JP2020089108A - Clamp device and manufacturing method of stator using the clamp device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress a misalignment of a mating surface when the tip portions of two legs are clamped. SOLUTION: This is an outer leg portion located on the outer side in the radial direction of two leg portions protruding from different slots and tilted so as to be adjacent to each other in the radial direction, and an intermediate portion on the tip side of the base end portion of the tip portion. A first holding portion that holds down the outer surface of the base end portion of the outer leg portion and the first slope having a first slope that is inclined toward the tip on the outer outer surface in the radial direction of the two. A second slope that is an inner leg located radially inside the leg and is inclined toward the tip on the inner side surface of the middle portion on the tip side of the base end of the tip in the radial direction. A second holding portion for holding the inner side surface of the base end portion of the formed inner leg portion and the second slope is provided. [Selection diagram] FIG. 12

Description

The present invention relates to a clamp device and a stator manufacturing method using the clamp device.

Conventionally, as this type of clamp device, one used for manufacturing a stator including a stator core (stator core) and a plurality of segment coils (coil segments) has been proposed (see, for example, Patent Document 1). .. The stator core includes a plurality of slots each extending in the radial direction and formed at intervals in the circumferential direction. The plurality of segment coils have a pair of leg portions that are inserted into different slots, and the tip portions of the corresponding leg portions are welded to each other to form a plurality of stator coils. The clamp device includes a clamp body and a positioning protrusion. The clamp body protrudes from different slots and clamps the tips of two adjacent segment coils. The positioning protrusion enters between the tip ends of the two segment coils to be joined to the center side. Since the end portions of the segment coils are positioned by the positioning protrusions, interference between the center portions of the end portions of two adjacent segment coils protruding from different slots is suppressed.

JP, 2016-189657, A

However, in the above-described clamp device, the radial thickness of the stator core at the tip of each segment coil may vary. When such a variation in thickness occurs, when the tip ends of the two segment coils are clamped by the clamp device from the outer side and the inner side in the radial direction of the stator core, the clamp position changes, and the position of the mating surface between the tip portions is changed. May deviate from the desired position. Such misalignment of the mating surfaces affects subsequent processing steps, and is therefore desired to be suppressed.

The main purpose of the clamp device of the present invention and the method of manufacturing a stator using the clamp device is to suppress the positional deviation of the mating surfaces when the tips of the two legs are clamped.

The clamp device of the present invention and the method of manufacturing a stator using the clamp device employs the following means in order to achieve the above-described main object.

The clamp device of the present invention is
A stator core that includes a plurality of slots that respectively extend in the radial direction and are spaced apart in the circumferential direction; and a pair of leg portions that are inserted into the different slots and that correspond to the tip portions of the corresponding leg portions. A clamp device used for manufacturing a stator including a plurality of segment coils forming a plurality of stator coils by electrical joining, and clamping the tip portions of two adjacent leg portions protruding from the different slots. There
Of the two leg portions that protrude from the different slots and are tilted so as to be adjacent to each other in the radial direction, the outer leg portion is located on the outer side in the radial direction and is closer to the base end portion of the tip portion of the outer leg portion. The outer side surface and the first slant surface of the base end portion of the outer leg portion, in which a first slant surface that is tapered toward the tip is formed on a radially outer outer surface of a middle portion on the tip side. A first pressing portion for pressing
Of the two leg portions, the inner leg portion located on the inner side in the radial direction is directed toward the tip on the inner side surface on the inner side in the radial direction of the intermediate portion on the tip end side from the base end portion of the tip end portion of the inner leg portion. A second pressing portion that presses the inner side surface of the base end portion of the inner leg and the second inclined surface, the second inclined surface being inclined so as to taper
The main point is to provide.

In this clamp device of the present invention, the tips of two adjacent leg portions projecting from different slots are clamped. Prior to clamping the tip portions of the two legs, the outer leg portion located on the radially outer side of the two leg portions projecting from different slots and laid down to be adjacent in the radial direction has A first inclined surface is formed on the outer side surface on the radially outer side of the intermediate portion on the distal side of the base end portion, which is inclined toward the distal end with a first angle larger than 0 with respect to the inner side surface on the radially inner side. ing. The inner leg portion located radially inward of the two leg portions has a second slanting taper toward the distal end on the radially inner inner side surface of the intermediate portion on the distal end side from the proximal end portion of the distal end portion. A slope is formed. In the clamp device of the present invention, the first pressing portion presses the outer side surface and the first inclined surface of the base end portion of the outer leg portion, and the second pressing portion presses the inner side surface and the second side surface of the base end portion of the inner leg portion. Hold down the slope. With this, when the tip ends of the leg portions of the plurality of segment coils have variations in thickness in the radial direction, the tip portions of the two leg portions can be accurately clamped by the clamping device, and the mating surfaces of the tip portions can be Positional shift can be suppressed.

The stator manufacturing method of the present invention is
The clamping device of the present invention in the above-described aspect, that is, basically, the stator core including a plurality of slots that extend in the radial direction and are formed at intervals in the circumferential direction, and are inserted into the slots different from each other. A plurality of segment coils having a pair of legs and a plurality of segment coils forming a plurality of stator coils by electrically joining the tip ends of the corresponding legs are used to manufacture a stator, and project from the different slots. A clamping device that clamps the tip ends of two adjacent leg portions, the outer side being located radially outside of the two leg portions that protrude from the different slots and are tilted to be adjacent in the radial direction. The outer leg portion is a leg portion, and a first inclined surface that is inclined toward the tip is formed on an outer side surface of a middle portion of the tip portion closer to the tip end than the base end portion in a radial outer side. A first pressing portion that presses the outer side surface of the base end portion and the first slope, and an inner leg portion that is located radially inward of the two leg portions and that is closer to the tip end side than the base end portion of the tip end portion. The inner side surface and the second slant surface of the base end portion of the inner leg portion in which a second slant surface that is tapered toward the tip is formed on the inner side surface of the middle portion of the inner side in the radial direction. A stator manufacturing method for manufacturing the stator using a clamp device comprising: a second pressing portion for pressing;
The first slope is formed on the outer side surface of the middle portion of the outer leg portion of the two leg portions, and the first slope is formed on the inner side surface of the middle portion of the inner leg portion of the two leg portions. 2 a first step of forming a slope,
The outer side surface and the first inclined surface of the base end portion of the outer leg portion are pressed by the first pressing portion, and the inner side surface and the second inclined surface of the base end portion of the inner side leg portion are A second step of clamping the tip portion of the outer leg portion and the tip portion of the inner leg portion by pressing with a second holding portion;
The main point is to provide.

In this stator manufacturing method of the present invention, since the stator is manufactured using the clamp device of the present invention in any of the above-described aspects, the same effects as the effects of the clamp device of the present invention, that is, the tips are This brings about an effect of suppressing the positional deviation of the mating surfaces.

In the stator manufacturing method of the present invention as described above, in the second step, with the tip end portion of the outer leg portion and the tip end portion of the inner leg portion being clamped, with respect to a mating surface of the tip end portions. The tip portions may be joined together by performing laser welding. Since the laser welding can be performed in a state in which the positional deviation of the mating surfaces of the tip portions is suppressed, the tip portions can be joined more appropriately.

It is a schematic block diagram which shows the rotary electric machine M containing the stator 1 manufactured using the clamp apparatus 50a of one Example of this invention. It is a top view which shows the rotary electric machine M. It is an equivalent circuit diagram for explaining an outline of connection of stator coils 3u, 3v, and 3w. It is a schematic diagram showing an example of a state where tip parts T of two leg parts 40 are joined. 6 is a flowchart showing an example of a manufacturing process of the stator 1. It is a schematic diagram showing an example of shape of tip part T of segment coil 4 from which sag Sa was removed. It is explanatory drawing for demonstrating the shape of the front-end|tip part T of the outer side leg part 40o after performing step S150. It is explanatory drawing for demonstrating the shape of the front-end|tip part T of the inner side leg part 40i after performing step S150. It is explanatory drawing for demonstrating a mode that the front-end|tip part T of the outer side leg part 40o is bent to the outer peripheral side of the stator core 2 in step S150. FIG. 8 is a schematic plan view showing an outline of how the tip portions T of the two leg portions 40 to which the tip portions T are joined are clamped by the clamp devices 50a to 50c. It is the schematic which shows the outline of a mode that the two leg parts 40 which adjoin in a radial direction are clamped by the clamp apparatus 50a. It is an enlarged view of the principal part of the clamp device 50a. It is explanatory drawing for demonstrating a mode that the front-end|tip parts T of the two leg parts 40 are clamped by the clamp apparatus 50a. It is explanatory drawing which shows an example of the 1st, 2nd pressing part 156,157 of the clamp apparatus of the comparative example which clamps each front-end|tip part T of the two leg parts 40 by which the front-end|tip parts T are joined. is there.

Next, modes for carrying out the present invention will be described using examples.

FIG. 1 is a schematic configuration diagram showing a rotary electric machine M including a stator 1 manufactured using a clamp device 50a according to an embodiment of the present invention. FIG. 2 is a plan view showing the rotary electric machine M. FIG. 3 is an equivalent circuit diagram for explaining the outline of the connection of the stator coils 3u, 3v, 3w. FIG. 4 is a schematic diagram showing an example in which the tip ends T of the two leg portions 40 are joined together. The rotary electric machine M is, for example, a three-phase AC electric motor used as a drive source or a generator of an electric vehicle or a hybrid vehicle. As illustrated, the rotary electric machine M includes a stator 1 and a rotor 10 rotatably arranged in the stator 1 via an air gap.

As shown in FIGS. 1 and 2, the stator 1 includes a stator core 2 and stator coils 3u, 3v, 3w. The stator core 2 is formed by laminating a plurality of electromagnetic steel plates 2p formed in an annular shape by, for example, press working, and has an annular shape as a whole. In addition, the stator core 2 includes a plurality of teeth portions 2t that are radially inwardly spaced from the annular outer peripheral portion (yoke) and project inward in the radial direction, and a plurality of slots formed between the teeth portions 2t adjacent to each other. 2s and. The plurality of slots 2s extend in the radial direction of the stator core 2 and are arranged in the circumferential direction at regular intervals, and an insulator (insulating paper) not shown is arranged in each slot 2s.

As shown in FIG. 3, the stator coils 3u, 3v, 3w are connected by a single star connection (1Y connection). In the present embodiment, the U-phase stator coil 3u includes a first coil U1 and a second coil U2. Similarly, the V-phase stator coil 3v includes a first coil V1 and a second coil V2, and the W-phase stator coil 3w includes a first coil W1 and a second coil W2. Further, the first coils U1, V1, W1 are respectively provided with lead wires Lu, Lv, Lw, and the second coils U2, V2, W2 are respectively provided with a neutral wire N.

As shown in FIG. 1, each of the stator coils 3u, 3v, 3w is formed by electrically connecting a plurality of segment coils 4 inserted into a plurality of slots 2s of the stator core 2. The segment coil 4 is formed, for example, by bending a rectangular wire (electric conductor) having an insulating coating Ic made of enamel resin or the like formed on its surface into a substantially U shape, and removing the insulating coating Ic from each tip. A pair of legs 40 having a section T are provided. The pair of leg portions 40 of each segment coil 4 are inserted into different slots 2s of the stator core 2, and the portions of each leg portion 40 protruding from one end surface (upper end surface in FIG. 1) of the stator core 2 are not shown. The tilting process is performed using the tilting device.

More specifically, the plurality of segment coils 4 have the same number and even number (eg, 6, 8) from each of the plurality of slots 2s in a state where the side surfaces on the long side of the leg portion 40 are overlapped so as to abut each other. The individual leg parts 40 are attached to the stator core 2 so as to project. The plurality of leg portions 40 protruding from each slot 2s are expanded in the radial direction of the stator core 2 using an expansion jig. Further, the odd-numbered (on the odd-numbered layer) leg portions 40 from the axial center side of the stator core 2 are tilted to one side in the circumferential direction while being twisted around the axial center of the stator core 2, and the even-numbered (on the even-numbered layer) legs. The portion 40 is tilted to the other side in the circumferential direction while being twisted around the axis of the stator core 2. As a result, the tip ends T of any two leg portions 40 that are adjacent in the radial direction incline with respect to the axial center of the stator core 2 and extend in opposite directions along the circumferential direction. A plurality of stator coils 3u, 3v, 3w wound around the stator core 2 are formed by joining the tip end portions T of the two corresponding leg portions 40 adjacent in the radial direction by laser welding.

As shown in FIG. 2, the lead wire Lu of the stator coil 3u is electrically joined by welding to the tip portion of the power line 5u electrically joined to the U-phase terminal 6u. The lead wire Lv of the stator coil 3v is electrically joined by welding to the tip end of the power line 5v that is electrically joined to the V-phase terminal 6v. Further, the lead wire Lw of the stator coil 3w is electrically joined by welding to the tip end of the power line 5w electrically joined to the W-phase terminal 6w. The power lines 5u, 5v, 5w are fixed to the resin holding member 7, respectively. The terminals 6u, 6v, 6w are fixed to a terminal block (not shown) installed (fixed) in the housing of the rotating electric machine M when the stator 1 is assembled to the housing, and an inverter (not shown) is provided through a power line (not shown). Connected to.

In the plurality of stator coils 3u, 3v, 3w wound around the stator core 2 as described above, a predetermined number of joints of the tip ends T are arranged in the radial direction by a predetermined number and are arranged in the axial direction of the stator core 2 as shown in FIG. An annular coil end portion 3a protruding outward from the middle upper end face is formed.

Further, as shown in FIG. 4, in the stator 1, of the two leg portions 40 whose tip portions T are joined to each other, one tip portion T of the outer leg portion 40o positioned radially outside (upper side in the drawing). Is bent to the inner peripheral side (lower side in the drawing) of the stator core 2, and the other tip end T of the inner leg portion 40i located on the axial center side (lower side in the drawing) of the stator core 2 is the radial direction of the stator core 2. Is bent outward (upper side in the figure). The inner side surface Tsi of the tip portion T of the outer leg portion 40o and the outer side surface Tso of the inner leg portion 40i are joined to each other via the laser welded portion WL.

Further, resin such as varnish is applied to the stator core 2 from the coil end portion 3a side on the upper side in FIG. 1 toward the coil end portion 3b side on the lower side in FIG. As a result, each segment coil 4 and an insulator (not shown) are fixed to the stator core 2 by the resin. Further, the stator 1 of this embodiment includes an annular mold portion 8 that covers the coil end portion 3a. The mold portion 8 is formed of a resin, and the resin enters the gap between the segment coils 4 adjacent to each other, so that the joining portion between the tip ends T and the lead lines Lu-Lw and the power lines 5u-5w are formed. The exposed portion of the conductor such as the joint is well insulated.

As shown in FIG. 2, the rotor 10 of the rotating electric machine M is configured by embedding a plurality of permanent magnets 15 in a rotor core 11 fixed to a rotating shaft (not shown).

Next, a method of manufacturing the stator 1 of the rotary electric machine M configured as described above will be described. FIG. 5 is a flowchart showing an example of the manufacturing process of the stator 1.

In the manufacturing process of the stator 1, first, a rectangular wire (conductor) having an insulating coating Ic made of enamel resin or the like formed on its surface is cut using a cutting blade for each length corresponding to the segment coil 4. A plurality of segment coils 4 are formed (step S100). At this time, the vicinity of the cutting surface of the segment coil 4, that is, the vicinity of the tip may be curved at a position where the cutting blade is received, and sagging Sa may occur.

Next, the insulating coating Ic on the surface of the tip portion T of the segment coil 4 is peeled off (step S110). As a result, the rectangular wire at the tip portion T of each segment coil 4 is exposed. The insulating coating Ic to be peeled off is a slight range of the entire length of the segment coil 4 and is, for example, about 5 mm, 7 mm, 9 mm.

Next, the sagging Sa of the tip portion T is cut out by punching using a die having a shape corresponding to the rectangular wire when sagging Sa does not occur (step S120). FIG. 6 is a schematic view showing an example of the shape of the tip portion T of the segment coil 4 from which the sag Sa has been removed. In the figure, the broken line indicates the shape of a rectangular wire when sagging Sa does not occur during the cutting in step S100. In the figure, the alternate long and short dash line indicates the sag Sa formed at the time of cutting in step S100. Although the sag Sa is cut off in step S110, the segment coil 4 has a shape in which the end Ed of the tip T tapers toward the tip.

Subsequently, each segment coil 4 is bent into a substantially U-shape to form a plurality of segment coils 4, and the plurality of segment coils 4 that are adjacent to each other in the radial direction of the stator core 2 are formed in the same number from each of the plurality of slots 2s. The even number of legs 40 are inserted into the stator core 2 so as to project (step S130).

Then, the plurality of leg portions 40 protruding from each slot 2s are molded (step S140). The legs 40 are formed by first expanding the plurality of legs 40 protruding from each slot 2s in the radial direction of the stator core 2 and then using a tilting device (not shown) from the axial side of the stator core 2. While twisting the odd-numbered (on the odd-numbered layer) leg portions 40 to one side in the circumferential direction while twisting about the axial center of the stator core 2, twist the even-numbered (on the even-numbered layer) leg portions 40 around the axial center of the stator core 2. However, it is performed by tilting to the other side in the circumferential direction.

Subsequently, a bending process of bending the plurality of leg portions 40 toward the outer peripheral side or the axial center side of the stator core 2 is performed (step S150). FIG. 7 is an explanatory diagram for explaining the shape of the distal end portion T of the outer leg portion 40o after performing step S150. FIG. 8 is an explanatory diagram for explaining the shape of the tip end portion T of the inner leg portion 40i after performing step S150. FIG. 9 is an explanatory diagram for explaining a state in which the tip end portion T of the outer leg portion 40o is bent to the outer peripheral side (lower side in the figure) of the stator core 2 in step S150.

In the bending process, as shown in FIG. 7, the outer surface Tso of the intermediate portion Tc on the tip side of the base end portion Teb of the tip end portion T of the outer leg portion 40o is moved to the inner peripheral side of the stator core 2 (in the drawing by a jig not shown). By pressing downward, the outer surface Tso of the intermediate portion Tc is deformed to form a slope Tslo, and as shown in FIG. 9, the tip portion T is moved to the inner peripheral side of the stator 1 (lower side in the drawing). ). Here, the intermediate portion Tc is a portion that is predetermined as a portion that is slightly deformed even if the amount of sag Sa changes slightly. Therefore, the inclined surface Tslo is formed at the same position even if the amount of sag Sa slightly changes. At this time, the inner surface Tsi of the tip end T of the outer leg portion 40o, the outer surface Tso and the circumferential direction of the stator core 2 are formed. A predetermined value θci is an angle θa formed by a tangent line Lt (two-dot chain line in the figure) that is in contact with the curve Lcd at an intersection Ci with the virtual curve Lcd (one-dot chain line in the figure) shown. The predetermined value θci includes the two leg portions 40 (the inner leg portion 40i and the outer leg portion 40o) that join the distal end portions T to each other, and the two leg portions 40 that are located radially adjacent to the two leg portions 40. Is slightly larger than the angle at which they do not touch, and is set to, for example, 6°, 7°, 8°. A predetermined value θref is an angle θ1 formed by the slope Tslo and a straight line Lso parallel to the inner side surface Tsi, that is, an angle formed by the slope Tslo and the inner side surface Tsi. The predetermined value θref may be, for example, 2°, 3°, 4° or the like.

Further, as shown in FIG. 8, the inner side surface Tsi of the intermediate portion Tc on the tip side of the base end portion Teb of the tip portion T of the inner leg portion 40i is moved to the outer peripheral side (upper side in the figure) of the stator core 2 by a jig (not shown). By pressing, the inner side surface Tsi of the intermediate portion Tc is deformed to form the inclined surface Tsli, and the tip portion T is bent to the outer peripheral side (upper side in the drawing) of the stator core 2. Here, the intermediate portion Tc is a portion that is determined in advance so that the deformation due to the sagging Sa is small even if the amount of the sagging Sa slightly changes. Therefore, the inclined surface Tsli is formed at the same position even if the amount of sag Sa slightly changes. At this time, the outer surface Tso of the tip portion T of the inner leg 40i, the outer surface Tso, and the circumferential direction of the stator core 2 are formed. A predetermined value θci is an angle θb formed by a tangent line Lt (two-dot chain line in the drawing) that is in contact with the curve Lcd at an intersection Ci with an imaginary curve Lcd (one-dot chain line in the drawing). The angle θ2 formed by the slope Tsli and the straight line Lso parallel to the outer surface Tso, that is, the angle formed by the slope Tsli and the outer surface Tso is defined as a predetermined value θref.

In this way, by setting the angles θa and θb in the outer leg portion 40o and the inner leg portion 40i to the predetermined value θci, the inner side surface Tsi of the tip portion T of the outer leg portion 40o and the tip portion T of the inner leg portion 40i. Can be made parallel to the outer surface Tso of. The angles θ1 and θ2 will be described later.

Next, of the two leg portions 40 to which the tip portions T are joined, the outer surface Tso of the tip portion T of the inner leg portion 40i and the tip portion T of the outer leg portion 40o corresponding to the inner leg portion 40i The side surface Tsi is joined by laser welding, or the leader line Lu-Lw and the power line 5u-5w are joined by laser welding (step S160). The tip T of the inner leg 40i and the corresponding tip T of the outer leg 40o are joined to each other by the outer surface Tso of the tip T of the inner leg 40i and the tip of the outer leg 40o corresponding to the inner leg 40i. This is performed by welding the periphery of the mating surface with a laser in a state where the inner surface Tsi of the portion T is clamped by any of the clamping devices 50a to 50c and is aligned.

FIG. 10 is a schematic plan view showing a state in which the tip portions T of the two leg portions 40 to which the tip portions T are joined are clamped by the clamp devices 50a to 50c. In the clamp devices 50a to 50c, in this order, the distal end portions T of the two leg portions 40 located on the radially inner side (lower side in the figure) and the two leg portions 40 located on the outer side in the radial direction (upper side in the figure). Are arranged so as to clamp the tip portions T of each other and the tip portions T of the two leg portions 40 positioned at the radial middle between the radially inner side and the radially outer side.

FIG. 11 is a schematic view showing an outline of how two leg portions 40 that are adjacent in the radial direction are clamped by the clamp device 50a. FIG. 12 is an enlarged view of a main part of the clamp device 50a. As shown in FIGS. 11 and 12, the clamp device 50a includes a support portion 52, a crank portion 54, and a drive device (not shown). Since the clamp devices 50b and 50c have the same configuration as the clamp device 50a, the description thereof will be omitted.

The support portion 52 extends outwardly in the radial direction of the stator core 2 to the axially upper side (upper side in FIG. 11) of the stator core 2 and then bends and extends substantially perpendicularly to the inner side of the stator core 2 in the radial direction. It has a plate shape. The distal end of the support portion 52 on the radially inner side of the stator core 2 supports the crank portion 54. The support portion 52 is configured to be movable in the circumferential direction and the axial direction of the stator core 2 by a drive device (not shown).

A through hole 55 and first and second pressing portions 56 and 57 are formed in the crank portion 54. The through hole 55 is located at a position aligned with the laser welded portion WL (FIG. 4) of the two leg portions 40 where the tip portions T are joined when the crank portion 54 is arranged on the stator core 2, and the through hole 55 is in the axial direction of the stator core 2. It is formed so as to penetrate therethrough (in the vertical direction in FIG. 11). The diameter of the through hole 55 is, for example, about 2 mm, 2.5 mm, or 3 mm. The through hole 55 serves as a passage for the laser when the tip portions T of the two leg portions 40 are joined together.

The first and second pressing portions 56 and 57 connect the two leg portions 40 (the outer leg portions 40o and the inner leg portions 40i) whose tip portions T are joined to each other when the crank portion 54 is arranged on the stator core 2. It is arranged so as to be able to be sandwiched from the radially inner side and the radially outer side. The first and second pressing portions 56 and 57 are formed in a shape that tapers downward in the axial direction of the stator core 2.

As shown in FIG. 12, the second pressing portion 57 includes pressing surfaces 58c and 58d on the radially outer outer surface of the stator core 2. The pressing surface 58c is formed to be parallel to the inner side surface Tsi of the base end portion Teb of the tip end portion T of the inner leg portion 40i after the bending process in step S150. The pressing surface 58d is formed to be parallel to the inclined surface Tsli of the intermediate portion Tc of the tip portion T of the inner leg portion 40i. Therefore, the angle formed by the pressing surfaces 58c and 58d is substantially the same as the angle θ2 (FIG. 8) formed by the inner side surface Tsi of the base end portion Teb of the tip end T of the inner leg portion 40i and the slope Tsli. ing. Although not shown, the first pressing portion 56 includes pressing surfaces 58a and 58b on the radially inner inner surface of the stator core 2. The pressing surface 58a is formed to be parallel to the outer side surface Tso of the base end portion Teb of the tip end portion T of the outer side leg portion 40o. The pressing surface 58b is formed so as to be parallel to the slope Tslo of the intermediate portion Tc of the tip portion T of the outer leg portion 40o. Therefore, the angle formed by the pressing surfaces 58a and 58b is substantially the same as the angle θ1 (FIG. 7) formed by the outer surface Tso of the base end portion Teb of the tip end T of the outer leg portion 40o and the slope Tslo. ing. The first pressing portion 56 is fixed to the crank portion 54. The second pressing portion 57 is configured to be movable in the radial direction of the stator core 2 by a driving device (not shown).

The support portion 52 of the clamp device 50a moves up and down with respect to the stator core 2 by a driving device (not shown). As a result, the first and second pressing portions 56 and 57 can be moved toward and away from the leg portions 40 of the plurality of segment coils 4 assembled to the stator core 2. When clamping the tip end portions T of the two leg portions 40 to which the tip end portions T are joined, first of all, the clamp devices 50a to 50c of the clamping devices 50a to 50c are arranged with the second pressing portion 57 sufficiently arranged inward in the radial direction. The support portion 52 is brought close to the stator core 2. Then, of the two leg portions 40 to which the pressing surfaces 58a and 58b of the first pressing portion 56 are joined, the outer surface Tso and the slope surface Tslo of the tip end portion T of the outer leg portion 40o are brought into contact with the first pressing portion 56 and the first pressing portion 56. The entire clamp device 50a is lowered so that the tip end portions T of the two leg portions 40 joined to the two holding portions 57 are arranged. Then, the second holding portion 57 is moved outward in the radial direction, and the inner side surface Tsi of the tip portion T of the inner leg portion 40i of the two leg portions 40 to which the holding surfaces 58c and 58d of the second holding portion 57 are joined. By pressing the sloping surface Tsli with a constant pressure, the tip end portions T of the two leg portions 40 are clamped by the clamp device 50a. The release of the clamp is performed by moving the second pressing portion 57 inward in the radial direction.

FIG. 13 is an explanatory diagram for explaining how the tip portions T of the two leg portions 40 are clamped by the clamp device 50a. When the tip portions T of the two leg portions 40 whose tip portions T are joined to each other are clamped by the clamp device 50a, the bent portion of the boundary between the holding surfaces 58a and 58b of the first holding portion 56 becomes the tip portion of the outer leg portion 40o. It is fitted to the bent portion at the boundary between the outer surface Tso of the base end portion Teb of T and the inclined surface Tslo of the intermediate portion Tc. The pressing surface 58a of the first pressing portion 56 presses the outer surface Tso of the base end portion Teb of the tip end portion T of the outer leg portion 40o, and the pressing surface 58b is the middle portion Tc of the tip end portion T of the outer leg portion 40o. Hold down the slope Tslo. At this time, since the slope Tslo is formed at the same position even if the amount of sag Sa is slightly changed, the first pressing portion 56 should contact the predetermined position of the tip end T of the outer leg 40o. become. The bent portion of the boundary between the pressing surfaces 58c and 58d of the second pressing portion 57 is fitted to the bent portion of the boundary between the inner side surface Tsi of the base end portion Teb of the tip end portion T of the inner leg portion 40i and the inclined surface Tsli of the intermediate portion Tc. To meet. The pressing surface 58c of the second pressing portion 57 presses the inner side surface Tsi of the base end portion Teb of the tip portion T of the inner leg portion 40i, and the pressing surface 58d is the slope of the middle portion Tc of the tip portion T of the inner leg portion 40i. Hold down Tsli. At this time, since the slope Tsli is formed at the same position even if the amount of sag Sa is slightly changed, the first pressing portion 56 should be in contact with the predetermined position of the tip end T of the inner leg 40i. become. In this way, the first and second pressing portions 56 and 57 clamp the tip end portions T of the two leg portions 40 to which the tip end portions T are joined together at the predetermined positions on the two surfaces, respectively. The reason why the tip end portions T of the two leg portions 40, which are joined to each other by the first and second pressing portions 56 and 57, are clamped on the two surfaces, respectively, is as follows.

FIG. 14: is an example of the 1st, 2nd pressing part 156,157 of the clamp apparatus of the comparative example which clamps each front-end|tip part T of the two leg parts 40 by which the front-end|tip parts T are joined. FIG. In the figure, for comparison, the broken line shows that the tip end portion T of the leg portion 40 having a larger amount of sag Sa than the solid line is clamped by the first and second pressing portions 156 and 157. In the comparative example, when the bending process of bending the plurality of leg portions 40 toward the outer peripheral side or the axial center side of the stator core 2 is performed in step S150, the slopes Tslo and slope Tsli are formed at the tip end portions T of the two leg portions 40. Not not. In the clamp device of the comparative example, the second pressing portion 157 is moved toward the fixed first pressing portion 156 so that the second pressing portion 157 causes the tips of the two leg portions 40 from the radially inner side of the stator core 2 to the outer side. The part T is pressed and clamped. When the sag Sa becomes large, as shown by the broken line, when the tip end portion T of the two leg portions 40 is pressed by the second pressing portion 157 from the radially inner side to the outer side of the stator core 2, the outer leg portion 40o and the inner leg portion 40o. The tip portion T of 40i slightly rotates, and the positions where the two tip portions T are clamped by the first and second pressing portions 156 and 157 are displaced, and the position of the mating surface of the tip portion T is displaced. In the embodiment, the inclined surface Tslo and the inclined surface Tsli are formed at the predetermined positions of the tip end portions T of the two leg portions 40, and the bent portion of the boundary between the holding surfaces 58a and 58b of the first holding portion 56 is the outer leg portion. The outer surface Tso of the base end portion Teb of the front end portion 40o of 40o is fitted into the bent portion of the boundary between the inclined surface Tslo of the intermediate portion Tc, and the bent portion of the boundary between the holding surfaces 58c and 58d of the second holding portion 57 is The inner leg portion 40i is fitted into the bent portion of the boundary between the inner side surface Tsi of the base end portion Teb of the tip end portion Ti and the inclined surface Tsli of the middle portion Tc. Then, the first pressing portion 156 of the clamp device presses the outer surface Tso of the base end portion Teb of the distal end portion T of the outer leg portion 40o and the slope surface Tslo of the middle portion Tc, and the second pressing portion 157 presses the inner leg portion 157. Since the inner side surface Tsi of the base end portion Teb of the tip end portion T of the portion 40i and the inclined surface Tsli of the middle portion Tc are pressed down, the two tip end portions T are clamped at a predetermined position even if the amount of sag Sa is slightly changed. be able to. By doing so, it is possible to suppress the positional deviation of the mating surfaces between the tip portions T of the two leg portions 40.

In this way, after the tip portions T of the two leg portions 40 are clamped, the laser is irradiated from above the stator core 2 to the through hole 55 of the crank portion 54 of the clamp device 50a, and the two leg portions 40 (outer leg portion 40o, inner leg portion 40o). The mating surfaces of the tip portions T of the portion 40i) are welded and joined. Then, the clamp by the clamp device 50a is released. When the clamping by the clamp device 50a between the tip ends T is released, springback occurs in which the second pressing portion 157 of the clamp device 50a returns in the opposite direction to the pressing direction. In the embodiment, the angles of the angles θa and θb in the outer leg portion 40o and the inner leg portion 40i are set to a predetermined value θci, which is slightly larger than the angle at which the two leg portions 40 located next to each other in the radial direction of the two leg portions 40 do not come into contact with each other. Angle. Accordingly, when springback occurs, the two legs 40 whose tip portions T are connected to each other and the two legs 40 located next to each other in the radial direction of the two angles 40a and θb. The angle can be such that 40 does not contact. Thereby, the contact between the two leg portions 40 (the inner leg portion 40i and the outer leg portion 40o) to be joined and the two leg portions 40 located next to each other in the radial direction of the two leg portions 40 is suppressed. it can.

When the clamp by the clamp device 50a is released in this manner, the plurality of segment coils 4 and the like are fixed to the stator core 2 using resin such as varnish (step S170), and the present manufacturing process is completed.

According to the clamp device 50a of the embodiment described above, the inside of the first pressing portion 56 that presses the outer surface Tso and the slope Tslo of the base end portion Teb of the outer leg portion 40o and the base end portion Teb of the inner leg portion 40i. Since the second pressing portion 57 that presses the side surface Tsi and the inclined surface Tsli is provided, the tip end portions T of the two leg portions 40 (the outer leg portion 40o and the inner leg portion 40i) to which the tip end portions T are joined are aligned with each other. It is possible to suppress the displacement of the surface.

In the clamping device 50a of the embodiment, the second pressing portion 57 is moved inward in the radial direction without moving the first pressing portion 56 to clamp the tip portions T of the outer leg portion 40o and the inner leg portion 40i. ing. However, without moving the second pressing portion 57, the first pressing portion 56 may be moved outward in the radial direction to clamp the tip end portions T of the outer leg portion 40o and the inner leg portion 40i. Further, the first pressing portion 56 may be moved outward in the radial direction and the second pressing portion 57 may be moved inward in the radial direction to clamp the tip end portions T of the outer leg portion 40o and the inner leg portion 40i.

Correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problem will be described. In the embodiment, the first pressing portion 56 corresponds to the “first pressing portion” and the second pressing portion 57 corresponds to the “second pressing portion” for the clamp device of the present invention. In the stator manufacturing method of the present invention, the step S150 corresponds to the "first step", and the step S160 corresponds to the "second step".

The correspondence between the main elements of the embodiment and the main elements of the invention described in the column of means for solving the problem is the same as that of the embodiment described in the section of means for solving the problem. This is an example for specifically explaining the mode for carrying out the invention, and does not limit the elements of the invention described in the column of means for solving the problem. That is, the interpretation of the invention described in the column of means for solving the problem should be made based on the description in that column, and the embodiment is the invention of the invention described in the column of means for solving the problem. This is just a specific example.

Although the embodiments for carrying out the present invention have been described above with reference to the embodiments, the present invention is not limited to these embodiments, and various embodiments are possible within the scope not departing from the gist of the present invention. Of course, it can be implemented.

INDUSTRIAL APPLICABILITY The present invention can be used in the stator manufacturing industry and the like.

1 stator, 2 stator core, 2p electromagnetic steel plate, 2s slot, 2t teeth part, 3a, 3b coil end part, 3u, 3v, 3w stator coil, 4 segment coil, 5u, 5v, 5w power line, 6u, 6v, 6w terminal , 7 holding member, 8 mold part, 10 rotor, 11 rotor core, 15 permanent magnet, 20 clamp device, 40 leg part, 40i inner leg part, 40o outer leg part, 50a, 50b, 50c clamp device, 52 support part, 54 Crank part, 55 through hole, 56,156 1st pressing part, 57,157 2nd pressing part, 58a-58d pressing surface, Ci intersection point, Ed end part, Ic insulating film, Lcd curve, Lt tangent line, Lu, Lv, Lw Leader wire, M rotating electric machine, Sa sag, T tip portion, Tc middle portion, Teb base end portion, Tsi inner side surface, Tslo, Tsli slope, Tso outer side surface, U1, V1, W1 first coil, U2, V2. W2 second coil, WL laser weld,

Claims (3)

A stator core that includes a plurality of slots that respectively extend in the radial direction and are spaced apart in the circumferential direction; and a pair of leg portions that are inserted into the different slots and that correspond to the tip portions of the corresponding leg portions. A clamp device used for manufacturing a stator including a plurality of segment coils forming a plurality of stator coils by electrical joining, and clamping the tip portions of two adjacent leg portions protruding from the different slots. There
Of the two leg portions that protrude from the different slots and are tilted so as to be adjacent to each other in the radial direction, the outer leg portion is located on the outer side in the radial direction and is closer to the base end portion of the tip portion of the outer leg portion. The outer side surface and the first slant surface of the base end portion of the outer leg portion, in which a first slant surface that is tapered toward the tip is formed on a radially outer outer surface of a middle portion on the tip side. A first pressing portion for pressing
Of the two leg portions, the inner leg portion located on the inner side in the radial direction is directed toward the tip on the inner side surface on the inner side in the radial direction of the intermediate portion on the tip end side from the base end portion of the tip end portion of the inner leg portion. A second pressing portion that presses the inner side surface of the base end portion of the inner leg and the second inclined surface, the second inclined surface being inclined so as to taper
Clamping device. A stator manufacturing method for manufacturing the stator using the clamp device according to claim 1.
The first slope is formed on the outer side surface of the middle portion of the outer leg portion of the two leg portions, and the first slope is formed on the inner side surface of the middle portion of the inner leg portion of the two leg portions. 2 a first step of forming a slope,
The outer side surface and the first inclined surface of the base end portion of the outer leg portion are pressed by the first pressing portion, and the inner side surface and the second inclined surface of the base end portion of the inner side leg portion are A second step of clamping the tip portion of the outer leg portion and the tip portion of the inner leg portion by pressing with a second holding portion;
And a method for manufacturing a stator. The method of manufacturing a stator according to claim 2, wherein
In the second step, the tip portion of the outer leg portion and the tip portion of the inner leg portion are clamped, and laser welding is performed on a mating surface of the tip portions. Join one another,
Stator manufacturing method.