JP3514939B2 - Method for manufacturing electric motor and stator - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric motor having a plurality of phase coils for generating a rotating magnetic field in a stator and a method for manufacturing the stator.

[0002]

2. Description of the Related Art In a conventional motor manufacturing method, in a motor of several tens of W or less, an enameled wire is directly wound around a stator, and then a coil end is subjected to finish shaping to miniaturize the coil end. In addition, in a motor with a higher output, it is common to perform a die roll externally and then forcibly insert it into the slot radially from both sides of the slot opening with an inserter simultaneously toward the outer diameter direction. . A semi-closed slot is generally used as the slot shape. At this time, the externally wound wire is disturbed in alignment at the time of insertion, and the wires are inserted while intersecting each other. Even if the coil has two or more phases, winding is performed using a winding frame that does not differ in coil shape, and after all the one-phase coils are inserted into the core, the coil is wound in the outer diameter direction of the core. By tilting around the core end face, the coil end shaping for each phase was performed so that the coil of the next phase could be inserted. After all the coils have been inserted, the coil end pushed to the outer diameter side of the stator core of the coil inserted first and the coil end remaining on the inner diameter side of the coil inserted last are set in the radial and axial directions. It was compressed and shaped to make the coil end smaller.

[0003]

However, in the conventional insertion method and coil end finishing method, there is a limit to the original miniaturization. That is, the space factor is limited in the insertion by the direct winding and the inserter.
In this method, the space factor is generally 70% due to the disturbance caused by the line-to-line intersection that occurs during insertion. In addition, coil end shaping compresses an extra required coil end length to a certain range at the time of inserting a coil and inserting the next coil, and the length of the coil end, which is a major cause of loss, is , Remains long.

An object of the present invention is to solve the above problems.
An object of the present invention is to provide an electric motor and a stator manufacturing method for the electric motor, in which the size and weight of the electric motor are reduced by improving the space factor of the coil and the loss by reducing the loss of the coil end. Another object of the present invention is to improve the space factor of the coil and the efficiency by reducing the loss of the coil end to realize a small size and weight reduction, and an electric motor having a three-phase concentric winding stator and its stator. It is to provide a manufacturing method.

[0005]

In order to achieve the above object, the present invention relates to a motor having a plurality of phase coils for generating a rotating magnetic field in a stator, and a coil of a desired phase among the plurality of phase coils. The crossover portion and the rising portion from the slot in the axial direction of the core are arranged in a shape that does not interfere with the end portions of the coils of other phases.

Further, according to the present invention, in a motor having a plurality of phase coils for generating a rotating magnetic field in a stator, among the plurality of phase coils, a coil of a desired phase whose crossover portion is located on the outermost side in the radial direction is provided. The inside of the crossover portion of the coil is located outside the extension of the slot into which the coil of another phase is inserted. Further, according to the present invention, in a motor having a stator constituted by three-phase concentric winding, a slot space factor (a cross-sectional area of a coil with respect to a cross-sectional area of a slot excluding an insulator) is 80% or more, and a coil of each phase. The end shape (coil portion extending axially outward from the core after insertion) is made different, and the crossover portions of the coils of the respective phases are arranged in alignment.

Further, according to the present invention, in an electric motor having a coil for generating a rotating magnetic field in the stator, the outer diameter of the cross section of the conductor (including the insulating layer) for one turn is d, and the slot with which the core withstand voltage is guaranteed within the slot. When the total radial thickness of the insulating paper in the slot is t and the number of turns is T, the width of the slot opening of the stator is (d + t) or less and the depth of the slot is (dx It is characterized by having a slot shape and a coil shape that satisfy the requirement that it is smaller than T). Further, according to the present invention, the slot space factor is improved in each of the winding step of forming the coil by the aligned winding and the pair of coil sides inserted into the pair of slots in the coil formed in the winding step. As shown in the figure, it is compression molded into a rectangular shape and integrated by bonding etc. so that the line is not disturbed,
Further, a coil forming step of deforming the crossing portion so as to approach the straddling angle of the pair of slots, and positioning the coil formed in the coil forming step at the inner diameter of the core to form each coil side of the pair of coils. And an assembling step of sequentially inserting and assembling into the corresponding slots.

In the present invention, the U-coil is formed by the aligned winding, the V-coil is formed by the aligned winding, and the W-coil is formed by the aligned winding.
In each of the winding step of forming the coil and the U coil, V coil, and W coil formed in the winding step,
Each of the pair of coil sides inserted into the pair of slots,
Coil forming process in which a rectangular shape is compression-molded to improve the slot space factor and integrated by bonding or the like so that the lines are not disturbed, and the crossover portion is deformed so as to approach the straddling angle of the paired slots. And assembling each of the U coil, the V coil, and the W coil formed in the coil forming step by positioning them in the inner diameter of the core and inserting each of the coil sides of each coil into the corresponding slots in order. And a step of manufacturing the stator.

As described above, according to the above configuration,
Since the slot space factor of the stator coil is improved, the coil ends are arranged in high density and the winding resistance is reduced, the efficiency of the motor is improved, and the motor can be made compact and lightweight. Further, according to the above configuration, by finishing the coil shape before incorporating it into the stator core, the shape of the coil is stabilized, the finishing shaping process of the coil end can be reduced, and the work efficiency can be improved. The damage to the insulating coating of the coil after the wire assembly can be reduced, and the quality can be stabilized.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described with reference to the drawings. The electric motor is composed of a stator and a rotor. Then, the stator is configured by three-dimensionally inserting a plurality of coils into slot portions such as an iron core and a core. Next, as an embodiment of the present invention, in a stator coil composed of a multi-phase coil used in an electric motor such as an induction motor or a synchronous motor, a plurality of coils are three-dimensionally arranged on an iron core, a core or the like. A case of a coil having a structure that is combined with each other will be described. FIG. 1 shows a configuration of an AC induction motor 3 according to the present invention.
It is a figure which shows the stator (stator) comprised by the concentric winding. In the embodiment shown in FIG. 1, the U coil 2
The case where there are eight a, V coils 2b and W coils 2c is shown. 2 (a), (b), and (c) show the coil shapes of AA, BB, and CC cross sections shown in FIG. 1, respectively. In addition, in the AA cross section shown in FIG.
The coil 2b and the W coil 2c are omitted. Further, in the BB cross section shown in FIG. 1, the W coil 2c is omitted. A coil portion protruding from the core 1 shown in FIG. 2 is called a coil end. FIG. 3 shows a perspective view of an electric motor (motor), which mainly includes a stator 1 and a rotor 4.
2. It is composed of the motor frame 40 and is assembled to the motor. FIG. 4 shows three-phase coils 2a and 2
It shows a perspective view of a state in which three U coils 2a to be inserted first among b and 2c are incorporated. FIG. 5 shows an enlarged cross-sectional view of the slot portion of the stator in which the coil is incorporated.

In the figure, reference numeral 1 is a stator core, which is formed by press-punching and laminating a silicon steel plate which is an electromagnetic steel plate.
In the figure, 2 and 2a, 2b, 2c are stator coils, which are obtained by winding an enameled wire having an insulating coating on the outermost layer a predetermined number of times. In the figure, 3 is a slot formed in the core 1, and in the present invention, a slot width s which is a coil inlet in a direction closer to the center of the core 1 (see FIG. 5).
However, it has an open slot shape that is less than the maximum width of the slot. In addition, as shown in FIGS.
This is a structure in which the coils 2d and 2e are densely incorporated in the slot 3. At this time, around the coils 2d and 2e, a slot insulating paper 4 having properties equivalent to the insulating properties of the enamel wire, for example, polyamide, polyimide, polyphenylene sulfide, Nomex, etc. is provided,
It is incorporated in the core 1 together with the coils 2d and 2e. And
The structure is such that the slot wedge 5 is inserted so that the inserted coils 2d and 2e do not protrude from the open slot 3 toward the core inner diameter side. The slot wedge 5 uses an insulating paper similar to the slot insulating paper. When a film or sheet containing a magnetic material or a magnetic plate containing a magnetic material is used as the slot wedge 5, the change in magnetic flux between the slots, that is, between the teeth 6, is reduced, and the cogging torque that causes vibration is reduced. Therefore, it is more effective.

In the present invention, as shown in FIGS. 1 and 2, the coils of the respective phases do not interfere with the coils already inserted, and as shown in FIG. 1 has a structure that is densely incorporated in the radial direction and the axial direction. In the figure, a stator and a coil in the case of 3 phases, 48 slots, and 8 poles are shown. The three-phase coils 2a, 2b, and 2c are called a U coil, a V coil, and a W coil, respectively. As shown in FIG.
The end coil portion (crossover portion) of the coil 2a has a shape in which a slot into which the V coil 2b and the W coil 2c are inserted can be seen from the axial direction. In the crossover portion of the coil, a slot for the V coil and a slot for the W coil are formed. It has a shape in which it is wound in a substantially arc shape along the slot. That is, the inner diameter R2 of the end coil portion of the U coil 2a is made slightly larger than the outer diameter R2 'of the slot so that the slot in which the V coil 2b and the W coil 2c are inserted can be seen in the axial direction. R1 indicates the inner diameter of the core 1, and R3 indicates the outer diameter of the end coil portion of the U coil 2a. Also, FIG.
As shown in (a), (b) and (c), in the end coil portion (crossover portion) of the U coil 2a, the coil ends are aligned in the axial direction. For example, in the case of a 9-turn coil, in the cross section of the coil end. It has a shape that fits within the arrangement of lines of 2 rows × 5 columns, and has a crossover portion at a position separated by a width x equivalent to the bending r of the line (twice the enamel wire diameter) on the core end surface. Further, this x is equal to or larger than the dimension that guarantees the insulation to the ground.

As shown in FIG. 2 (b), the end coil portion of the V coil 2b (the crossing portion of the slot) passes above the U coil 2a in the axial direction, and a space is formed inside the crossing portion. W coil 2c to be inserted next
The slot portion is formed in the space. As shown in FIG. 1, the end coil portion of the V coil 2b is arranged on the U coil 2a in the radial direction, inclining in the outer radial direction from the portion x away from the core end face. End coil part of W coil 2c (crossover part of slot)
2C has a shape that can be accommodated in the space provided with the V coil 2b as shown in FIG. 2C, and has a shape in which the crossover portion is arranged on the inner diameter side. At this time, all the inserted coils 2
The end coil portions a, 2b, and 2c do not protrude into the inner diameter of the stator 1 and have a shape that allows the rotor to be easily incorporated after the stator is assembled.

[0014] Specifically, the conductor diameter is 2.4 m.
m enamel wire (insulating layer: polyamide-imide)
Fig. 2 (c) shows the case of incorporating a coil wound 9 turns.
As shown in, xa = 15 mm, xb = 6 mm, ya = 25
It is possible to realize mm and x + xa + xb + xs of 30 mm or less. At this time, when incorporating the coil into the core 1,
It is possible to insert without interfering with the coil already inserted and the coil being inserted. Further, as shown in FIG. 5A, in order to improve the space factor of the slot, it is more effective to form the coil cross section into a rectangular shape in a rectangular shape.
Further, unlike FIG. 5A, as shown in FIG. 5B, a fine wire may be used to perform the aligned winding. Furthermore, FIG.
It is also possible to increase the space factor by forming a rectangular cross section. This molding method will be described later. FIG. 6 (a)-
(D) shows a winding method of the U coil 2a and the W coil 2c. FIG. 7 is a perspective view showing an overview of the U coil 2a. The portion indicated by Sc of the coil in FIG. 7 is inserted into the slot of the core 1 (hereinafter referred to as a slot coil). FIG. 8 is a perspective view showing an overview of the W coil 2c. The portion indicated by Sc of the coil in FIG. 8 is inserted into the slot of the core 1 (hereinafter referred to as a slot coil). FIG. 9 is a perspective view showing an overview of the V coil 2b. Figure 9
The portion indicated by Sc of the inside coil is inserted into the slot of the core 1 (hereinafter referred to as a slot coil).

FIG. 10 is a diagram showing a winding method of the V coil 2b. FIG. 11 shows this slot coil 2s (21).
FIG. 3 is a cross-sectional view of a molding die in a method of molding a high density. FIG. 12 shows the dimensional relationship between the before-molding 21 and after-molding 21 of the coil cross section in the coil molding in FIG. 11. FIG. 13 shows a jig for fixing the slot coils 2s (23) at a high density in an aligned state. Figure 14
7 illustrates a jig and method for deforming a coil, particularly the coil end portion, to create the shape of the coil end. Figure 15 shows
The operation | movement which incorporates the deformed coil in the slot of the core 1 is shown. Since the coil shapes of the U coil 2a and the W coil 2c according to the present invention are formed and the coil ends also have an aligned shape, the reel 10 having the two rotating shafts is used as shown in FIG. . The end coil portion (crossover portion) of the U coil 2a is formed between R2 and R3 in the radial direction as shown in FIG. 2 (a), and is axially located between x and x + xa from the core end face. Molded. W coil 2c
2C, the end coil portion (crossover portion) is formed between R4 and R5 in the radial direction and axially between xc and xc + xa larger than x from the core end face. Molded. Therefore, it is necessary to change the size of the winding frame for the U coil 2a and the size of the winding frame for the W coil 2c.
The bobbin 10 is provided with a guide 11 for maintaining the alignment of the slot coil parts.

In order to form the coil shapes of the U coil 2a and the W coil 2c, first, the winding starting point of the coil enameled wire 20 is fixed to the winding frame 10 to obtain the state shown in FIG. 6 (a). From here, 180 around the Z axis (α rotation direction) in the figure
The state shown in FIG. 6 (b) is obtained by rotating once. At this time, the enamel wire 20 is guided in the direction perpendicular to the Z axis. Next, by rotating 90 degrees around the X axis (β rotation direction), the state shown in FIG. 6C is obtained. Here, in order to align the wound coil end portions, the enameled wire is shaped along the winding frame 10 in the axial center direction. Furthermore, X
By rotating 90 degrees around the axis (β rotation direction),
The state of (d) is obtained. Up to this point, one half turn is over. At this point, the coil end may be shaped. The operations shown in FIGS. 6A to 6D are repeated, and the winding is completed by rotating the winding a predetermined number of times. Further, by adjusting the angle β around the X axis every ½ turn and controlling the trajectory of the wire, it is possible to make the coil ends into two or more rows.

The U coil 2a wound in this way
Is shown in FIG. 7, and the wound W coil 2c is shown in FIG.
FIG. 10B shows a winding frame 41 for winding the V coil 2b. By rotating such a winding frame 41 around the shaft 42, the enamel wire 42 is wound to form the enamel wire 42, as shown in FIG.
V coil 2b shown in is formed. However, since the shape of the V coil 2b actually inserted into the slot of the core 1 is as shown in FIGS. 9 and 2B and 2C, it is necessary to shape the end coil portion (crossover portion). .

Further, in order to increase the slot space factor, it is necessary to shape the slot coil Sc inserted into the slot 3 into a square shape. 11 and 12 show a method of forming the slot coil Sc in a square shape and a sectional shape of the coil. Both sides of the Sc portion shown in FIG. 7, FIG. 8 and FIG. 9 are placed in the molding die shown in FIG. 11 and molded into a rectangular cross section. In the molding die, a block 13 is arranged in the center of the groove of the base 17, and side guides 12a and 12b for laterally applying pressure to the coil are provided on both sides of the block via the side punches 14a and 14b. In the structure, the coils are arranged so that they can be pressed at substantially the same time. Further, when the coil is pressed in the vertical direction, the punches 16a, 16 having a punch width equal to or smaller than the coil width dimension after forming are formed.
b. First, block 13 and side punch 12
Place the coil in the mold with a gap between and above the wire diameter,
A pressure force is applied to the punch 16 to perform vertical molding. At this time, the side punches 14a and 14b are provided with stoppers so as to stop after moving a certain distance, or with stoppers so as to be stationary at the same position. Further, when the stopper is not provided, the lateral pressure may be applied with a pressure that does not disturb the alignment of the coils. Punch 16a, 16
After the vertical forming by b is completed, a pressing force is applied to the side punches 14a and 14b through the side base 15 to form the coil in the lateral direction. At this time, it is preferable to provide stoppers on the punches 16a and 16b so that the punches 16a and 16b stand still at a constant distance, or to apply pressure with a force weaker than the lateral molding reaction force. As shown in FIG. 12, the two stages of vertical and horizontal molding are used to produce 21
The coil cross section indicated by is formed into a substantially rectangular shape indicated by 22. For example, an enamel wire with a conductor diameter of 2.4 mm (insulating layer:
Polyamideimide) was used to form a coil wound for 9 turns, and the cross section of the coil, which had hb = 23 mm and wb = 2.6 mm, is 22 at ha = 17 mm, wb =
It can be molded into a substantially quadrangular shape having a size of 2.6 mm, and the radius r of the line cross section after the molding is 0.2 to 0.3 mm. Therefore, the coil cross-section 22 after molding can satisfy the slot space factor of 90% or more. Further, in the rectangular forming of the coil cross section by the above-mentioned forming method, since the vertical forming and the horizontal forming are performed in two stages, the degree of freedom of the coil forming cross section is expanded, and the slot opening s (slot) which is an important dimension in motor design is widened. Width of the coil entrance at
The degree of freedom of design is increased.

As described above, by forming the slot coil Sc to be inserted into the slot 3 into a square shape and integrating them by adhesion or the like, the line is not disturbed, and the slot space factor is increased and the coil is not disturbed. It is possible to increase the density of the ends, allow a margin for the magnetic flux in the motor design, and reduce the winding resistance and the copper loss as the coil circumference decreases with the decrease of the coil ends.
As a result, it is possible to improve the motor efficiency and reduce the size and weight of the motor. Next, a method for forming a shape to be incorporated in the core 1 will be described with reference to FIGS. 13 to 15. FIG.
The slot coil Sc is gripped and fixed on each side by the shaping jig 31 composed of the gripping jigs (gripping parts) 30a to 30c shown in FIG. The shaping jig 31 includes three or more gripping jigs (gripping parts) 30a, 30b, and 30c.
The structure is such that it can be constrained in the horizontal and vertical directions with respect to the coil cross section, and the slot coil cross section (gap W, height h) 23 can be aligned and high density can be restrained by screws or presses. To do. Both sides of the slot coil,
FIG. 14A shows a state in which the shaping jigs 31a and 31b shown in FIG. Next, in order to match the angles on both sides of the slot coil with the straddle angle γ of the slot, FIG.
, The end coil portion 2p is deformed by applying a moment between the alignment jig 31a and the alignment jig 31b, and the alignment jig 31a and the alignment jig 31b.
And are arranged on the deformation base 32. This deformation base 32
It is desirable that the angle γ be less than or equal to the slot straddling angle in consideration of the springback after deformation. The slot straddling angle is, for example, 37.5 degrees in the case of a 3-phase 8-pole 48-slot stator. As shown in FIG. 14B, the alignment jigs 31 a and 31 b, which constrain the coils so that they have a coil shape after being inserted into the core, are fixed onto the deformation base 32. Here, as shown in FIG. 14C, pressure is applied by the outer shape guide 33 and the inner shape guide 34 to correct the coil end shape after winding. At this time, a top capable of pressurizing in the core axial direction may be provided to apply pressure. FIG. 14 shows a modification of the U coil 2a,
External dimensions R of the end coil portion 2p shown in FIG.
3 and the internal dimension R2 correspond to the dimensions of R3 and R2 shown in FIG. 2 (a), and are V coil 2b and W coil 2c, respectively.
The values are shown when the slots to be inserted are dimensioned more than the radius except for high density and aligned. Therefore, by the deformation of the coil end shown in FIG. 14C, a coil end shape equivalent to that after insertion can be obtained. Next, as shown in FIG. 14D, while one alignment jig 31a is fixed to the deformation base 32, the other alignment jig 31b is deformed along the deformation base 32 toward the center of the core. . At this time,
In the coil cross section 23, deformation is performed until the outer diameter side of the moved alignment jig 31b becomes smaller than R1 which is the radius of the core inner diameter. Also at this time, the springback after the deformation is taken into consideration, and after the processing is completed, the deformation is performed so as to maintain the shape.

Next, the operation of inserting (assembling) the deformed coil into the core will be described with reference to FIG. Figure 15 shows
Similar to the above, the U coil 2a is shown. Figure 15
In (a), using the deformed coil in FIG. 14,
One side 23d of the slot coil is arranged parallel to the groove of the slot. At this time, the other deformed slot coil 23e is located within the inner diameter of the core 1. Figure 1
In FIG. 5 (a), after the coil and the slot are positioned, pressure is applied to the outside along the radial direction of the core and the core is inserted into the slot. The shape after this insertion is shown in FIG. At this time, due to the deformation of the coil described with reference to FIG. 14, the slot coil 23e, which has not been inserted yet, is positioned parallel to the groove of the slot to be inserted and on the inner diameter side of the core. Here, as shown in FIG. 15A, after the slot coil 23e is positioned with respect to the slot into which the slot coil 23e is to be inserted, the slot coil 23e is pressed outward along the core radial direction and inserted into the slot. ,
The insertion of the slot coil 23e is completed as shown in FIG. When inserting the slot coil 23e into the core, it is preferable to provide a guide for positioning and inserting the slot and the slot coil 23e in parallel. Also,
One-sided slot coil 2 shown in FIGS. 15 (a) and 15 (b)
After inserting 3d, the slot wedge 5 shown in FIG. 5 may be inserted to fix one side, or a jig that pressurizes for insertion may be fixed so that one side does not move to the inner diameter side. In addition, the slot coil side 23e after the one shown in FIG.
Is different from the initial insertion, the coil end 2p is deformed. Therefore, since the insertion resistance between the slot and the coil increases, it is preferable to use a booster mechanism having a wedge shape or a mechanism capable of obtaining an insertion force by a rack and pinion, a cam or the like. The insertion resistance varies depending on the number of turns of the coil, the cross-sectional area of the coil end including the conductor diameter, and the material of the wire including the conductor and the insulating layer. It also depends on the frictional resistance between the slot insulating paper around the coil and the core.

Although the above description has been given with respect to the U coil 2a, the V coil 2b and the W coil 2c having other shapes can be similarly deformed and assembled. Further, it is preferable that the enameled wire is a self-bonding conductive wire having an epoxy-based or nylon-based bonding layer as the outermost layer, and is heated after the deformation step to fix the alignment coils. The heating method at this time may be heating by energization using the resistance of the coil, or by passing the coil through a heating furnace. Further, as a method of fixing the coil, a method of using a film or sheet in which an adhesive layer is applied to slot insulating paper, or a method of fixing the coil with a heat resistant adhesive tape may be used. According to the embodiment described above, the slot space factor is high,
In addition, a stator in which the coil ends are arranged at high density is obtained, and in the step of inserting the coil into the core at this time,
Each phase, that is, it can be inserted without interference with the already inserted coil, and further, when the coil is inserted, there is little deformation in the axial direction of the coil end, so the insertion is completed with the state close to the designed shape after insertion. However, the stator can be assembled without the need for finishing shaping of the coil end after inserting the coil.

[0022]

According to the present invention, since the slot space factor of the stator coil is improved, the coil ends are arranged in high density and the winding resistance is reduced, the efficiency of the motor is improved, and It is possible to reduce the size and weight of the motor. Further, according to the present invention, by finishing the coil shape before incorporating it into the stator core, the shape of the coil is stabilized, the finishing shaping process of the coil end can be reduced, and the work efficiency can be improved. It is possible to reduce the damage to the insulating coating of the coil after the wire assembly and stabilize the quality.

[Brief description of drawings]

FIG. 1 is a front view showing an embodiment of a stator incorporating a coil in an electric motor according to the present invention.

2 is a side sectional view of FIG. 1, in which (a) is a sectional view taken along the line AA shown in FIG. 1, (b) is a sectional view taken along the line BB shown in FIG. 1, and (c) is a diagram. It is CC sectional view taken on the line shown in FIG.

FIG. 3 is a perspective view showing an embodiment of an electric motor according to the present invention.

FIG. 4 is a perspective view showing a stator incorporating a U coil according to the present invention.

FIG. 5 is a view showing a slot cross-sectional shape of a stator having a coil according to the present invention inserted therein.

FIG. 6 is a perspective view showing a method of forming a U coil and a W coil by performing aligned winding according to the present invention.

FIG. 7 is a perspective view showing a shape of a U-coil which is aligned and wound according to the present invention.

FIG. 8 is a perspective view showing the shape of an aligned-wound W coil according to the present invention.

FIG. 9 is a perspective view showing the shape of a V coil having an aligned winding according to the present invention.

FIG. 10 is a perspective view showing a method of forming a V coil by aligning windings according to the present invention.

FIG. 11 is a sectional view showing an embodiment of a slot coil molding die for molding the slot coil according to the present invention.

12 is a diagram showing cross-sectional shapes of the slot coil before and after molding using the slot coil molding die shown in FIG.

FIG. 13 is a perspective view showing an embodiment of an alignment jig for maintaining the alignment of the slot coils according to the present invention.

FIG. 14 is an embodiment of a method of deforming a crossover portion so that each pair of coil sides (slot coils) inserted into a pair of slots in the coil according to the present invention approaches a straddling angle of the pair of slots. It is a figure for explaining an example.

FIG. 15 is a diagram for explaining an example of a method of incorporating a coil into a core according to the present invention.

[Explanation of symbols]

1 ... Stator, 2 ... Coil, 2a ... U coil, 2
b ... V coil, 2c ... W coil, 3 ... slot,
4 ... Slot insulating paper, 5 ... Slot wedge, 6 ... Teeth, 10 ... Reel, 20 ... Enamel wire, 2s ... Slot coil, 12a, 12b ... Side guide, 13 ...
Blocks, 14a, 14b ... Side punches, 15 ...
Side base, 16a, 16b ... Punch, 21 ... Coil cross section after winding, 22 ... Coil cross section after molding, 2
3d ... Slot coil to be inserted first, 23e ... Slot coil to be inserted later, 31, 31a, 31b ... Aligning jig, 32 ... Deformation base

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Hiromichi Hiramatsu Inventor Hiromichi Hiramatsu 292 Yoshida-cho, Totsuka-ku, Yokohama, Kanagawa Inside the Hitachi, Ltd. Institute of Industrial Science (72) Inventor Takashi Ishigami 292 Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Incorporated company Hitachi, Ltd., Production Engineering Laboratory (72) Inventor Suetaro Shibukawa 2520, Takaba, Hitachinaka City, Ibaraki Prefecture Incorporated Hitachi, Ltd. Automotive Equipment Division (72) Osamu Koizumi, 2520, Takaba, Hitachinaka City, Ibaraki Prefecture Incorporated company Hitachi Ltd. Automotive Equipment Division (72) Inventor Fumio Tajima 7-1-1 Omika-cho, Hitachi-shi, Ibaraki Hitachi Ltd. Hitachi Research Laboratory (56) Reference JP-A-7-163074 (JP, A) JP-A-5-191940 (JP, A) JP-A-9-215238 (JP, A) (58) Fields investigated (Int. Cl. ⁷⁾ , DB name) H02K 3/48 H02K 15/04 H02K 15/06

Claims (5)

(57) [Claims] 1. A motor having a plurality of phase coils for generating a rotating magnetic field in a stator, wherein among the plurality of phase coils, a crossover portion for a coil of a desired phase and a rising portion in a core axis direction from a slot are provided. An electric motor characterized by being arranged in a shape that does not interfere with the end portions of coils of other phases. 2. A motor having a plurality of phase coils for generating a rotating magnetic field in a stator, wherein among the plurality of phase coils, a coil of a desired phase whose crossover portion is located on the outermost side in the radial direction is used. The inside of the transition part of
An electric motor, which is located outside an extension of a slot into which a coil of another phase is inserted. 3. A motor having a stator composed of three-phase concentric windings, wherein the slot space factor (the cross-sectional area of the coil with respect to the cross-sectional area of the slot excluding the insulator) is 80% or more, and the coil of each phase. An electric motor having different end shapes, and the crossing portions of the coils of each phase are aligned. 4. A winding step of forming a coil by aligning windings, and a pair of coil sides inserted into a pair of slots of the coil formed in the winding step are compression molded into a rectangular shape. A coil forming step of deforming the crossing portion so as to approach the straddling angle of the pair of slots, and positioning the coil formed in the coil forming step at the inner diameter of the core so that each pair of coil sides of the coil is And a step of assembling by sequentially inserting into a corresponding slot and assembling. 5. A winding step of forming a U coil by aligning windings, forming a V coil by aligning windings, and forming a W coil by aligning windings, and forming by the winding step. In each of the U coil, the V coil, and the W coil, each pair of coil sides inserted into the pair of slots is compression-molded into a rectangular shape to form a crossover portion so as to approach the straddling angle of the pair of slots. The coil forming step of deforming, and each of the U coil, V coil, and W coil formed in the coil forming step are positioned at the inner diameter of the core, and each pair of coil sides of each coil is sequentially inserted into the corresponding slot. And a method of assembling the stator.