JP2005137174A - Stator manufacturing method and stator of rotating electrical machine manufactured by stator manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED To reduce an increase in manufacturing cost due to an increase in junction points.
The stator manufacturing method includes a step of inserting a coil into a stator core (S2000), a step of applying a conductive adhesive to the bus bar (S2100), a step of assembling the bus bar to the coil (S2200), A step of applying a load to the bus bar (S2300) and a step of heating the contact portion between the bus bar and the open end of the coil in a state where the load is applied to the bus bar (S2400) are included.
[Selection] FIG.

Description

  The present invention relates to a method of manufacturing a rotating electrical machine including a stator and a rotor, and more particularly to a method of manufacturing a stator and a stator manufactured by a method of manufacturing a stator.

  2. Description of the Related Art Conventionally, in a rotating electric machine composed of a stator and a rotor, for example, a synchronous motor, coils are provided on a plurality of teeth provided on the inner peripheral side of a hollow cylindrical stator core in a direction parallel to the rotating shaft of the synchronous motor Is wound. The coil wound around the tooth portion is formed, for example, by inserting a U-shaped coil having two open end portions into a slot. In order to electrically connect the open end of the U-shaped coil inserted into the slot with the open end of the adjacent U-shaped coil at the opposite position across the teeth, laser welding or Joined by TIG (Tungsten Inert Gas arc) welding. In this way, a coil having a predetermined number of turns is formed. Then, by connecting each of the coils wound around the plurality of tooth portions, a three-phase AC winding is configured as a whole. With respect to such a synchronous motor, there is a technique disclosed in the following publications.

  Japanese Patent Laying-Open No. 2000-14068 (Patent Document 1) discloses a stator for a vehicle alternator in which insulation between a stator winding and a stator core is ensured while achieving high output and a method for manufacturing the same. Is disclosed. A stator for a vehicle alternator and a method for manufacturing the same include a stator core having a plurality of slots each having an opening formed on an inner peripheral side, and a stator winding having a housing portion accommodated in the slot. And an electric conductor to be formed. An electrically insulating member is interposed between the accommodating portion of the stator winding and the inner wall surface of the slot. The electrical insulating member has a closing portion that closes the opening.

  According to the vehicle alternator stator and the manufacturing method thereof disclosed in Patent Document 1, the opening on the inner peripheral side of the slot is blocked by the blocking portion of the electrical insulating member. It is possible to prevent the electric conductor from jumping out. Moreover, it can prevent that electrolyte solution, such as salt water, penetrate | invades from an opening part, and it can prevent that the coating of an electrical conductor is damaged by an electrolysis action and raise | generates an insulation defect. In addition, since it is not necessary to insert a separate pressing member into the slot, problems such as breakage of the insulating coating of the electric conductor when the pressing member is inserted and poor assembly of the pressing member can be avoided.

  Japanese Patent Laying-Open No. 2001-292548 (Patent Document 2) discloses a stator for a rotating electrical machine that significantly shortens the length of a coil end portion. The stator of this rotating electrical machine is mounted in a plurality of slots of the stator core. In this stator, a straight rectangular wire is formed in advance so as to be U-shaped. Then, two straight sides are inserted into adjacent slots across the stator tooth portion. Thereafter, the coil is formed so as to form a one-turn closed circuit by connecting both ends of the coil opposite to the U-shaped side with a thin bar-shaped piece. Then, a plurality of such coils are inserted, and a predetermined number of turns is formed by connecting the opposite ends of the U-shaped side. When the anti-U-shaped side end face and the thin plate bar-like piece are overlapped and connected, the thickness of the overlapping portion is reduced by half. And when both overlap, it is made to correspond to the plate | board thickness of a flat wire coil. The surface that halves the plate thickness halves the plate thickness of the surface toward the stator inner diameter at the left side of the coil piece end. A coil is previously formed on the right side end so as to halve the plate thickness of the surface toward the stator outer diameter. On the other hand, the thin plate-like piece halves the plate thickness of the surface opposite to the coil. And when both are piled up, it connects and comprises so that a thin bar piece may be pinched | interposed into two linear parts of a U-shaped coil.

According to the stator of a rotating electrical machine disclosed in Patent Document 2, the straddling width of the coil is determined by the adjacent slot width. Therefore, the axial length of the U-shaped portion protruding from the stator core is equivalent to the adjacent slot width. On the other hand, the axial length of the portion protruding from the stator core on the half U-shaped side of the coil is connected by a thin bar-shaped piece. Therefore, only the width of the thin plate connecting piece is occupied in the axial direction. As a result, a stator in which the length of the coil end portion is reliably shortened can be provided.
JP 2000-14068 A JP 2001-292548 A

  However, the joining of the U-shaped coil and the adjacent U-shaped coil needs to be performed on all open ends of all the coils included in the synchronous motor. Also, the number of junctions tends to increase as the number of motors or the number of turns increases. For example, in a hybrid drive motor for an automobile, there may be as many as 400 junction points. Therefore, in the case of joining by welding, it is necessary to ensure the positioning accuracy of the torch at all joining points in the welding process. Furthermore, there is a problem that the manufacturing cost increases due to an increase in welding time accompanying an increase in the number of joint points. Further, there has been a problem that the insulation coating such as the enamel of the coil is burned out by the joining by welding.

  Patent Document 1 and Patent Document 2 described above do not disclose a technique for solving the problems associated with an increase in such welding joint points.

  The present invention has been made to solve the above-described problems, and its object is to be manufactured by a stator manufacturing method and a stator manufacturing method for a rotating electrical machine that reduce the manufacturing cost associated with an increase in joint points. Is to provide a stator.

  A stator manufacturing method according to a first aspect of the present invention is a method for manufacturing a stator in a rotating electrical machine including a stator and a rotor. The stator includes a stator core having a plurality of slots provided in a direction parallel to the rotation axis of the rotating electrical machine and teeth formed between the slots, and a coil in which a plurality of metal conductors are stacked. The coil is a rectangular thin plate having an open end portion that is inserted into a slot and can be wound around a tooth as viewed from the stacking direction of the metal conductors. The stator manufacturing method includes a step of inserting a coil into a slot along a direction parallel to the rotation axis and winding the coil around a tooth, and straddling the teeth of two metal conductors adjacent to each other in the coil stacking direction. Applying a conductive adhesive to at least one of the two open ends that are opposite to each other and the connecting member that connects the two open ends in a direction to close the two straddles over the teeth; and A step of applying a load to the connection member so that both ends of the connection member are in contact with each other, and a step of curing the adhesive in a state where the load is applied.

  According to the first invention, in the step of applying the conductive adhesive, at least one of the connection members (for example, bus bars) connected in the closing direction across the teeth of the two metal conductors adjacent to each other in the coil stacking direction. Apply a conductive adhesive. In the step of applying a load, a load is applied to the bus bar so that the open end and the both ends of the bus bar come into contact with each other. In the step of curing the adhesive, the adhesive is cured with a load applied. As described above, in joining the plurality of open ends and the bus bar having the stator of the rotating electrical machine (for example, a synchronous motor), by applying a load to the plurality of bus bars and curing the adhesive, A plurality of bus bars can be joined at a time. In addition, as compared with the case where the joining of the open end portion and the bus bar is joined by laser welding or TIG welding, it is not necessary to ensure the positional accuracy of the joining portion and the torch at all joining points. Shortening and manufacturing cost can be reduced. Further, it is possible to prevent burnout of an insulating member (for example, enamel coating or the like) in the vicinity of the joint due to joining by laser welding or TIG welding. Moreover, an adhesive decomposes | disassembles at high temperature by using an organic material as a conductive adhesive. Therefore, it is possible to easily distinguish the coil and the stator core. As a result, the recyclability of the coil and stator core is improved. Further, by curing the adhesive in a state where a load is applied, the adhesive can be cured in a state where the bus bar and the open end are in pressure contact with each other. Therefore, the resistance during energization can be reduced. As a result, it is possible to provide a method for manufacturing a stator for a rotating electrical machine that reduces the manufacturing cost associated with an increase in the number of joint points.

  In the stator manufacturing method according to the second invention, in addition to the configuration of the first invention, the step of applying a load uses an assembly member for assembling the plurality of connection members to the open end, The method includes applying a load by fastening the stator core and the assembly member.

  According to the second invention, the bus bar is fastened by fastening the stator core and the assembly member (for example, bus bar positioning block) to which the plurality of connecting members (for example, bus bar) are fixed by the fastening member (for example, bolt). A fastening load can be applied to the. When the load due to the fastening force of the bolt is applied, the open end and the bus bar are brought into a pressure contact state. Therefore, a special load application process can be abolished. In addition, the bus bar positioning block integrates a plurality of bus bars to improve workability. Therefore, a load can be applied to the bus bar by a simple operation of fastening the bus bar positioning block to the stator core with a bolt or the like. Further, the bus bar positioning block can be fixed to the stator core by fastening bolts. Therefore, an adhesive that does not require heat curing can be used as the conductive adhesive. As a result, the heat curing process can be abolished.

  In the stator manufacturing method according to the third invention, in addition to the configuration of the second invention, a plurality of assembly members are provided on the stator core. The step of applying a load includes the step of applying a load by fastening the stator core and the assembly member using a fixing member common to the plurality of assembly members.

  According to the third invention, a fixing member (for example, a circular plate) provided so as to come into contact with all of the assembly members (for example, bus bar positioning blocks) to which a plurality of connecting members (for example, bus bars) included in the stator are fixed. By fastening the shape member) to the stator core with fastening members (for example, bolts), all the bus bars included in the stator core can be joined at a time. Therefore, the time required for joining can be shortened. As a result, the manufacturing cost can be reduced. Further, the bus bar positioning block can be fixed with a disk-shaped member. Therefore, an adhesive that does not require heat curing can be used as the conductive adhesive. As a result, the heat curing process can be abolished.

  In the stator manufacturing method according to the fourth invention, in addition to the structure of any one of the first to third inventions, the step of curing the adhesive comprises contacting the two open ends and both ends of the connecting member. Heating the part.

  According to the fourth invention, in the step of heating the contact portion, when a thermosetting adhesive is used as the conductive adhesive, the contact portion between the two open end portions and both end portions of the connecting member is heated. As a result, the manufacturing time of the coil can be shortened.

  In the stator manufacturing method according to the fifth aspect of the invention, in addition to any of the configurations of the first to fourth aspects of the invention, the open end portion of the metal conductor is formed with a fitting portion that fits with the connecting member. .

  According to the fifth aspect of the present invention, when the bus bar is assembled, the bus bar is fitted into the fitting portion by forming the fitting portion that fits with the connecting member (for example, bus bar) at the open end portion of the metal conductor. Can be assembled. Therefore, the assembly property of the bus bar is improved.

  In the stator manufacturing method according to the sixth aspect of the invention, in addition to the configuration of the fifth aspect of the invention, the metal conductor is a predetermined number of metal flat plates of a conductor that are press-formed into a U-shape or U-shape. It is formed by being laminated, and at least a part of the metal flat plate has a different length at a front end portion of the U-shape or U-shape at a right angle to the thickness direction of the metal flat plate.

  According to the sixth invention, the fitting portion can be formed by setting the length perpendicular to the plate thickness direction of at least some of the metal flat plates of a predetermined number of metal flat plates to a different length. Therefore, when the bus bar is assembled, the assembly can be performed by fitting the bus bar into the fitting portion, so that the assembly property of the bus bar is improved.

  In the stator manufacturing method according to the seventh invention, in addition to the configurations of the first to sixth inventions, the stator of the rotating electrical machine is manufactured by the stator manufacturing method.

  According to the seventh invention, in the step of applying the conductive adhesive, at least one of the connection members (for example, bus bars) connected in the closing direction across the teeth of the two metal conductors adjacent to each other in the coil stacking direction. Apply a conductive adhesive. In the step of applying a load, a load is applied to the bus bar so that the open end and the both ends of the bus bar come into contact with each other. In the step of curing the adhesive, the adhesive is cured with a load applied. By manufacturing a stator of a rotating electrical machine (for example, a synchronous motor) by such a stator manufacturing method, all of the joining between the open end and the bus bar are joined by laser welding or TIG welding. Therefore, it is not necessary to ensure the positional accuracy between the joining portion and the torch at the joining point, so that the manufacturing time can be shortened and the manufacturing cost can be reduced.

  A stator for a rotating electrical machine according to an eighth aspect of the present invention is a stator for a rotating electrical machine including a stator and a rotor. The stator includes a stator core having a plurality of slots provided in a direction parallel to the rotation axis of the rotating electrical machine and teeth formed between the slots, and a coil in which a plurality of metal conductors are stacked. The coil is a rectangular thin plate having an open end portion that is inserted into a slot and can be wound around a tooth as viewed from the stacking direction of the metal conductors. The coil has two open ends at positions facing each other across the teeth of two metal conductors adjacent to each other in the stacking direction of the coil wound around the teeth, and the direction in which the two open ends are closed across the teeth. It is formed by adhering a conductive adhesive between the connecting member and the connecting member.

  According to the eighth invention, the stator includes a stator core having a plurality of slots provided in a direction parallel to the rotation axis of a rotating electrical machine (for example, a synchronous motor) and teeth formed between the slots, and a metal. And a coil in which a plurality of conductors are stacked. The coil has two open ends at positions facing each other across the teeth of two metal conductors adjacent to each other in the stacking direction of the coil wound around the teeth, and the direction in which the two open ends are closed across the teeth. It is formed by adhering a conductive adhesive between a connecting member (for example, a bus bar) connected to the connector. Therefore, it is not necessary to ensure the positional accuracy of the joining portion and the torch at all joining points as compared with the case of joining the open end portion and the bus bar by laser welding or TIG welding. Shortening and manufacturing cost can be reduced. Further, it is possible to prevent burnout of an insulating member (for example, enamel coating or the like) in the vicinity of the joint due to joining by laser welding or TIG welding. Moreover, an adhesive decomposes | disassembles at high temperature by using an organic material as a conductive adhesive. Therefore, it is possible to easily distinguish the coil and the stator core. As a result, the recyclability of the coil and stator core is improved.

  In the stator of the rotating electrical machine according to the ninth aspect of the invention, in addition to the configuration of the eighth aspect of the invention, a fitting portion that fits with the connection member is formed at the open end of the metal conductor.

  According to the ninth aspect of the present invention, when the bus bar is assembled, the bus bar is fitted into the fitting portion by forming the fitting portion that fits with the connecting member (for example, bus bar) at the open end portion of the metal conductor. Can be assembled. Therefore, the assembly property of the bus bar is improved.

  In the stator of the rotating electrical machine according to the tenth invention, in addition to the configuration of the ninth invention, the metal conductor is a predetermined number of metal flat plates of a conductor press-molded into a U-shape or a U-shape. Only at least a part of the flat metal plate has a length different from the thickness direction of the flat metal plate at the open end of the U-shape or U-shape.

  According to the tenth invention, the fitting portion can be formed by setting the length orthogonal to the plate thickness direction of at least some of the metal flat plates of the predetermined number of metal flat plates to a different length. Therefore, when the bus bar is assembled, the assembly can be performed by fitting the bus bar into the fitting portion, so that the assembly property of the bus bar is improved.

  Hereinafter, a stator for a rotating electrical machine and a stator for the rotating electrical machine manufactured by the stator manufacturing method according to an embodiment of the present invention will be described with reference to the drawings. In the following description, the same parts are denoted by the same reference numerals. Their names and functions are also the same. Therefore, detailed description thereof will not be repeated.

  In describing the stator manufacturing method according to the present embodiment, first, the structure of the stator of the rotating electrical machine manufactured by the stator manufacturing method will be described by taking the stator of the synchronous motor as an example.

<First Embodiment>
A synchronous motor is comprised from the rotor which consists of a stator and a permanent magnet. As shown in FIG. 1, the stator 100 includes a stator core (hereinafter referred to as a stator core) 102, a coil 112, a bus bar 110, a bus bar positioning block 104, and a transition member 106.

  The stator core 102 has a hollow cylindrical shape in which a plurality of electromagnetic steel plates are laminated. The stator core 102 has a predetermined number of grooves (hereinafter referred to as slots) in a direction parallel to the rotation axis of the synchronous motor. The predetermined number of slots has a number corresponding to the number of poles. The number of poles is not particularly limited, but is 21 for example in the present embodiment. In addition, teeth (hereinafter referred to as teeth) 108 are provided between the slots. The number of teeth corresponds to the number of poles as well as the slot. Therefore, in the present embodiment, the stator core 102 having 21 poles has 21 slots formed between the 21 teeth.

  The teeth 108 have a laminated coil (not shown), which is a metal conductor in which a plurality of metal plates (not shown) of a predetermined shape whose ends are open so as to be wound are laminated. The teeth 108 are inserted into slots on both sides of the teeth 108 so as to straddle the teeth 108 in a direction parallel to the rotation axis of the synchronous motor. In the slots on both sides of the tooth 108, a plurality of laminated coils are inserted in the radial direction of the synchronous motor. The number of laminated coils to be inserted is not particularly limited. For example, in the present embodiment, ten laminated coils are inserted in the radial direction so as to straddle the teeth 108.

  The open end of the laminate coil is joined to both ends of the bus bar 110, which is a linear conductor. At this time, one end of the bus bar 110 is joined to one of the open ends of the multilayer coil. The other end of the bus bar 110 is joined to one of the open ends of the multilayer coil adjacent to the multilayer coil. Similarly, one of the open ends of the 10 laminated coils is connected to one of the open ends of the adjacent laminated coils via the bus bar, whereby the coil is wound around the tooth 108 10 times. It becomes a state. That is, a 10-turn coil 112 is formed.

  In the tooth 108, a plurality of bus bars for connecting the open ends of the plurality of laminated coils are positioned and fixed to the bus bar positioning block 104. Therefore, when the bus bar positioning block 104 is installed at a predetermined position and pressed, the bus bars corresponding to the open ends of the plurality of laminated coils are assembled. Then, the assembled bus bar and the open end are joined by a joining process such as laser welding or TIG welding.

  A coil 112 that is connected to a plurality of bus bars and wound around the teeth 108 has coil ends that are not connected to the bus bars on the inner peripheral side of one slot and the outer peripheral side of the other slot of the teeth 108 on both sides. Part. Each of the coil end portions is connected to a coil wound around another tooth by a crossover member 106. Similarly, in other teeth included in the stator core 102, a 10-turn coil is formed. And as for the connection between the coils of each tooth, the coil edge part for every 3 teeth is connected using a crossover member. The coil end portions 140, 142, and 144 are connected to each other by a crossover member. In this way, the stator 100 of the three-phase synchronous motor is formed. A magnetic field is generated by controlling the phase of AC power to be supplied to each of the coil ends 134, 136, and 138. The rotor of the synchronous motor obtains a rotational force based on the generated magnetic field.

  Although the material of the metal flat plate which comprises a laminated body coil will not be specifically limited if it is a metal flat plate of a conductor at least, In this Embodiment, it is a copper rolling raw material, for example. By using a copper rolled material as the metal flat plate, copper has a high heat transfer coefficient, so that the heat dissipation of the coil can be further improved. Copper also has a low internal resistance and a high conductivity as a conductor. Therefore, heat generation when the current density is improved can be reduced. And the surface treatment of the insulation coating of a copper oxide is given to the surface of the metal flat plate of a copper rolling raw material.

  In addition, the metal flat plate having a predetermined shape that is open to be wound around the stator core that constitutes the laminated body coil has an open end, parallel upper and lower bases, and a connecting end that connects the upper and lower bases. It is a shape which has a part. In the present embodiment, the laminated body coil is formed, for example, by laminating U-shaped metal flat plates. That is, the laminated body coil is formed by laminating metal flat plates press-molded in a U-shape in a pressing step. However, the shape of the press-molded metal flat plate is not particularly limited to the U-shape. For example, the metal flat plate may be press-molded into a U shape.

  As shown in FIG. 2, the laminated body coil 114 in this Embodiment is formed by laminating a plurality of U-shaped metal flat plates. At this time, the upper base and the lower base parallel to the open end of the multilayer coil 114 are inserted into the slots 146 and 148 on both sides of the tooth 108, respectively. Moreover, the connection end part which connects an upper base and a lower base forms a coil end part. At this time, in the laminated coil 114, a cross section of an upper base and a lower base inserted into the slots 146 and 148 is shown in FIG. Further, FIG. 3B shows a cross section of the connection end portion forming the coil end portion. Comparing FIG. 3A and FIG. 3B, the cross-sectional area of the connection end portion forming the coil end portion in the multilayer coil 114 is the cross-sectional area of the upper base and the lower base inserted into the slots 146 and 148. Bigger than.

  Therefore, the volume of the coil forming the coil end portion is increased as compared with the case where the cross-sectional areas of the laminated body coil 114 in the coil end portion and the slots 146 and 148 are the same. Therefore, the heat capacity in the coil end portion is improved. The heat generated in the slot is transmitted to the coil end portion of the same turn having almost no thermal resistance. As a result, heat dissipation from the coil in the slot to the coil end portion is improved. Therefore, the current density can be improved in the coil in the slot having a small space. That is, the stator core 102 can be reduced in size by the improvement in current density.

  Hereinafter, as described with reference to FIG. 2, by making the cross-sectional area of the connection end portion forming the coil end portion in the multilayer coil 114 larger than the cross-sectional areas of the upper base and the lower base inserted into the slot, The principle that can improve the current density in the slot will be described.

  The short-term thermal rating of the coil is considered as follows. 1) Assume that all the heat generated by the coil is used to increase the temperature of the coil. 2) The temperature of the coil should be uniform everywhere. Further, the thermal resistance inside the multilayer coil in the same turn is sufficiently smaller than the heat radiation resistance to the outside.

At this time, the total calorific value Q of the multilayer coil is Q = 2 × (Ra (resistance of the upper and lower bases of the multilayer coil 114) + Rb (resistance of the connection end of the multilayer coil 114)) × I ² It can be expressed as (current) × dt (energization time). That is, Q = γ (copper specific heat) × ρ (copper density) × 2 × (Aa (cross-sectional area of upper and lower base) × La (length of upper and lower base) + Ab (cross-sectional area of connecting end) ) × Lb (length of connection end)) × dT (temperature increase).

  On the other hand, the coil resistance R can be expressed as R = 2 × (Ra + Rb) = 2 × α (specific resistance) × (La / Aa + Lb / Ab).

That is, Q = 2 × α × (La / Aa + Lb / Ab) × I ² × dt = γ × ρ × 2 × (Aa × La + Ab × Lb) × dT. Here, when Lb = X × La and Ab = Aa, the above formulas are rearranged, and (I / Aa) ² = γ × ρ / α × (dT / dt) × (X × Y ² + Y) / ( X + Y). That is, in the general motor, the term of γ × ρ / α × (dT / dt) on the right side of the above formula is the cross-sectional area of the upper and lower bases on the slot side and the cross-sectional area of the connection end on the coil end side. This is a substantial expression when and are the same. That is, the temperature rise dT at the rated time is proportional to the square of the current density (I / Aa). The term (X × Y ² + Y) / (X + Y) is concerned when the length and cross-sectional area of the upper and lower bases on the slot side are different from the length and cross-sectional area of the connection end on the coil end side. It should be a term. For example, when Lb is 0.3 times the length of La (X = 0.3) and Ab is 3 times the cross-sectional area of Aa (Y = 3), (X × Y ² + Y) / (X + Y) The term is 1.314. That is, the current density in the slot can be improved about 1.3 times under the same temperature condition. This means that the size can be reduced by about 30%. From the above, in the multilayer coil 114, by making the cross-sectional area of the connection end part forming the coil end part larger than the cross-sectional areas of the upper base and the lower base inserted into the slot, the current density in the slot can be increased. Can be improved.

  Further, the coil in the slot is in contact with the stator core 102. Therefore, it is easy to keep the temperature low by dissipating heat generated by copper loss to the stator core. On the other hand, the coil at the coil end portion is exposed to air. For this reason, it is difficult to dissipate heat generated by copper loss to the outside. Therefore, in the present embodiment, the U-shape is formed so that the metal flat plate forming the coil end contacts the stator core. As a result, heat can be radiated from the coil end portion to the stator core 102. Therefore, the heat dissipation of the coil end part can be enhanced. That is, for example, when the slot is formed perpendicular to the end face of the stator core, the angle inside the upper and lower bases and the connection end is made to be a right angle when the U-shaped coil is viewed from the stacking direction. Therefore, the metal flat plate which forms a coil end can be made to contact a stator core. For example, even when the slot is formed with a skew angle, the angle inside the connection end portion with the upper base and the lower base is set to an angle corresponding to the skew angle. Therefore, the metal flat plate which forms a coil end can be made to contact a stator core.

  The axial length of the physique of the motor is defined by the physique of the stator core and the coil end portion wound around the stator core. Therefore, the space factor of a coil end part can be raised by forming a metal flat plate and a laminated body coil in a U shape. As a result, the stator can be miniaturized.

  Next, a plurality of U-shaped metal flat plates forming the multilayer coil 114 are provided with three protruding portions as shown in the multilayer coil 114 of FIG. And in order to form the laminated body coil 114, each other is fixed by what is called lamination caulking which press-fits the convex part of the protrusion part of another metal flat plate to the concave part of the protrusion part of a metal flat plate. Similarly, the laminated coil 114 is formed by fixing by a laminated caulking to a predetermined number of metal flat plates. The metal flat plates forming the laminated body coil 114 are fixed to each other, so that the laminated body can be transported. As a result, workability at the time of assembling the laminated body coil 114 to the stator is improved. Note that the predetermined number is not particularly limited, but in the present embodiment, the multilayer coil 114 is formed by stacking three or four metal flat plates.

  FIG. 4A is a cross-sectional view cut in the stacking direction so as to include the protruding portion of the U-shaped metal flat plate 116. Then, as shown in FIG. 4 (B), the protrusions of the protrusions of the metal flat plate 116 are press-fitted into the recesses of the protrusions of the metal flat plate 120 by lamination caulking. And the convex part of the metal flat plate 120 is press-fitted in the hole provided in the metal flat plate 122 and fixed to each other. In this way, the laminated body coil 114 as shown in FIG. 4C is formed.

  Moreover, you may use an adhesive agent for fixation with an adjacent laminated body coil. That is, the laminate coil 114 and the laminate coil 124 may be bonded as shown in FIG. 4D by applying the concave portion of the protruding portion of the metal flat plate as an adhesive tray. When the laminate coils are bonded to each other, the caulking portion can be used as an adhesive tray. Therefore, workability at the time of assembling the coil can be improved.

  In the following description, a process of forming the stator 100 from a copper rolled material will be described based on the configuration of the stator 100 described above.

  FIG. 5 is a view showing an appearance of a metal flat plate 126 made of a rolled copper material. The surface of the metal flat plate 126 made of a rolled copper material is subjected to a surface treatment with an insulating coating of copper oxide. In the pressing process, the metal flat plate 126 of the copper rolled material is press-molded into a U-shape. And the metal flat plate press-molded in the U-shape is laminated by a predetermined number as described with reference to FIG. Then, by fixing the metal flat plates to each other by lamination caulking, the laminated body coil 114 is formed as shown in FIG. Then, as shown in FIG. 6B, the laminated coil 114 is subjected to an insulation process for the adjacent laminated coil. Insulation with the adjacent laminated body coil is not particularly limited. For example, an inorganic material such as glass may be interposed, and enamel treatment may be performed for each laminated body. Then, as shown in FIG. 6C, the laminate coil 114 can be bonded to another laminate coil by applying an adhesive at a predetermined position on the insulator. Or you may use the recessed part of the mutual protrusion part of a laminated body coil as a receiving tray of an adhesive agent as demonstrated using FIG.4 (D).

  By bonding a plurality of laminated coils with an insulator interposed, a coil 112 is formed as shown in FIG. At this time, a U-shaped metal flat plate having different dimensions is laminated in each of the laminated coils forming the coil 112. Thus, the cross-sectional shape of the laminated body coil inserted into the slot can be freely set. That is, in accordance with the shape of the slot, the width of the metal flat plate inserted into the U-shaped slot is increased from the inner peripheral side to the outer peripheral side in the radial direction of the synchronous motor (from the top to the bottom in FIG. 7). To do. Therefore, the space factor of the coil 112 in the slot can be increased.

  As shown in FIG. 8, the coil 112 formed by a plurality of laminated coils is inserted across the teeth 108 of the stator core 102. That is, the respective open ends corresponding to the upper and lower bases of the coil 112 are inserted into the slots 146 and 148 on both sides of the tooth 108 in a direction parallel to the rotational axis direction of the synchronous motor.

  At the contact portion where the open end of the laminated coil and the bus bar are in contact with each other, a predetermined number of notches having different lengths perpendicular to the plate thickness direction are formed in a part of a predetermined number of metal flat plates. By providing, a fitting part is formed. By forming the fitting portion, the assemblability of the bus bar is improved.

  FIG. 9 shows the open end of coil 112 inserted into slots 146 and 148. As shown in FIG. 9, the laminated body coil which forms the coil 112 has a fitting part of a different shape in each laminated body coil. In addition, since each of the laminated coils has a fitting portion having a different shape, an assembly error can be prevented when the bus bar is assembled. Different shapes of the fitting portions can be realized by changing the number of metal flat plates having notches of a predetermined shape in the metal flat plate forming the laminated body coil.

  In addition, as shown in FIG. 10, when the several bus bar corresponding to the junction part of each laminated body coil is assembled | attached separately, it shall differ from the shape of the fitting part in an adjacent laminated body coil at least. Since the shapes of the fitting portions of the adjacent laminated coils are different, it is possible to prevent an assembly error of the bus bar.

  In particular, as shown in FIG. 11, when an assembly operation or the like is performed at once by the positioning block 104 to which a plurality of bus bars are fixed, at least one of the fitting portions at the open end of each laminated body coil in the coil 112 is at least one. By having different shapes, it is possible to prevent an assembly error when the bus bar is assembled. Furthermore, since the joining location is specified, the joining process can be performed without a jig for positioning. In the present embodiment, the fitting portions have different shapes in the three laminated coils on the inner peripheral side, the three laminated coils in the center, and the four laminated coils on the outer peripheral side.

  When the bus bar is assembled to the laminate coil, as shown in FIG. 12, each fitting portion of the bus bar assembled to the coil 112 and the open end portion of each laminate coil is laser welded for each point, or Multi-point joining is performed by TIG welding.

  When the bus bar and the open end of each laminated body coil are joined, the coil wound for each tooth is connected using the transition member. That is, since the synchronous motor of the present embodiment is a three-phase AC synchronous motor, the coil end on the outer peripheral side of the coil and the coil end on the inner peripheral side are shown in FIG. They are connected using a transition member. Then, as shown in FIG. 14, the coil 112 and the transition member 106 are joined by laser welding or TIG welding. As a result, the stator 100 as shown in FIG. 1 is formed. Then, the coil end portion is subjected to a molding process using a resin or the like to form a stator 100 as shown in FIG.

  As described above, the method of manufacturing the stator 100 is performed according to the procedure shown in FIG. 16 when the open end of the coil and the bus bar are joined by laser welding or TIG welding.

  That is, at step (hereinafter, step is abbreviated as S) 1000, coil 112 is inserted into stator core 102. At S1100, bus bar positioning block 104 to which a plurality of bus bars are fixed is assembled to coil 112. In S1200, one of the plurality of fitting portions between the bus bar and the coil is subjected to a joining process by laser welding or TIG welding. In S1300, the joining process is repeatedly performed by the number of joining places.

  However, as described above, in the synchronous motor according to the present embodiment, the junction point is actually 10 (number of turns) × 2 (number of open ends per one turn of coil) × 21 (number of poles) = 420. It also extends. That is, since it is necessary to perform multi-point joining at about 400 or more locations, there may be a problem that the manufacturing cost increases due to ensuring the positioning accuracy of the torch in the welding process and increasing the welding time. Another problem is that the insulation coating such as enamel of the coil burns out due to welding.

  Therefore, in the method of manufacturing a stator according to the present embodiment, the joining of the bus bar and the open end of the coil as shown in FIG. 12 is not performed by joining each point by laser welding or TIG welding. In addition, a bonding process using a conductive adhesive is performed. That is, a conductive adhesive is applied to the bus bar in advance. However, the conductive adhesive is not particularly applied to the bus bar. For example, a conductive adhesive may be applied to the open end of the coil, or a conductive adhesive may be applied to both the bus bar and the open end of the coil.

  The bus bar is assembled to the coil, and a load is applied to the assembled bus bar. Thereby, it will be in the state where the bus bar and the coil were press-contacted. At this time, the adhesive is cured by performing the curing process of the adhesive in the fitting portion, and the joining of the bus bar and the coil is completed.

  The conductive adhesive is not particularly limited, and is, for example, a resin adhesive including a tin alloy. In the present embodiment, the adhesive is a conductive thermosetting adhesive that cures when the temperature reaches a predetermined temperature or higher. That is, the adhesive curing process in the fitting part is a process of heating the fitting part so as to be equal to or higher than a predetermined temperature. Furthermore, an adhesive containing an organic material may be used as the conductive adhesive. That is, since the adhesive containing an organic material decomposes at a high temperature, the coil and the stator core can be easily distinguished at the time of recycling. Therefore, the recyclability of the coil and stator core is improved.

  Below, the manufacturing method of the stator which concerns on this Embodiment is demonstrated in detail using drawing. As shown in FIG. 17, the U-shaped coil 112 is inserted into the tooth 108. And one end of the bus bar 110 for connecting with an adjacent laminated body coil is assembled | attached to any one edge part 150 of the two open ends of the laminated body coil 114 which forms the coil 112. . The other end of the bus bar 110 is assembled to an end portion 152 at a position facing the end portion 150 of the two end portions on the open side of the coil adjacent to the coil 112 across the tooth 108. As described above, the bus bar is a connecting member for connecting the open end portions at positions facing each other across the teeth 108 in two adjacent laminated coils. At this time, a conductive adhesive is applied to at least one of the end portion 150 of the laminated body coil 114 and the both end portions of the bus bar 110. The bus bar and the end portions 150 and 152 are brought into pressure contact with each other by applying a load at the fitting portion between the bus bar and the end portions 150 and 152. And the joining process of the bus-bar 110 and the edge parts 150 and 152 is completed by heating a fitting part more than predetermined temperature in the state to which the load was provided. By improving the adhesion between the bus bar and the end portions 150 and 152, the resistance when the coil 112 is energized can be reduced.

  The application of the conductive adhesive is not particularly limited, but may be applied by dipping or may be applied by spraying. That is, in the present embodiment, for example, the following method can be considered as a method of applying the adhesive to the bus bar.

  As shown in FIG. 18, the adhesive can be applied to the hatched portions at both ends of the bus bar by masking the central portion of the bus bar 110 including the bus bar positioning block 104 and spraying the adhesive. Alternatively, a hatched portion on one side of both ends of the bus bar is first dipped into a container filled with an adhesive. Thereafter, the opposite shaded area is further dipped. In this way, the adhesive may be applied to the hatched portions at both ends of the bus bar.

  Or as shown in FIG. 19, the shape of the both ends which contact the edge part of the coil 112 of the bus-bar 110 is protruded. Then, dipping is performed in a container filled with an adhesive at both ends. In this way, an adhesive may be applied to both ends of the bus bar protruding as shown by the hatched portion.

  Such a method of manufacturing a stator according to the present embodiment is performed according to the procedure shown in FIG.

  At S2000, coil 112 is inserted into stator core 102. The coil 112 inserted into the slots 146 and 148 across the teeth 108 of the stator core 102 is in a state as shown in FIG.

  In S2100, a conductive adhesive is applied to the bus bar. Application of the conductive adhesive is performed by spraying or dipping as described with reference to FIGS.

  At S2200, the bus bar is assembled to coil 112. That is, as shown in FIG. 11, the bus bar positioning block 104 to which a plurality of bus bars are fixed is assembled at a predetermined position. By assembling the bus bar positioning block, a plurality of bus bars are assembled to the coil 112 at a time.

  In S2300, a load is applied to the bus bar. In S2400, in a state where a load is applied to the bus bar, the fitting portion between the bus bar and the two ends 150 and 152 of the coil 112 is heated. At this time, when the fitting portion is heated to a predetermined temperature or higher, the conductive adhesive is cured.

  Next, the load applied to bring the bus bar into contact with the two ends 150 and 152 of the coil 112 will be described. The method for applying the load is not particularly limited. For example, the load may be applied by a hydraulic device.

  Alternatively, the coil 112 forming a 10-turn winding can be assembled with a plurality of bus bars at once by the bus bar positioning block 104 to which the plurality of bus bars are fixed. At this time, the bus bar positioning block 104 is fastened to the stator core 102 with bolts. That is, a state where the plurality of bus bars and the open end of the coil 112 are in pressure contact may be realized by applying a load due to the fastening force of the bolt.

  As shown in FIG. 21, a bus bar positioning block 104 to which a plurality of bus bars are fixed is assembled to the coil 112 at a predetermined position. Therefore, a plurality of bus bars can be assembled to the coil 112 at a time. Then, a fastening force is generated by fastening the bus bar positioning block 104 to the stator core 102 by the outer peripheral side bolt 156 and the inner peripheral side bolt 154 in the stator core on the bus bar positioning block 104. Then, by applying a load due to the fastening force of the bolt, the plurality of bus bars and the open end portion of the coil 112 are brought into a pressure contact state. Then, the adhesive is cured to complete the joining process. The plurality of bus bars have the bus bar positioning block 104 fixed to the stator core by the outer peripheral side bolts 156 and the inner peripheral side bolts 154. In this case, it is not necessary to use a thermosetting adhesive as the adhesive. . That is, even if it uses the adhesive agent hardened | cured with progress of time, a bus bar and a coil can be joined.

  Therefore, the stator manufacturing method when the bus bar positioning block is fastened to the stator core and a load is applied to the bus bar is performed according to the procedure shown in FIG.

  At S3000, coil 112 is inserted into stator core 102. The coil 112 inserted into the slots 146 and 148 across the teeth 108 of the stator core 102 is in a state as shown in FIG.

  In S3100, a conductive adhesive is applied to the bus bar. Application of the conductive adhesive is performed by spraying or dipping as described with reference to FIGS.

  At S3200, the bus bar is assembled to coil 112. That is, as shown in FIG. 11, the bus bar positioning block 104 to which a plurality of bus bars are fixed is assembled at a predetermined position. By assembling the bus bar positioning block, a plurality of bus bars are assembled to the coil 112 at a time.

  At S3300, bus bar positioning block 104 is fastened to stator core 102 by outer peripheral side bolt 156 and inner peripheral side bolt 154. A load is applied to the bus bar by the fastening force of the bolt. Then, the adhesive is cured with time and the joining process is completed.

  The effects of the stator manufacturing method according to the present embodiment will be described below.

  A conductive adhesive is applied to at least one of the bus bars connected in the closing direction across the teeth of the two metal conductors adjacent to each other in the stacking direction of the stacked body. Then, a load is applied to the bus bar so that the open end and the both ends of the bus bar are in contact with each other. The adhesive is cured with a load applied. By manufacturing the stator in this manner, in joining the plurality of open ends and the bus bar of the stator, a load is applied to the plurality of bus bars and the adhesive is cured, so that a plurality of The bus bar joining process can be performed at a time. Further, it is not necessary to ensure the positional accuracy of the joining portion and the torch compared to the case where the joining between the open end and the bus bar is joined by laser welding or TIG welding. Therefore, the manufacturing time can be shortened and the manufacturing cost can be reduced.

  Further, by eliminating the joining process by laser welding or TIG welding, it is possible to prevent the insulating member such as enamel coating near the joint from being burned out. Moreover, decomposition | disassembly is possible at high temperature by using an organic material as a conductive adhesive. That is, the stator and the coil can be easily distinguished. As a result, recyclability is improved. In addition, by curing the adhesive in a state where a load is applied, the adhesive can be cured in a state where the adhesion between the bus bar and the open end is improved. Therefore, the resistance during energization can be reduced.

  Moreover, when using a thermosetting adhesive as a conductive adhesive, hardening can be accelerated | stimulated by heating each fitting part of two open ends and the both ends of a connection member. Therefore, the manufacturing time of the coil can be shortened.

  Further, at least one of the predetermined number of metal flat plates at the open end of the metal conductor is shaped to have different dimensions in the width direction perpendicular to the plate thickness direction of the metal flat plate, and fitted to the bus bar at the open end. By forming the fitting part to be performed, the assembly property of the bus bar to the laminate can be improved.

  Moreover, the load by the fastening force of a volt | bolt can be provided with respect to a bus bar by fastening a stator iron core and the bus-bar positioning block to which the several bus-bar was fixed with the volt | bolt. As a result, adhesion between the open end and the bus bar can be ensured. Therefore, a special load application process by a hydraulic device or the like can be eliminated. The bus bar positioning block integrates a plurality of bus bars to improve workability. Therefore, a load can be applied to the bus bar by a simple operation of fastening the bus bar positioning block to the stator core with a bolt or the like. Further, the bus bar positioning block can be fixed to the stator core by fastening with bolts. Therefore, an adhesive that does not require heat curing can be used as the conductive adhesive. As a result, the heat curing process can be abolished.

<Second Embodiment>
Hereinafter, a stator manufacturing method according to the second embodiment of the present invention will be described. The configuration of the rotating electrical machine according to the present embodiment is provided so as to contact all the bus bar positioning blocks included in the stator core described above in the configuration of the rotating electrical machine taking the synchronous motor according to the first embodiment as an example. The difference is that the fixing member is included. The rest of the configuration is the configuration of the synchronous motor according to the first embodiment. The same reference numerals are assigned to the same components. Their functions are the same. Therefore, detailed description thereof will not be repeated here.

  The synchronous motor according to the present embodiment includes a fixing member provided so as to be in contact with all the bus bar positioning blocks included in the stator core described above.

  The shape of the fixing member is not particularly limited, but in the present embodiment, for example, a disk-shaped non-conductor or insulation-coated member provided so as to contact all the bus bar positioning blocks included in the stator core It is. That is, as shown in FIG. 23, the synchronous motor 200 according to the present embodiment includes a stator core 108, a coil 112, a bus bar positioning block 104, a rotating shaft 204, a rotor 208, a bolt 210, and a nut 202. , And a disk 206.

  Adjacent laminate coils are connected to the coil 112 by a plurality of bus bars fixed to the bus bar positioning block 104. And the circumferential surface which the disk 206 has is provided in parallel with the surface orthogonal to the rotating shaft 204 of a synchronous motor. That is, the disk 206 is provided so as to contact all the bus bar positioning blocks included in the stator 100. The disk 206 is provided with a hole through which the bolt 210 is passed. The bolt 210 is inserted in a direction parallel to the rotation shaft 204. The bolt 210 passes through the stator core 108 and is fastened to the nut 202. That is, the disc 206 is fixed to the stator core 108 by fastening the bolt 210 to the nut 202. A fastening load is applied in a direction parallel to the rotation shaft 204 to all the bus bar positioning blocks by fastening. For this reason, the load due to the fastening force of the bolt is applied, and the bus bar and the open end of the coil are in pressure contact with each other. And an adhesive agent is hardened in the fastened state, and a joining process is completed. Since the plurality of bus bars are fixed to the stator core 102 by the circular plate 206, a thermosetting adhesive may not be used as the adhesive. For example, the bus bar and the coil can be joined by using an adhesive that hardens over time.

  Therefore, the stator manufacturing method in the present embodiment is performed according to the procedure shown in FIG.

  At S4000, coil 112 is inserted into stator core 102. The coil 112 inserted into the slots 146 and 148 across the teeth 108 of the stator core 102 is in a state as shown in FIG.

  In S4100, a conductive adhesive is applied to the bus bar. Application of the conductive adhesive is performed by spraying or dipping as described with reference to FIGS.

  At S4200, the bus bar is assembled to coil 112. That is, as shown in FIG. 11, the bus bar positioning block 104 to which a plurality of bus bars are fixed is assembled at a predetermined position. By assembling the bus bar positioning block, a plurality of bus bars are assembled to the coil 112 at a time.

  In S4300, the disc 206 is provided so as to contact all the bus bar positioning blocks of the stator 100.

  In S <b> 4400, disc 206 is fastened to stator core 102 with bolt 310. At this time, the place to be fastened is not limited to one place. For example, it may be fastened with a plurality of bolts at regular intervals. And the load by the fastening force of this volt | bolt is given, It will be in the state which the bus-bar and the open end part of the coil 112 were press-contacted. Then, the adhesive is cured with time and the joining process is completed.

  According to the stator manufacturing method according to the present embodiment, the disk-shaped member provided so as to contact all of the bus bar positioning blocks to which the plurality of bus bars of the stator are fixed is fastened to the stator core by bolts. The Therefore, all the bus bars included in the stator core can be joined at a time by applying a load due to the fastening force of the bolt. As a result, the time required for joining can be shortened. And manufacturing cost can be reduced. Moreover, a disk can be fixed to a stator core by fastening with a volt | bolt. Therefore, an adhesive that does not require heat curing can be used as the conductive adhesive. As a result, the heat curing process can be abolished.

<Modification of Second Embodiment>
Hereinafter, a stator manufacturing method according to a modification of the second embodiment of the present invention will be described. The configuration of the rotating electrical machine according to this modification is included in the surface on the opposite side of the surface of the stator core 102 on which the disk 206 is provided in the configuration of the rotating electrical machine taking the synchronous motor according to the second embodiment as an example. It is different in that it includes a fixing member provided so as to be in contact with all the coils, and a bolt for fixing the disc 206 and the fixing member to the stator core 102. Other than that, it is the structure of the synchronous motor which concerns on 2nd Embodiment. The same reference numerals are assigned to the same components. Their functions are the same. Therefore, detailed description thereof will not be repeated here.

  The synchronous motor according to the present modification includes a fixing member provided on the surface opposite to the surface of the stator core 102 on which the disc 206 is provided so as to contact all the coils.

  Although the shape of the fixing member is not particularly limited, in the present modification, for example, it is a disk-shaped non-conductor or an insulation-coated member provided so as to be in contact with all the coils included in the stator core.

  That is, as shown in FIG. 25, the synchronous motor 300 includes a stator core 108, a coil 112, a bus bar positioning block 104, a rotating shaft 204, a rotor 208, a bolt 310, a nut 202, a disc 206, a circle. Plate 306.

  Adjacent laminate coils are connected to the coil 112 by a plurality of bus bars fixed to the bus bar positioning block 104. A circumferential surface of the disk 206 is provided in parallel to a surface orthogonal to the rotation shaft 204. The disc 206 is provided so as to contact all the bus bar positioning blocks included in the stator 100. The disc 206 is provided with a hole through which the bolt 310 is passed. On the other hand, the disc 306 is provided so as to contact all the coils on the surface opposite to the surface of the stator core on which the disc 206 is provided. The disk 306 is provided with a hole through which the bolt 310 is passed. The bolt 310 is inserted in a direction parallel to the rotation shaft 204. The bolt 210 passes through the disk 206, the disk 306, and the stator core 108 and is fastened by the nut 202. That is, the two surfaces perpendicular to the rotation axis 204 of the stator core 102 are fastened so as to be sandwiched between the discs 206 and 306. The coil end portion is in contact with the disk 306. Further, the bus bar positioning block comes into contact with the disk 206.

  Therefore, by fastening the discs 206 and 306 with the bolts 310 using the nuts 202, a fastening load can be applied to all the bus bar positioning blocks in a direction parallel to the rotation shaft 204. At this time, since the disk 306 suppresses the movement in the direction opposite to the coil fastening direction, a fastening load can be applied to all bus bar positioning blocks without the need for a coil fixing jig or the like. When the load due to the fastening force of the bolt is applied, the bus bar and the open end of the coil are in pressure contact with each other. Then, the adhesive is cured with the load applied, and the joining process is completed. Since the plurality of bus bars are fixed to the stator core by the circular plate 206, a thermosetting adhesive may not be used as the adhesive. For example, the bus bar and the coil can be joined by using an adhesive that hardens over time.

  The procedure of the manufacturing method of the stator in the present embodiment is the same as that of the second embodiment except that the disk 206 and the disk 306 are assembled to the stator core 102 in S4300 of the flowchart of FIG. The same procedure. Therefore, detailed description thereof will not be repeated here.

  According to the stator manufacturing method according to the present modification, a disk-shaped member provided so as to come into contact with all of the bus bar positioning blocks to which a plurality of bus bars included in the stator are fixed is fastened to the stator core with bolts. Therefore, all the bus bars included in the stator core can be joined at a time. As a result, the time required for joining can be shortened. And manufacturing cost can be reduced. Moreover, a disk can be fixed to a stator core by fastening with a volt | bolt. Therefore, the heat curing process can be abolished by using an adhesive that does not require heat curing as the conductive adhesive. Also, by tightening the two faces perpendicular to the rotation axis of the stator core with two disk-shaped members and fastening with bolts, the load due to the fastening force can be applied to the bus bar without the need for a coil fixing jig or the like. It can be surely given.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

It is a figure which shows the external appearance of the stator which concerns on 1st Embodiment. It is a figure which shows the external appearance of the U-shaped laminated body coil which concerns on 1st Embodiment. It is a figure which shows the cross section of the laminated body coil which concerns on 1st Embodiment. It is a figure which shows the lamination | stacking cross section of the lamination direction of the laminated body coil which concerns on 1st Embodiment. It is a figure which shows the external appearance of the metal flat plate of the copper rolling raw material which concerns on 1st Embodiment. It is a figure which shows progress of the insulation process of the laminated body coil which concerns on 1st Embodiment. It is a figure which shows the external appearance of the coil formed with the several laminated body coil which concerns on 1st Embodiment. It is a figure which shows the assembly | attachment progress of the coil inserted in the stator core which concerns on 1st Embodiment. It is a figure which shows the external appearance of the coil assembled | attached to the stator core which concerns on 1st Embodiment. It is a figure which shows the external appearance of the coil by which the bus-bar which concerns on 1st Embodiment was assembled | attached. It is a figure which shows the external appearance of the coil by which the bus-bar positioning block to which the several bus-bar which concerns on 1st Embodiment is fixed is assembled | attached. It is a figure which shows joining with the bus bar assembled | attached with the open end part of the coil which concerns on 1st Embodiment. It is a figure which shows progress of assembling a crossover member to the edge part of the coil which concerns on 1st Embodiment. It is a figure which shows joining of the edge part of the crossover member assembled | attached to the edge part of the coil which concerns on 1st Embodiment. It is a figure which shows the external appearance of the stator which performed the mold process to the coil end part which concerns on 1st Embodiment. It is a flowchart which shows the manufacturing method of the stator using laser welding or TIG welding. It is a figure which shows the coil seen from the center of the rotating shaft of the stator which concerns on 1st Embodiment to the outer peripheral direction. It is a figure which shows the external appearance of the bus-bar positioning block with which the some bus bar which concerns on 1st Embodiment was assembled | attached. It is a figure which shows the external appearance of the bus-bar positioning block with which the some bus bar which concerns on 1st Embodiment was assembled | attached. It is a flowchart which shows the manufacturing method of the stator using the thermosetting adhesive which concerns on 1st Embodiment. It is a figure which shows the external appearance of the bus-bar positioning block assembled | attached to the stator core which concerns on 1st Embodiment. It is a flowchart which shows the manufacturing method of the stator using the fastening load of the volt | bolt which concerns on 1st Embodiment. It is a figure which shows the cross section of the synchronous motor which concerns on 2nd Embodiment. It is a flowchart which shows the manufacturing method of the stator using the fastening load of the volt | bolt which concerns on 2nd Embodiment. It is a figure which shows the cross section of the synchronous motor which concerns on the modification of 2nd Embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 100 Stator, 102 Stator core, 104 Bus bar positioning block, 106 Transition member, 108 Teeth, 110 Bus bar, 112 Coil, 114, 124 Laminate coil, 116, 120, 122, 126 Metal flat plate, 134, 136, 138, 140, 142,144 Coil end, 146,148 slot, 150,152 end, 154 Inner peripheral bolt, 156 Outer peripheral bolt, 200,300 Synchronous motor, 202 Nut, 204 Rotating shaft, 206,306 Disc, 208 Rotor 210, 310 volts.

Claims (10)

A method of manufacturing the stator in a rotating electrical machine including a stator and a rotor, wherein the stator is formed between a plurality of slots provided in a direction parallel to a rotation axis of the rotating electrical machine and the slots. And a coil in which a plurality of metal conductors are stacked, and the coil is inserted into the slot and wound around the teeth when viewed from the stacking direction of the metal conductors. A rectangular thin plate having a portion,
Inserting the coil into the slot along a direction parallel to the rotation axis, and winding the coil around the teeth;
Two open end portions at positions facing each other across the teeth in two metal conductors adjacent to each other in the coil stacking direction, and a connecting member for connecting the two open end portions in a direction closing the teeth Applying a conductive adhesive to at least one of
Applying a load to the connecting member such that the open end and both ends of the connecting member are in contact with each other;
Curing the adhesive in a state where the load is applied.   The step of applying the load includes the step of applying the load by fastening the stator core and the assembly member using an assembly member for assembling the plurality of connection members to the open end. The stator manufacturing method according to claim 1, comprising: A plurality of the assembly members are provided on the stator core,
The step of applying the load includes a step of applying a load by fastening the stator core and the assembly member using a fixing member common to the plurality of assembly members. The stator manufacturing method as described.   The method of manufacturing a stator according to claim 1, wherein the step of curing the adhesive includes a step of heating a contact portion between the two open end portions and both end portions of the connection member.   The stator manufacturing method according to claim 1, wherein a fitting portion that fits with the connection member is formed at an open end portion of the metal conductor. The metal conductor is formed by laminating a predetermined number of metal flat plates of a conductor press-molded into a U-shape or U-shape,
The stator manufacturing method according to claim 5, wherein at least a part of the flat metal plate has a length that is orthogonal to a plate thickness direction of the flat metal plate at a distal end portion of the U-shape or U-shape. .   The stator of the rotary electric machine manufactured by the stator manufacturing method in any one of Claims 1-6. A stator of a rotating electric machine composed of a stator and a rotor,
The stator is
A stator core having a plurality of slots provided in a direction parallel to the rotation axis of the rotating electrical machine and teeth formed between the slots;
Including a coil in which a plurality of metal conductors are laminated,
The coil is a rectangular thin plate having an open end that is inserted into the slot and can be wound around a tooth as viewed from the stacking direction of the metal conductors,
Two open ends at positions facing each other across the teeth in two metal conductors adjacent to each other in the stacking direction of the coil wound around the teeth, and the two open ends straddling the teeth A stator of a rotating electrical machine, which is formed by being bonded with a conductive adhesive interposed between connecting members connected in a closing direction.   The stator of the rotating electrical machine according to claim 8, wherein a fitting portion that fits with the connection member is formed at an open end portion of the metal conductor. The metal conductor is formed by laminating a predetermined number of metal flat plates of a conductor press-molded into a U-shape or U-shape,
The fixing of the rotating electrical machine according to claim 9, wherein at least a part of the metal flat plate has a length orthogonal to a plate thickness direction of the metal flat plate at a distal end portion of the U-shaped or U-shaped open side. Child.

Images