls 64 of the machining jig 60. Therefore, with the above-described configuration of the machining jig 60 according to the present embodiment, the bending start point of each coil protrusion 21 can be set to be located in the vicinity of the stator core 10.

In the first and second operation performing step S64, as shown in fig. 11 and 12, the operation unit 70 may simultaneously or alternately perform a first operation of rotating the machining jig 60 in the circumferential direction of the stator core 10 and a second operation of axially moving the machining jig 60 away from the stator core 10. The first operation and the second operation are set according to the circumferential width of each groove 65 formed in the machining jig 60. More specifically, the operating unit 70 axially moves the machining jig 60 away from the stator core 10 while rotating the machining jig 60 in the circumferential direction of the stator core 10, so as to prevent the distal end portions 22 of the coil protrusions 21 from coming into contact with those axially extending walls 64 of the machining jig 60 that are located in front of the respective coil protrusions 21 in the rotational direction. Further, in fig. 11 and 12, the moving direction of the machining jig 60 relative to the stator core 10 during the first operation and the second operation is indicated by an arrow B.

By the first operation and the second operation performed by the operation unit 70, the coil protrusion 21 can be bent in the circumferential direction of the stator core 10 while controlling the radius of curvature of the coil protrusion 21. Therefore, the change in the radius of curvature of the coil protrusion 21 can be suppressed.

In the third operation performing step S65, as shown in fig. 13, after performing the first operation and the second operation until the coil protrusions 21 are retracted from the grooves 65 formed in the machining jig 60, the operation unit 70 further performs a third operation of axially moving the machining jig 60 toward the stator core 10, in which the stator core-side ends 66 of the axially extending walls 64 of the machining jig 60 are held in contact with the distal end portions 22 of the respective coil protrusions 21 or those portions of the respective coil protrusions 21 that are immediately adjacent to the distal end portions 22. Thus, the coil protrusions 21 are pressed by the stator core-side end portions 66 of the respective axially extending walls 64 of the machining jig 60, and are thereby bent toward the stator core 10. As a result, the radius of curvature of the coil protrusion 21 is further reduced, thereby further reducing the height of the coil end 25 of the stator coil. In addition, in fig. 13, during the third operation, the moving direction of the machining jig 60 relative to the stator core 10 is indicated by an arrow C.

After all the steps S61 to S65 as described above have been performed, the bending step S60 is terminated. As a result, a semi-finished product of the stator 1 as shown in fig. 1 is obtained. In the semi-finished product, the distal end portion 22 of each coil protrusion 21 is positioned radially adjacent to or radially against the distal end portion 22 of the other coil protrusion 21. In the bending step S60 as described above, since the height of the coil end 25 is reduced and the variation in the radius of curvature of the coil protrusion 21 is suppressed, the positional accuracy of the distal end portion 22 of the coil protrusion 21 is improved. Therefore, in the subsequent welding step S70, each corresponding pair of distal end portions 22 of the coil protrusions 21 can be easily welded. Referring again to fig. 7, in the welding step S70, each pair of radially adjacent or radially abutting distal end portions (i.e., exposed portions) 22 of the coil protrusions 21 are welded to form a weld (or joint) between the above-described distal end portions 22. 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 at least one of induction heating and energization 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. In the encapsulating insulator forming step, the coil tabs and those portions of the coil protrusions 21 that are immediately adjacent to the coil tabs are encapsulated by the encapsulating insulator 40. Specifically, in this step, the coil tabs and those portions of the coil protrusions 21 that are immediately adjacent to the coil tabs are placed in grooves formed in a mold (not shown). Then, a liquid thermosetting resin for forming the package insulator 40 is injected into the groove of the mold. Thereafter, the liquid thermosetting resin is heated by at least one of induction heating and energization heating. Thus, the liquid thermosetting resin is cured to form the package insulator 40. Then, the stator 1 is removed from the mold.

As a result, the stator 1 shown in fig. 2 and 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 support member 50, the support member 50 configured to support the stator core 10; machining jigs 60, each of the machining jigs 60 having a cylindrical portion 61 and a protruding portion 62; and an operation unit 70, the operation unit 70 being configured to perform the first operation and the second operation simultaneously or alternately.

With the above-described configuration of the manufacturing apparatus according to the present embodiment, the protruding portion 62 of the machining jig 60 will apply a load to a portion of the coil protruding portion 21 located near the stator core 10, thereby bending the coil protruding portion 21 in the circumferential direction of the stator core 10. Therefore, the radius of curvature of the coil protrusion 21 can be reduced. As a result, the height of the coil end 25 of the stator coil can be reduced, thereby reducing the axial dimension of the entire stator 1.

Further, with the above-described configuration of the manufacturing apparatus according to the present embodiment, the operation unit 70 will perform the first operation and the second operation simultaneously or alternately, so that the radius of curvature of the coil protrusion 21 can be controlled. Therefore, it is possible to suppress variation in the radius of curvature of the coil protrusion 21, thereby improving the positional accuracy of the distal end portion 22 of the coil protrusion 21. As a result, in the subsequent welding step S70, each corresponding pair of distal end portions 22 of the coil protrusions 21 can be easily welded.

In the manufacturing apparatus according to the present embodiment, the operation unit 70 is configured to simultaneously or alternately perform the first operation and the second operation according to a predetermined interval between the protruding portions 62 of the machining jig 60 in the circumferential direction (i.e., the circumferential width of each groove 65). Therefore, it is possible to bend the coil protrusion 21 in the circumferential direction of the stator core 10 while controlling the radius of curvature of the coil protrusion 21. As a result, the change in the radius of curvature of the coil protrusion 21 can be suppressed.

In the manufacturing apparatus according to the present embodiment, the operation unit 70 is configured to perform the third operation after performing the first operation and the second operation. The third operation is an operation of axially moving the machining jig 60 toward the stator core 10, in which the stator core-side end 66 of the axially extending wall 64 of the machining jig 60 is held in contact with the distal end portions 22 of the respective coil protrusions 21 or those portions of the respective coil protrusions 21 that are immediately adjacent to the distal end portions 22. Therefore, by performing the third operation, the radius of curvature of the coil protrusion 21 can be further reduced, thereby reducing the height of the coil end 25 of the stator coil.

In the manufacturing apparatus according to the present embodiment, each of the machining jigs 60 has its protruding portion 62 formed as axially extending walls 64, each of the axially extending walls 64 extending in the axial direction of the cylindrical portion 61 and arranged at predetermined intervals in the circumferential direction of the cylindrical portion 61. Further, the machining jig 60 is configured to allow the coil protrusions 21 to be respectively inserted into the grooves 65 formed between the axially extending walls 64 of the machining jig 60.

By forming the protruding portion 62 of the machining jig 60 as the axially extending wall 64, the coil protruding portion 21 can be prevented from being excessively bent during the first operation.

In the bending step S60 of the manufacturing method according to the present embodiment, each of the machining jigs 60 is arranged such that the cylindrical portion 61 thereof is located radially outward or radially inward of the coil protrusion 21. Then, the first operation and the second operation are performed simultaneously or alternately. Thereafter, a third operation is performed to axially move the machining jig 60 toward the stator core 10, wherein the protrusion 62 of the machining jig 60 is held in contact with the distal end portion 22 of the corresponding coil protrusion 21 or those portions of the corresponding coil protrusion 21 immediately adjacent to the distal end portion 22.

By the above-described manufacturing method according to the present embodiment, the height of the coil end 25 of the stator coil can be reduced, thereby reducing the axial dimension of the entire stator 1. Further, it is also possible to improve the positional accuracy of the distal end portions 22 of the coil protrusions 21, thereby making it possible to easily weld each corresponding pair of distal end portions 22 of the coil protrusions 21 in the subsequent welding step S70.

[ second embodiment ]

In the first embodiment as described above, the protruding portions 62 of each of the machining jigs 60 are formed as the axially extending walls 64, and the axially extending walls 64 each extend in the axial direction of the cylindrical portion 61 and are arranged at predetermined intervals in the circumferential direction of the cylindrical portion 61 (see fig. 5).

In contrast, in the second embodiment, as shown in fig. 14, each of the machining jigs 60 has its protruding portion 62 formed as pins 67, and the pins 67 each radially protrude from the stator-core-side end portion of the cylindrical portion 61 and are arranged at predetermined intervals in the circumferential direction of the cylindrical portion 61. Each circumferential interval between the pins 67 is predetermined to be larger than the circumferential width of each coil protrusion 21. Therefore, for each circumferentially adjacent pair of pins 67, a corresponding one of the coil protrusions 21 may be inserted between the above-mentioned pins 67.

In addition, the machining jig 60 shown in fig. 14 is configured such that all the pins 67 protrude radially outward from the cylindrical portion 61. However, the machining jig 60 may alternatively be configured such that all the pins 67 protrude radially inward from the cylindrical portion 61.

Next, a bending step S60 of the manufacturing method according to the second embodiment is described with reference to fig. 15 to 18.

Fig. 15 to 18 are schematic views in the radial direction of the stator core 10, showing only three circumferentially adjacent coil protrusions 21 of all the coil protrusions 21 and a part of one machining jig 60 corresponding to the three coil protrusions 21. In addition, in the present embodiment, in the bending step S60, each machining jig 60 is moved relative to the stator core 10 by the operation unit 70, as in the first embodiment.

In the bending step S60, each machining jig 60 is axially moved toward the stator core 10 so that the first axial end face 10a of the stator core 10 and the stator core-side axial end portion of the machining jig 60 become close to each other. Therefore, as shown in fig. 15, between each circumferentially adjacent pair of pins 67 of the machining jig 60, a corresponding coil protrusion 21 is inserted. In this state, the pin 67 of the machining jig 60 is positioned at a predetermined distance D from the first axial end face 10a of the stator core 10. The distance D is predetermined to allow the coil protrusion 21 to be bent between the pins 67 of the machining jig 60. Therefore, each coil protrusion 21 is bent when the first operation is performed by the operation unit 70 to rotate the machining jig 60 in the circumferential direction of the stator core 10, with the bending start point between the first axial end surface 10a of the stator core 10 and the position where the coil protrusion 21 abuts against the corresponding one of the pins 67 of the machining jig 60. Therefore, with the above-described configuration of the machining jig 60 according to the present embodiment, it is also possible to set the bending start point of each coil protrusion 21 to be located in the vicinity of the stator core 10.

Further, as shown in fig. 16 and 17, the operation unit 70 simultaneously or alternately performs a first operation of rotating the machining jig 60 in the circumferential direction of the stator core 10 and a second operation of axially moving the machining jig 60 away from the stator core 10. More specifically, the operation unit 70 moves the machining jig 60 axially away from the stator core 10 while rotating the machining jig 60 in the circumferential direction of the stator core 10 so that each pin 67 slides between one circumferentially adjacent pair of the coil protrusions 21. Further, in fig. 16 and 17, the moving direction of the machining jig 60 relative to the stator core 10 during the first operation and the second operation is indicated by an arrow B.

By the first operation and the second operation performed by the operation unit 70, the coil protrusion 21 can be bent in the circumferential direction of the stator core 10 while controlling the radius of curvature of the coil protrusion 21. Therefore, the change in the radius of curvature of the coil protrusion 21 can be suppressed.

Further, as shown in fig. 18, after the first operation and the second operation are performed until the pins 67 are retracted from the gaps between the circumferentially adjacent coil protrusions 21, the operation unit 70 further performs a third operation of axially moving the machining jig 60 toward the stator core 10, in which the pins 67 of the machining jig 60 are held in contact with the distal end portions 22 of the respective coil protrusions 21 or those portions of the respective coil protrusions 21 that are immediately adjacent to the distal end portions 22. Therefore, the coil protrusion 21 is pressed by the pin 67 of the machining jig 60, and is thereby bent toward the stator core 10. As a result, the radius of curvature of the coil protrusion 21 is further reduced, thereby further reducing the height of the coil end 25 of the stator coil. In addition, in fig. 18, during the third operation, the moving direction of the machining jig 60 relative to the stator core 10 is indicated by an arrow C.

According to the second embodiment, the same advantageous effects as those achievable according to the first embodiment can also be achieved.

[ third embodiment ]

Fig. 19 and 20 collectively show the configuration of a machining jig 60 according to a third embodiment.

As shown in fig. 19 and 20, the machining jig 60 according to the third embodiment includes a pair of a first machining jig 601 and a second machining jig 602. The first machining jig 601 and the second machining jig 602 are arranged coaxially with each other such that the second machining jig 602 is located radially outside the first machining jig 601.

In the third embodiment, each of the first machining jig 601 and the second machining jig 602 is configured similarly to the machining jig 60 in the first embodiment.

Specifically, the first machining jig 601 includes: the first cylindrical portion 611; and a plurality of first axially extending walls 641 (or protruding portions 62), each of the plurality of first axially extending walls 641 protruding radially outward from the first cylindrical portion 611 and extending in the axial direction of the first cylindrical portion 611. Further, the first axially extending walls 641 are arranged at predetermined intervals in the circumferential direction of the first cylindrical portion 611 so that a first groove 651 is formed between each circumferentially adjacent opposing first axially extending wall 641. The circumferential width of each first groove 651 formed between the first axially extending walls 641 is set larger than the circumferential width of each coil protrusion 21. Therefore, for each of the first recesses 651, a corresponding one of the coil protrusions 21 may be inserted therein.

Similarly, the second machining jig 602 has: a second cylindrical portion 612; and a plurality of second axially extending walls 642 (or projecting portions 62), each of the plurality of second axially extending walls 642 projecting radially inward from the second cylinder portion 612 and extending in the axial direction of the second cylinder portion 612. Further, the second axially extending walls 642 are arranged at predetermined intervals in the circumferential direction of the second cylinder portion 612 such that a second groove 652 is formed between each circumferentially adjacent pair of the second axially extending walls 642. The circumferential width of each second groove 652 formed between the second axially extending walls 642 is set larger than the circumferential width of each coil protrusion 21. Therefore, for each of the second grooves 652, a corresponding one of the coil protrusions 21 may be inserted therein.

The second cylindrical portion 612 of the second machining jig 602 is coaxially arranged radially outward of the first cylindrical portion 611 of the first machining jig 601. That is, the inner diameter of the second cylindrical portion 612 is set larger than the outer diameter of the first cylindrical portion 611. Further, before the bending step S60, the radially inner end portions of the second axially extending walls 642 of the second machining jig 602 are respectively located adjacent to and radially aligned with the radially outer end portions of the first axially extending walls 641 of the first machining jig 601.

As described in the first embodiment, the coil protrusions 21 are radially arranged in a plurality of layers (see fig. 8). The plurality of layers includes a radially adjacent pair of a first layer and a second layer, the second layer being radially outward of the first layer. In the third embodiment, in the bending step S60, the coil protrusions 21 arranged in the first layer are inserted into the first grooves 651 of the first machining jig 601, respectively, and the coil protrusions 21 arranged in the second layer are inserted into the second grooves 652 of the second machining jig 602, respectively. That is, the coil protrusions 21 inserted into the first grooves 651 of the first machining jig 601 are located radially inward of and adjacent to the coil protrusions 21 inserted into the second grooves 652 of the second machining jig 602, respectively.

Further, in the third embodiment, in the bending step S60, the operation unit 70 simultaneously performs the first operation and the second operation on both the coil protrusion 21 inserted into the first groove 651 and the coil protrusion 21 inserted into the second groove 652. Specifically, the operation unit 70 performs a second operation of axially moving the first machining jig 601 away from the stator core 10 while performing a first operation of rotating the first machining jig 601 toward the first side in the circumferential direction of the stator core 10. Meanwhile, the operation unit 70 also performs a second operation of axially moving the second machining jig 602 away from the stator core 10 while performing a first operation of rotating the second machining jig 602 in the circumferential direction of the stator core 10 toward a second side opposite to the first side (see fig. 19 and 20). That is, in the first operation, the first machining jig 601 and the second machining jig 602 are respectively rotated in opposite directions by the operation unit 70. Therefore, the coil protrusion 21 inserted into the first groove 651 of the first machining jig 601 is bent toward the first side in the circumferential direction of the stator core 10, and the coil protrusion 21 inserted into the second groove 652 of the second machining jig 602 is bent toward the second side in the circumferential direction of the stator core 10.

As described above, the machining jig 60 according to the present embodiment includes the first machining jig 601 and the second machining jig 602 having different diameters from each other and arranged coaxially with each other. Therefore, with the machining jig 60 according to the present embodiment, it is possible to bend both the coil protrusion 21 disposed on the first layer and the coil protrusion 21 disposed on the second layer. As a result, the time required to bend all the coil protrusions 21 of the stator coil in the bending step S60 can be reduced.

In addition, according to the present embodiment, the same advantageous effects as those described in the first embodiment can also be achieved.

[ fourth embodiment ]

Fig. 21 and 22 collectively show the configuration of a machining jig 60 according to a fourth embodiment.

As shown in fig. 21 and 22, the machining jig 60 according to the fourth embodiment includes two pairs of pressing jigs, i.e., one pair of a first machining jig 601 and a second machining jig 602 and one pair of a third machining jig 603 and a fourth machining jig 604. The first pressing jig 601, the second pressing jig 602, the third pressing jig 603, and the fourth pressing jig 604 are all arranged coaxially with each other so as to be positioned radially in this order from the radially inner side. That is, the first pressing jig 601 is located at the radially innermost side, and the fourth pressing jig 604 is located at the radially outermost side.

In the present embodiment, the first machining jig 601 and the second machining jig 602 are the same as those in the third embodiment.

Further, in the present embodiment, the third machining jig 603 and the fourth machining jig 604 are configured similarly to the first machining jig 601 and the second machining jig 602.

Specifically, the third machining jig 603 includes: a third cylindrical portion 613; and a plurality of third axially extending walls 643 (or projections 62), each of the plurality of third axially extending walls 643 projecting radially outward from the third cylindrical portion 613 and extending in the axial direction of the third cylindrical portion 613. Further, the third axially extending walls 643 are arranged at predetermined intervals in the circumferential direction of the third cylindrical portion 613 such that third grooves 653 are formed between each circumferentially adjacent pair of the third axially extending walls 643. The circumferential width of each of the third grooves 653 formed between the third axially extending walls 643 is set larger than the circumferential width of each of the coil protrusions 21. Accordingly, for each of the third recesses 653, a corresponding one of the coil protrusions 21 may be inserted therein.

In addition, the inner diameter of the third cylindrical portion 613 is set larger than the outer diameter of the second cylindrical portion 612, and the radially inner peripheral surface of the third cylindrical portion 613 and the radially outer peripheral surface of the second cylindrical portion 612 are arranged adjacent to each other.

Similarly, the fourth machining jig 604 has: a fourth cylindrical portion 614; and a plurality of fourth axially extending walls 644 (or projecting portions 62), each of the plurality of fourth axially extending walls 644 projecting radially inward from the fourth cylinder portion 614 and extending in the axial direction of the fourth cylinder portion 614. Further, the fourth axially extending walls 644 are arranged at predetermined intervals in the circumferential direction of the fourth cylindrical portion 614 such that fourth grooves 654 are formed between each circumferentially adjacent pair of the fourth axially extending walls 644. The circumferential width of each fourth groove 654 formed between the fourth axially extending walls 644 is set to be larger than the circumferential width of each coil protrusion 21. Therefore, for each of the fourth recesses 654, a corresponding one of the coil protrusions 21 may be inserted therein.

The fourth cylindrical portion 614 of the fourth machining jig 604 is arranged radially outward of and coaxially with the third cylindrical portion 613 of the third machining jig 603. That is, the inner diameter of the fourth cylindrical portion 614 is set to be larger than the outer diameter of the third cylindrical portion 613. Further, before the bending step S60, radially inner ends of the fourth axially extending walls 644 of the fourth machining jig 604 are respectively located adjacent to and radially aligned with radially outer ends of the third axially extending walls 643 of the third machining jig 603.

As described in the first embodiment, the coil protrusions 21 are radially arranged in a plurality of layers (see fig. 8). The plurality of layers includes a first layer, a second layer, a third layer, and a fourth layer that are radially positioned in this order from the radially inner side. In the fourth embodiment, in the bending step S60, the coil protrusions 21 arranged in the first layer are inserted into the first recesses 651 of the first processing jig 601, the coil protrusions 21 arranged in the second layer are inserted into the second recesses 652 of the second processing jig 602, the coil protrusions 21 arranged in the third layer are inserted into the third recesses 653 of the third processing jig 603, and the coil protrusions 21 arranged in the fourth layer are inserted into the fourth recesses 654 of the fourth processing jig 604, respectively. That is, each coil protrusion 21 inserted into the first groove 651 of the first machining jig 601 is radially aligned with a corresponding one of the coil protrusions 21 inserted into the second groove 652 of the second machining jig 602, a corresponding one of the coil protrusions 21 inserted into the third groove 653 of the third machining jig 603, and a corresponding one of the coil protrusions 21 inserted into the fourth groove 654 of the fourth machining jig 604.

Further, in the fourth embodiment, in the bending step S60, the operation unit 70 performs the first operation and the second operation on both the coil protrusion 21 inserted into the first groove 651 and the coil protrusion 21 inserted into the second groove 652 in the same manner as described in the third embodiment. Further, the operation unit 70 simultaneously performs the first operation and the second operation on the coil protrusion 21 inserted into the third recess 653 and the coil protrusion 21 inserted into the fourth recess 654 in the same manner as on the coil protrusion 21 inserted into the first recess 651 and the coil protrusion 21 inserted into the second recess 652. Specifically, the operation unit 70 performs a second operation of axially moving the third machining jig 603 away from the stator core 10 while performing a first operation of rotating the third machining jig 603 toward the first side in the circumferential direction of the stator core 10. Meanwhile, the operation unit 70 also performs a second operation of axially moving the fourth machining jig 604 away from the stator core 10 while performing the first operation of rotating the fourth machining jig 604 in the circumferential direction of the stator core 10 toward the second side opposite to the first side (see fig. 21 and 22). That is, in the first operation, the first machining jig 601 and the second machining jig 602 are respectively rotated in opposite directions by the operation unit 70, the second machining jig 602 and the third machining jig 603 are respectively rotated in opposite directions by the operation unit 70, and the third machining jig 603 and the fourth machining jig 604 are respectively rotated in opposite directions by the operation unit 70. In other words, the operation unit 70 rotates each of the first machining jig 601, the second machining jig 602, the third machining jig 603, and the fourth machining jig 604, which are radially adjacent in pairs, in opposite directions, respectively. Accordingly, both the coil protrusion 21 inserted into the first groove 651 of the first machining jig 601 and the coil protrusion 21 inserted into the third groove 653 of the third machining jig 603 are bent toward the first side in the circumferential direction of the stator core 10, and both the coil protrusion 21 inserted into the second groove 652 of the second machining jig 602 and the coil protrusion 21 inserted into the fourth groove 654 of the fourth machining jig 604 are bent toward the second side in the circumferential direction of the stator core 10.

As described above, the machining jig 60 according to the present embodiment includes the first machining jig 601 to the fourth machining jig 604 having different diameters from each other and arranged coaxially with each other. Therefore, with the machining jig 60 according to the present embodiment, the coil protrusions 21 disposed on the first to fourth layers can be bent at the same time. As a result, the time required to bend all the coil protrusions 21 of the stator coil in the bending step S60 can be further reduced.

In addition, according to the present embodiment, the same advantageous effects as those described in the first embodiment can also be achieved.

[ fifth embodiment ]

Fig. 23 shows a configuration of a machining jig 60 according to a fifth embodiment.

As shown in fig. 23, the machining jig 60 according to the fifth embodiment includes a pair of a first machining jig 601 and a second machining jig 602. The first machining jig 601 and the second machining jig 602 are arranged coaxially with each other such that the second machining jig 602 is located radially outside the first machining jig 601.

In the fifth embodiment, each of the first machining jig 601 and the second machining jig 602 is configured similarly to the machining jig 60 in the second embodiment.

Specifically, the first machining jig 601 includes: the first cylindrical portion 611; and a plurality of first pins 671 (or protruding portions 62), each of the plurality of first pins 671 protruding radially outward from the first cylindrical portion 611 and arranged at predetermined intervals in the axial direction of the first cylindrical portion 611, respectively. Each circumferential interval between the first pins 671 is predetermined to be larger than the circumferential width of each coil protrusion 21. Therefore, for each circumferentially adjacent pair of first pins 671, a corresponding one of the coil protrusions 21 may be inserted between the above-described first pins 67.

Similarly, the second machining jig 602 has: a second cylindrical portion 612; and a plurality of second pins 672 (or protruding portions 62), each of which protrudes radially inward from the second cylindrical portion 612 and is arranged at predetermined intervals in the circumferential direction of the second cylindrical portion 612. Each circumferential interval between the second pins 672 is predetermined to be larger than the circumferential width of each coil protrusion 21. Therefore, for each circumferentially adjacent pair of the second pins 672, a corresponding one of the coil protrusions 21 may be inserted between the above-described second pins 672.

The second cylindrical portion 612 of the second machining jig 602 is arranged radially outward of and coaxially with the first cylindrical portion 611 of the first machining jig 601. That is, the inner diameter of the second cylindrical portion 612 is set larger than the outer diameter of the first cylindrical portion 611. Further, before the bending step S60, the radially inner end portions of the second pins 672 of the second machining jig 602 are respectively located adjacent to and radially aligned with the radially outer end portions of the first pins 671 of the first machining jig 601.

As described in the first embodiment, the coil protrusions 21 are radially arranged in a plurality of layers (see fig. 8). The plurality of layers includes a radially adjacent pair of a first layer and a second layer, the second layer being radially outward of the first layer. In the fifth embodiment, in the bending step S60, the coil protrusion 21 disposed at the first layer is inserted between the first pins 671 of the first machining jig 601, and the coil protrusion 21 disposed at the second layer is inserted between the second pins 672 of the second machining jig 602. That is, the coil protrusions 21 inserted between the first pins 671 of the first machining jig 601 are respectively located radially inward of and adjacent to the coil protrusions 21 inserted between the second pins 672 of the second machining jig 602.

Further, in the fifth embodiment, in the bending step S60, the operation unit 70 simultaneously performs the first operation and the second operation on both the coil protrusion 21 inserted between the first pins 671 of the first machining jig 601 and the coil protrusion 21 inserted between the second pins 672 of the second machining jig 602. Specifically, the operation unit 70 performs a second operation of axially moving the first machining jig 601 away from the stator core 10 while performing a first operation of rotating the first machining jig 601 toward the first side in the circumferential direction of the stator core 10. Meanwhile, the operation unit 70 also performs a second operation of axially moving the second machining jig 602 away from the stator core 10 while performing a first operation of rotating the second machining jig 602 in the circumferential direction of the stator core 10 toward a second side opposite to the first side (see fig. 23). That is, in the first operation, the first machining jig 601 and the second machining jig 602 are respectively rotated in opposite directions by the operation unit 70. Therefore, the coil protrusion 21 inserted between the first pins 671 of the first machining jig 601 is bent toward the first side in the circumferential direction of the stator core 10, and the coil protrusion 21 inserted between the second pins 672 of the second machining jig 602 is bent toward the second side in the circumferential direction of the stator core 10.

As described above, the machining jig 60 according to the present embodiment includes the first machining jig 601 and the second machining jig 602 having different diameters from each other and arranged coaxially with each other. Therefore, with the machining jig 60 according to the present embodiment, it is possible to bend the coil protrusion 21 disposed on the first layer and the coil protrusion 21 disposed on the second layer at the same time. As a result, the time required to bend all the coil protrusions 21 of the stator coil in the bending step S60 can be reduced.

In addition, according to the present embodiment, the same advantageous effects as those described in the first embodiment can also be achieved.

[ sixth embodiment ]

Fig. 24 shows the configuration of a machining jig 60 according to the sixth embodiment.

As shown in fig. 24, the machining jig 60 according to the sixth embodiment includes two pairs of pressing jigs, i.e., a pair of first and second machining jigs 601 and 602 and a pair of third and fourth machining jigs 603 and 604. The first pressing jig 601, the second pressing jig 602, the third pressing jig 603, and the fourth pressing jig 604 are all arranged coaxially with each other so as to be positioned radially in this order from the radially inner side. That is, the first pressing jig 601 is located at the radially innermost side, and the fourth pressing jig 604 is located at the radially outermost side.

In the present embodiment, the first machining jig 601 and the second machining jig 602 are the same as those in the fifth embodiment.

Further, in the present embodiment, the third machining jig 603 and the fourth machining jig 604 are configured similarly to the first machining jig 601 and the second machining jig 602.

Specifically, the third machining jig 603 includes: a third cylindrical portion 613; and a plurality of third pins 673 (or protruding portions 62), each of the plurality of third pins 673 protruding radially outward from the third cylindrical portion 613 and arranged at predetermined intervals in the circumferential direction of the third cylindrical portion 613. Each circumferential interval between the third pins 673 is predetermined to be larger than the circumferential width of each coil protrusion 21. Therefore, for each circumferentially adjacent pair of the third pins 673, a corresponding one of the coil protrusions 21 may be inserted between the above-described third pins 673.

In addition, the inner diameter of the third cylindrical portion 613 is set larger than the outer diameter of the second cylindrical portion 612, and the radially inner peripheral surface of the third cylindrical portion 613 and the radially outer peripheral surface of the second cylindrical portion 612 are arranged adjacent to each other.

Similarly, the fourth machining jig 604 has: a fourth cylindrical portion 614; and a plurality of fourth pins 674 (or projecting portions 62), each of the above-mentioned fourth pins 674 projecting radially inward from the fourth cylindrical portion 614 and being arranged at predetermined intervals in the circumferential direction of the fourth cylindrical portion 614. Each circumferential interval between the fourth pins 674 is predetermined to be larger than the circumferential width of each coil protrusion 21. Therefore, for each circumferentially adjacent pair of the fourth pins 674, a corresponding one of the coil protrusions 21 may be inserted between the above-described fourth pins 674.

The fourth cylindrical portion 614 of the fourth machining jig 604 is arranged radially outward of and coaxially with the third cylindrical portion 613 of the third machining jig 603. That is, the inner diameter of the fourth cylindrical portion 614 is set to be larger than the outer diameter of the third cylindrical portion 613. Further, before the bending step S60, the radially inner end portions of the fourth pins 674 of the fourth machining jig 604 are respectively located adjacent to and radially aligned with the radially outer end portions of the third pins 673 of the third machining jig 603.

As described in the first embodiment, the coil protrusions 21 are radially arranged in a plurality of layers (see fig. 8). The plurality of layers includes a first layer, a second layer, a third layer, and a fourth layer that are radially positioned in this order from the radially inner side. In the sixth embodiment, in the bending step S60, the coil overhang 21 disposed on the first layer is inserted between the first pins 671 of the first machining jig 601, the coil overhang 21 disposed on the second layer is inserted between the second pins 672 of the second machining jig 602, the coil overhang 21 disposed on the third layer is inserted between the third pins 673 of the third machining jig 603, and the coil overhang 21 disposed on the fourth layer is inserted between the fourth pins 674 of the fourth machining jig 604. That is, each coil protrusion 21 inserted between the first pins 671 of the first machining jig 601 is radially aligned with a corresponding one of the coil protrusions 21 inserted between the second pins 672 of the second machining jig 602, a corresponding one of the coil protrusions 21 inserted between the third pins 673 of the third machining jig 603, and a corresponding one of the coil protrusions 21 inserted between the fourth pins 674 of the fourth machining jig 604. Further, in the sixth embodiment, in the bending step S60, the operation unit 70 performs the first operation and the second operation on both the coil protrusion 21 inserted between the first pins 671 of the first machining jig 601 and the coil protrusion 21 inserted between the second pins 672 of the second machining jig 602 in the same manner as described in the fifth embodiment. Further, the operation unit 70 also simultaneously performs the first operation and the second operation on the coil protrusion 21 inserted between the third pins 673 of the third machining jig 603 and the coil protrusion 21 inserted between the fourth pins 674 of the fourth machining jig 604 in the same manner as the coil protrusion 21 inserted between the first pins 671 and the coil protrusion 21 inserted between the second pins 672. Specifically, the operation unit 70 performs a second operation of axially moving the third machining jig 603 away from the stator core 10 while performing a first operation of rotating the third machining jig 603 toward the first side in the circumferential direction of the stator core 10. Meanwhile, the operation unit 70 also performs a second operation of axially moving the fourth processing jig 604 away from the stator core 10 while performing the first operation of rotating the fourth processing jig 604 in the circumferential direction of the stator core 10 toward a second side opposite to the first side (see fig. 24). That is, in the first operation, the first machining jig 601 and the second machining jig 602 are respectively rotated in opposite directions by the operation unit 70, the second machining jig 602 and the third machining jig 603 are respectively rotated in opposite directions by the operation unit 70, and the third machining jig 603 and the fourth machining jig 604 are respectively rotated in opposite directions by the operation unit 70. In other words, each of the first machining jig 601, the second machining jig 602, the third machining jig 603, and the fourth machining jig 604, which are radially adjacent in pairs, are rotated in opposite directions by the operation unit 70, respectively. Accordingly, both the coil protrusion 21 inserted between the first pins 671 of the first machining jig 601 and the coil protrusion 21 inserted between the third pins 673 of the third machining jig 603 are bent toward the first side in the circumferential direction of the stator core 10, and both the coil protrusion 21 inserted between the second pins 672 of the second machining jig 602 and the coil protrusion 21 inserted between the fourth pins 674 of the fourth machining jig 604 are bent toward the second side in the circumferential direction of the stator core 10. As described above, the machining jig 60 according to the present embodiment includes the first machining jig 601 to the fourth machining jig 604 having different diameters from each other and arranged coaxially with each other. Therefore, with the machining jig 60 according to the present embodiment, the coil protrusions 21 disposed on the first to fourth layers can be bent at the same time. As a result, the time required to bend all the coil protrusions 21 of the stator coil in the bending step S60 can be further reduced.

In addition, according to the present embodiment, the same advantageous effects as those described in the first embodiment can also be achieved.

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 embodiment described above, as the first operation, the operation unit 70 rotates the machining jig 60 in the circumferential direction of the stator core 10 while keeping the stator core 10 stationary. Alternatively, the operation unit 70 may rotate the stator core 10 in the circumferential direction thereof while keeping the machining jig 60 stationary. As another alternative, the operating unit 70 may rotate both the stator core 10 and the machining jig 60 at different speeds and/or in opposite directions in the circumferential direction of the stator core 10. That is, as the first operation, the operation unit 70 needs to relatively rotate the stator core 10 and the machining jig 60 in the circumferential direction of the stator core 10.

In the embodiment described above, as the second operation, the operation unit 70 moves the machining jig 60 in the axial direction of the stator core 10 away from the stator core 10 while keeping the stator core 10 stationary. Alternatively, the operation unit 70 may move the stator core 10 in the axial direction of the stator core 10 away from the machining jig 10 while holding the machining jig 60 stationary. As another alternative, the operating unit 70 may move both the stator core 10 and the machining jig 60 away from each other in the axial direction of the stator core 10. That is, as the second operation, the operation unit 70 needs to relatively move the stator core 10 and the machining jig 60 in the axial direction of the stator core 10.

In the embodiment described above, as the third operation, the operation unit 70 moves the machining jig 60 in the axial direction of the stator core 10 toward the stator core 10 while keeping the stator core 10 stationary. Alternatively, the operation unit 70 may move the stator core 10 in the axial direction of the stator core 10 toward the machining jig 60 while keeping the machining jig 60 stationary. As another alternative, the operating unit 70 may move both the stator core 10 and the machining jig 60 toward each other in the axial direction of the stator core 10. That is, as the third operation, the operation unit 70 needs to relatively move the stator core 10 and the machining jig 60 toward each other in the axial direction of the stator core 10.

In the embodiment described above, no insulating cuff is provided at the axial end portion of the stator core 10. Alternatively, an insulating cuff may be provided at an axial end portion of the stator core 10.

In the embodiment described above, the coil section 20 is formed of an electric wire having a substantially rectangular cross-sectional shape. However, the coil section 20 may also be formed of an electrical wire having other cross-sectional shapes, such as a circular cross-sectional shape, an elliptical cross-sectional shape, a polygonal cross-sectional shape, or any combination of the foregoing cross-sectional shapes.

In the embodiment described above, the insulator 30 is formed of a curable and foamable resin that foams and cures when heated. However, the insulator 30 may alternatively be formed of other materials. Further, in this case, it is preferable to impregnate varnish into the slots 11 of the stator core 10, thereby fixing the coil section 20 and the insulator 30 in the slots 11.