WO2014002545A1

WO2014002545A1 - Method for manufacturing linear conductor, and method for manufacturing rotating electrical machine

Info

Publication number: WO2014002545A1
Application number: PCT/JP2013/058082
Authority: WO
Inventors: 杉浦圭介; 古賀清隆
Original assignee: アイシン・エィ・ダブリュ株式会社
Priority date: 2012-06-29
Filing date: 2013-03-21
Publication date: 2014-01-03
Also published as: JP2014030332A

Abstract

Provided is a method for manufacturing a linear conductor enabling a core to be wrapped at a high space factor. The method for manufacturing a linear conductor uses a sheathed conductor-wire bundle configured by using a flexible insulating sheathing (46) to sheath the circumference of a conductor-wire bundle in which multiple conductor wires are collected, the method having a pressurizing step for subjecting a processing-designated region of the coated conductor-wire bundle to pressurization in an intersecting direction (E) intersecting the direction in which the conductor-wire bundle extends. In the pressurizing step, the insulating sheathing (46) in the processing-designated region is plastically deformed, so that the perimeter of the processing-designated region (46) is increased in the perpendicular cross-section, which is a cross-section intersecting the extension direction.

Description

Method for manufacturing linear conductor and method for manufacturing rotating electrical machine

The present invention relates to a manufacturing method for manufacturing a linear conductor for a coil of a rotating electrical machine, and a manufacturing method of a rotating electrical machine including the manufacturing method.

As a conventional technique related to a linear conductor for a coil of a rotating electrical machine, there is a technique described in, for example, Japanese Unexamined Patent Application Publication No. 2011-91943 (Patent Document 1). Hereinafter, in the description of the column of the background art, member names and symbols in Patent Document 1 are quoted in []. Patent Document 1 discloses a linear configuration in which a conductor wire bundle [conductor bundle 44] in which a plurality of conductor wires [conductor 41] are assembled is covered with a deformable insulating coating material [insulator 43]. A technique is described in which the conductor [winding 42] is used as a linear conductor for a coil of a rotating electrical machine. In the configuration of Patent Document 1, as shown in FIG. 8 of the document, after the linear conductor is wound around the divided core [stator core 11] divided for each tooth, the forming die [ By moving the slide mold 47] to deform the cross-sectional shape of the linear conductor, a state in which the linear conductor is wound around the split core as shown in FIG. 9 of the document is realized.

By the way, in the structure of patent document 1, as shown in FIG. 8 of the said document, the perimeter of the insulation coating material of the part (henceforth a "coil side part") which comprises the coil side part in a linear conductor. Is the same for all coil sides. On the other hand, as shown in FIG. 9 of the document, the final cross-sectional shape of each of the plurality of coil sides is different from each other depending on the arrangement position of each coil side. Here, while the sum of the cross-sectional areas of the plurality of conductor strands constituting the conductor strand bundle is constant, the internal area of the insulation coating material is reduced in the degree of flatness of the cross-sectional shape of the coil side portion. There is a tendency to increase accordingly. Therefore, in the configuration of Patent Document 1, the degree of flatness of the cross-sectional shape between the state shown in FIG. 8 and the coil side portion arranged at the innermost radial direction (lower side in the drawing) in FIG. There is a risk that wrinkles will occur in the insulation coating material due to the large area difference between the total cross-sectional area of the plurality of conductor wires constituting the conductor wire bundle and the internal area of the insulation coating material for the coil sides that are greatly different. is there. This is because a plurality of coil sides are arranged so that a gap between adjacent coil sides becomes small, and a pressing force from adjacent coil sides acts on each coil side. is there. Such wrinkles of the insulating coating material may cause a decrease in the coil space factor and a decrease in the reliability of the rotating electrical machine.

Japanese Unexamined Patent Publication No. 2011-91943 (paragraphs 0049 to 0053, FIGS. 5 to 9)

Therefore, realization of a manufacturing method for manufacturing a linear conductor that can be easily wound around the core with a high space factor, and a rotating electrical machine in which the linear conductor is wound around the core with a high space factor. Realization of a manufacturing method for this purpose is desired.

The characteristic configuration of the manufacturing method for manufacturing a linear conductor for a coil of a rotating electrical machine according to the present invention is that a conductor wire bundle in which a plurality of conductor wires are assembled is surrounded by a flexible insulating coating material. Using a coated conductor wire bundle configured to be covered, and having a pressurizing step of pressurizing a processing target site in the covered conductor wire bundle in an intersecting direction intersecting an extending direction of the conductor wire bundle, In the pressurizing step, the insulating coating material at the site to be processed is plastically deformed to increase the peripheral length of the insulating coating material in an orthogonal cross section that is a cross section orthogonal to the extending direction.

Here, the “periphery of a conductor wire bundle” means the periphery (outer periphery) of a cross section in a plane orthogonal to the extending direction of the conductor wire bundle.

According to said characteristic structure, since the circumference in the orthogonal cross section of insulation coating material (henceforth only "perimeter") can be extended plastically by a pressurization process, the insulation coating material of the site | part to be processed Can be adjusted. Therefore, for the part to be processed, the circumference difference between the circumference of the insulation coating material and the circumference of the circumscribed curve circumscribing the conductor wire bundle can be kept short, and as a result, wrinkles occur in the insulation coating material. It is easy to suppress and increase the coil space factor.
Supplementally, since the number of conductor strands constituting the conductor strand bundle is constant, the perimeter of the circumscribed curve when a plurality of conductor strands constituting the conductor strand bundle are gathered with high density is the conductor It changes according to the shape of the orthogonal cross section of the wire bundle. According to the above characteristic configuration, the circumferential length of the insulating coating material is adjusted in accordance with the shape of the final orthogonal cross section of the part to be processed, and the circumferential length difference between the circumferential length of the insulating coating material and the circumferential length of the circumscribed curve Can be kept short. Therefore, wrinkles are generated in the insulation coating material on the coil side portion by winding the linear conductor around the core so that the processing target portion becomes the coil side portion that is a portion of the coil disposed in the slot. This can be suppressed, and as a result, the space factor of the coil can be increased.
As described above, according to the above characteristic configuration, it is possible to manufacture a linear conductor that can be easily wound around the core with a high space factor.

The characteristic configuration of the method for manufacturing a rotating electrical machine according to the present invention includes the above-described method for manufacturing a linear conductor, and a plurality of slots extending in the axial direction of a cylindrical core reference surface are distributed in the circumferential direction of the core reference surface. In the manufacturing method of manufacturing a rotating electrical machine in which a coil composed of the linear conductor is wound around a core, and in the pressurizing step, the coated conductor strand bundle is arranged in the slot. A part corresponding to a coil side part which is a coil part is set as the part to be processed, and an insertion step of inserting the part to be processed into the slot is provided.

According to the above characteristic configuration, the linear conductor wound around the core is a linear conductor that can be easily wound around the core with a high space factor as described above. It is possible to manufacture a rotating electrical machine in which a conductor is wound around a core.

Here, in the insertion step, it is preferable that the portion to be processed after being pressurized in the pressurization step is inserted into the slot.

According to this configuration, in the pressurization process, compared to the case where the pressurization process is performed on the processing target portion after being inserted into the slot by the insertion process, for example, a device such as a jig used in the pressurization process Restrictions on the shape, dimensions, etc. can be relaxed, and the pressurization process can be simplified.
Further, according to this configuration, the circumference difference between the circumference of the insulating coating material at the site to be processed and the circumference of the circumscribed curve according to the final cross-sectional shape of the coil side corresponding to the site to be processed However, the insertion process can be executed in a short state. Therefore, in the insertion process, the restoring force generated in the insulating coating material is suppressed at the time of execution of the insertion process as compared with the case where the processing target part before being pressurized in the pressurizing process is inserted into the slot. It is easy to change the shape of the orthogonal cross section to the final cross sectional shape of the coil side portion corresponding to the processing target site in the slot, and as a result, the manufacturing process can be simplified.

As described above, in the insertion step, the insulating portion that electrically insulates the coil side portion and the core in the configuration in which the portion to be processed after being pressed in the pressing step is inserted into the slot. An insulating step of providing a portion along the inner surface of the slot, and in the inserting step, the portion to be processed is inserted into the slot in which the insulating portion is provided by the insulating step. The portion to be processed is arranged inside the slot in a predetermined arrangement direction, and the arrangement direction is such that the portion to be pressed in the pressing step in the insulating coating material is in the circumferential direction with respect to the insulating portion. It is preferable to adopt a configuration in which they face each other.

According to this configuration, the electrical insulation between the coil side and the core, and the coil side and another member disposed adjacent to the coil side in the radial direction (hereinafter simply referred to in this paragraph) It is easy to appropriately ensure both the electrical insulation between the “other member” and the other member. As a supplementary explanation, the thickness (for example, the average value or the minimum value, the same applies hereinafter) of the insulating coating material by pressing the insulating coating material is generally the portion other than the pressing target portion (pressing material) in the insulating coating material. It becomes smaller than the thickness of the non-target portion. This is because, in addition to the plastic target extending by the execution of the pressing step, the pressing target portion is pressed against the inner surface of the pressing target portion during the pressing step, and the conductor strand in the pressing target portion is indented. This is because the portion is easily thinned. Further, in the above configuration, since the insulating portion is provided along the inner surface of the slot by the insulating process, it is possible to ensure electrical insulation between the coil side portion and the inner surface (that is, the core) of the slot. In addition to the insulating coating material, the insulating portion can be used. On the other hand, the electrical insulation between the coil side and the other member is mainly achieved when, for example, the other member is another coil side, the insulation coating material for these two coil sides. Need to be used only. Therefore, the insulation performance required for the insulation coating material is generally lower between the coil side and the insulating part than between the coil side and the other member. In view of these points, according to the above configuration, the portion to be processed is arranged such that the portion to be pressed is opposed to the insulating portion in the circumferential direction. That is, the pressing target portion with the smaller thickness is disposed in the facing portion of the coil side portion with the insulating portion, and the pressing non-target portion with the larger thickness is disposed in the facing portion with the other member of the coil side portion. The As a result, it becomes easy to appropriately ensure both the electrical insulation between the coil side and the core and the electrical insulation between the coil side and the other member.

Alternatively, in the inserting step, a plurality of the processing target portions are inserted into the slot, and a plurality of the processing target portions are disposed inside the slot in a predetermined arrangement direction, It is also preferable that the non-pressing target portion other than the pressing target portion in the pressurizing step in the insulating coating material is oriented in the circumferential direction with respect to the inner surface of the slot.

According to this configuration, even if the insulating portion that electrically insulates the coil side portion and the core is not provided along the inner surface of the slot, the electrical insulation between the coil side portion and the core, Appropriate both electrical insulation between the coil side and another member (hereinafter simply referred to as “other member” in this paragraph) disposed radially adjacent to the coil side. It is easy to ensure. Supplementally, as described above, the thickness of the pressing target portion of the insulating coating material is generally smaller than the thickness of the non-pressing target portion of the insulating coating material by executing the pressing step. When the other member is another coil side, generally, the potential difference between the coil side and the inner surface of the slot (that is, the core) is the potential difference between the coil side and the other member. Compared to larger. Therefore, when the insulating portion is not provided along the inner surface of the slot, the insulating performance required for the insulating covering material is generally higher than that between the coil side portion and the other member. It is higher between the inner surface. In view of these points, according to the above configuration, the portion to be processed is arranged such that the non-pressing target portion is opposed to the inner surface of the slot in the circumferential direction. That is, the pressing non-target portion with the larger thickness is disposed at the facing portion of the coil side portion with the inner surface of the slot, and the pressing target portion with the smaller thickness is disposed at the facing portion with the other member of the coil side portion. Is done. As a result, it becomes easy to appropriately ensure both the electrical insulation between the coil side and the core and the electrical insulation between the coil side and the other member.

In the manufacturing method of the rotating electric machine having each configuration described above, in the insertion step, a plurality of the processing target portions are inserted into the slots, and in the pressing step, the circumferential direction in the orthogonal cross section of the coil side portion is inserted. In order to increase the peripheral length of the insulating covering material of the coil side portion as the absolute value of the dimensional difference between the width and the radial width of the core reference surface in the orthogonal cross section increases, a plurality of It is preferable that the amount of pressure applied to each of the processing target portions is made different according to the absolute value of the dimensional difference of the coil side portion corresponding to each processing target portion.

According to this configuration, as the degree of flatness of the shape of the orthogonal cross section of the coil side portion increases, the peripheral length of the insulating coating material increases. Therefore, the circumferential length difference between the circumference of the circumscribed curve, which becomes longer as the degree of flatness of the shape of the orthogonal cross section of the coil side portion becomes higher, and the circumferential length of the insulating coating material, It becomes easy to increase the space factor of the coil by keeping each short.

As described above, in the insertion step, a plurality of the processing target sites are inserted into the slots, and in the insertion step, the circumferential slot width is different depending on the radial position. It is preferable that the processing target site is inserted into the slot.

When the slot width varies depending on the radial position, the degree of flatness of the cross-sectional shape of the coil side portion tends to increase as the slot width increases. Therefore, also in such a case, the circumference difference between the circumference of the insulating coating material and the circumference of the circumscribed curve can be kept short for each of the plurality of coil sides. That is, according to the above configuration of the present invention, the degree of freedom of the shape of the core can be increased, and the performance of the rotating electrical machine can be improved.

In the manufacturing method of the rotating electric machine having each configuration described above, in the insertion step, the processing is performed inside the slot formed so that the slot width in the circumferential direction differs according to the radial position of the core reference surface. A plurality of target portions are inserted, and a plurality of the processing target portions are arranged in a line along the radial direction inside the slot, and in the pressurizing step, the insulating coating material of the coil side portion is arranged. The amount of pressure applied to each of the plurality of processing target portions is increased so that the circumferential length becomes longer as the slot width increases based on the radial position where the coil side portion is disposed. It is preferable to adopt a configuration in which the coil side portion corresponding to the part to be processed is varied depending on the radial position.

According to this configuration, as the slot width increases, the circumferential length of the insulating coating material on the coil side portion to be arranged increases, so that the cross-sectional area of the coil side portion increases as the slot width increases. It is possible to manufacture a rotating electrical machine having a high space factor, which is a rotating electrical machine having a large flatness.

In addition, the insulating coating material is configured to be able to reduce the circumference by heating, and heats the part to be processed inserted into the slot by the insertion step to thereby insulate the part to be processed. It is preferable to further include a heating step for reducing the peripheral length of the covering material.

According to this configuration, in addition to increasing the peripheral length of the insulating coating material by the pressurizing step, it is possible to reduce the peripheral length of the insulating coating material by the heating step. Therefore, it becomes easy to adjust the peripheral length of the insulating coating material according to the shape of the final orthogonal cross section of the processing target site, and the peripheral length difference between the peripheral length of the insulating coating material and the peripheral length of the circumscribed curve is shortened. It becomes easy to suppress.

It is a perspective view of the rotary electric machine which concerns on embodiment of this invention. It is a partial sectional view of a stator concerning an embodiment of the present invention. It is a perspective view which shows the structure of the linear conductor which concerns on embodiment of this invention. It is sectional drawing which shows the structure of the linear conductor which concerns on embodiment of this invention. It is a schematic diagram which shows an example of the shape of the orthogonal cross section of the linear conductor which concerns on embodiment of this invention. It is a flowchart which shows the manufacturing method of the rotary electric machine which concerns on embodiment of this invention. It is a figure which shows typically the coil side part pressurization process and coil side part insertion process which concern on embodiment of this invention. It is a figure which shows an example of the shape of the orthogonal cross section of the linear conductor which concerns on embodiment of this invention. It is a flowchart which shows the manufacturing method of the rotary electric machine which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part insertion process which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part pressurization process which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part insertion process which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part pressurization process which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part insertion process which concerns on other embodiment of this invention. It is a figure which shows typically the coil side part pressurization process which concerns on other embodiment of this invention. FIG. 5 is a partial cross-sectional view of a stator according to another embodiment of the present invention. It is a flowchart which shows the manufacturing method of the rotary electric machine which concerns on other embodiment of this invention. FIG. 5 is a partial cross-sectional view of a stator according to another embodiment of the present invention.

Embodiments of the present invention will be described with reference to the drawings. Here, a case where the present invention is applied to an inner rotor type rotating electrical machine 100 (see FIG. 1) will be described as an example. In this embodiment, the rotating electrical machine 100 is a rotating field type rotating electrical machine, and the core to be wound with the coil 3 is the core of the stator 1 (stator core 2). That is, the stator core 2 corresponds to a “core” in the present invention. In this specification, the rotating electrical machine is used as a concept including a motor (electric motor), a generator (generator), and a motor / generator that performs both functions of the motor and the generator as necessary.

In the following description, unless otherwise specified, the “axial direction L”, “circumferential direction C”, and “radial direction R” are the cylindrical core reference surface 21 (see FIGS. 1 and 2). ) Axis. The “diameter first direction R1” and the “diameter second direction R2” represent a direction toward the inner side and an outer side of the radial direction R of the core reference surface 21, respectively. In the present specification, terms relating to the arrangement direction, arrangement position, and the like of each member are used as a concept including a state in which there is a difference due to an error (an error that is acceptable in manufacturing).

1. Overall configuration of rotating electrical machine The overall configuration of the rotating electrical machine 100 according to the present embodiment will be described. As shown in FIG. 1, the rotating electrical machine 100 includes a stator 1 and a rotor 6 that is rotatably provided on the first radial direction R1 side of the stator 1 (that is, radially inner side). The stator 1 includes a stator core 2 and a coil 3 wound around the stator core 2. The stator core 2 is formed using a magnetic material. In FIG. 1, in order to avoid complication, only the portion protruding from the pair of slots 22 is shown for the coil end portion which is the portion of the coil 3 protruding from the stator core 2 in the axial direction L, and the other portions are not shown. Is omitted. In FIG. 1, a cross section of a coil side portion 71 that is a portion of the coil 3 disposed in the slot 22 appears at the end portion in the axial direction L of the remaining slot 22. Further, in FIG. 1, the rotor 6 is shown in a simplified manner, and a part of the rotor 6 is drawn in perspective.

The stator core 2 is integrally formed at least in the circumferential direction C. That is, the stator core 2 does not have a circumferential joint that joins a portion divided in the circumferential direction C in the circumferential direction C. For example, in the case where a cylindrical core is formed by bending a rectangular parallelepiped core, or in the case where a cylindrical core is formed by arranging a plurality of divided cores in the circumferential direction, the circumferential joint portion is adjacent to each other in the circumferential direction. It is formed in order to join end faces. In the present embodiment, the stator core 2 is integrally formed in the circumferential direction C and the radial direction R, and is not integrally formed in the axial direction L. That is, the stator core 2 has an axial joint that joins the part divided in the axial direction L in the axial direction L. In the present embodiment, the stator core 2 is formed by laminating a plurality of annular plate-like magnetic plates 7 in the axial direction L, as shown in FIG. The magnetic plates 7 in the laminated state are joined to each other by welding or caulking or the like, and the joint between the magnetic plates 7 adjacent in the axial direction L constitutes the above-described axial joint. As the magnetic plate 7, for example, an electromagnetic steel plate (for example, a silicon steel plate) can be used.

The stator core 2 has a plurality of slots 22 distributed in the circumferential direction C. A tooth 23 is formed between two slots 22 adjacent to each other in the circumferential direction C. The above-described “cylindrical core reference surface 21” is a virtual surface that serves as a reference for the arrangement and configuration of the slots 22, and in the present embodiment, a plurality of (the same number as the slots 22) teeth 23 in the first diameter direction. A cylindrical virtual surface (core inner peripheral surface) including the end surface on the R1 side is used as the core reference surface 21. A surface on the second radial direction R2 side (core outer peripheral surface) of the stator core 2 may be used as the core reference surface 21.

The plurality of slots 22 are distributed at regular intervals along the circumferential direction C. Each slot 22 extends in the axial direction L and is formed to have an opening 22b on the first radial direction R1 side. The slot 22 is formed so as to penetrate the stator core 2 in the axial direction L. The slots 22 are formed so as to extend radially from the axis of the core reference surface 21 in the radial direction R. In the present embodiment, as shown in FIG. 2, the opening width W1, which is the width in the circumferential direction C of the opening 22b, is the circumferential direction C inside the slot 22 (the portion on the radial second direction R2 side from the opening 22b). The slot 22 is formed so as to be narrower than the internal width W2, which is the width of the. That is, in the present embodiment, the slot 22 is a semi-open slot.

In the present embodiment, as shown in FIG. 2, each tooth 23 is a parallel tooth in which two tooth side surfaces 23 a facing opposite sides in the circumferential direction C are parallel to each other, and each slot 22 has a width in the circumferential direction C. Is formed so as to gradually become wider toward the second radial direction R2. That is, each slot 22 is formed so that the slot width W, which is the width in the circumferential direction C, differs depending on the position in the radial direction R. Moreover, in this embodiment, the circumferential direction protrusion part 23b which protrudes in the circumferential direction C with respect to the other part of the teeth side surface 23a is formed in the front-end | tip part of each teeth 23, and the opening part 22b of the slot 22 is formed. The space is formed as a space sandwiched on both sides in the circumferential direction C by the circumferential protrusion 23b. As shown in FIG. 2, in this embodiment, a slot insulating portion 24 is formed on a wall surface portion (a portion including the tooth side surface 23 a) that forms the slot 22 in the stator core 2. Therefore, in this embodiment, the slot width W (opening width W1 and internal width W2) of the slot 22 depends on the thickness of the slot 23 in addition to the circumferential width C and the arrangement pitch of the teeth 23. Determined. The slot insulating part 24 is formed by, for example, insulating powder coating or a slot insulating sheet.

In this embodiment, the rotating electrical machine 100 is a three-phase AC motor or a three-phase AC generator driven by a three-phase AC (an example of a multi-phase AC). The coil 3 includes a U-phase coil, a V-phase coil, and a W-phase coil corresponding to each of the three phases (U-phase, V-phase, and W-phase). And the W-phase slots 22 are arranged so as to repeatedly appear along the circumferential direction C. Although details are omitted, for example, the coil 3 can be configured by winding the linear conductor 4 around the stator core 2 by a combination of one of lap winding and wave winding and one of concentrated winding and distributed winding. .

2. Next, the configuration of the linear conductor 4 according to this embodiment will be described. The linear conductor 4 is a conductor constituting the coil 3, and the coil 3 is configured by winding the linear conductor 4 around the stator core 2. As shown in FIG. 3, the linear conductor 4 is configured by covering the periphery of a bare conductor wire bundle 42 in which a plurality of flexible bare conductor wires 41 are assembled with a flexible insulating coating material 46. Has been. Here, the “bare conductor wire” is a bare conductor wire whose surface is not covered with an insulator. Therefore, a conductor wire provided with a coating or a coating with an electrically insulating material such as resin on its surface is not included in the bare conductor wire. On the other hand, a conductor wire having an oxide film formed on the surface is included in the bare conductor wire. In the present embodiment, the bare conductor wire 41 corresponds to a “conductor wire” in the present invention, and the bare conductor wire bundle 42 corresponds to a “conductor wire bundle” in the present invention.

The bare conductor wire 41 is a linear bare conductor, and is made of, for example, copper or aluminum. In the present embodiment, the bare conductor wire 41 has a circular cross-sectional shape orthogonal to the extending direction. For example, a bare wire having a diameter (wire diameter) of 0.2 mm or less is used as the bare conductor wire 41. be able to. The surface of the bare conductor wire 41 is not covered with an insulator, and the conductor surface is exposed. The “insulator” here does not include an oxide film formed by oxidizing the surface of the conductor. A plurality of such bare conductor strands 41 are assembled to form a bare conductor strand bundle 42. The bare conductor strand bundle 42 is configured by twisting and bundling a plurality of bare conductor strands 41 or by bundling a plurality of bare conductor strands 41 without twisting.

The insulating coating material 46 is a flexible electrical insulating member, and is made of, for example, a synthetic resin such as a fluorine resin, an epoxy resin, or polyphenylene sulfide. Here, “flexibility” means a property that can be bent or bent. In the present embodiment, the insulating coating material 46 also has stretchability. Here, “stretchability” is a property that can be stretched or shrunk. The insulating covering material 46 is provided so as to cover the periphery of the bare conductor wire bundle 42. Specifically, the insulation coating material 46 covers the entire circumference of the bare conductor strand bundle 42 and extends in the extending direction except for the connection portion provided at the end in the extending direction A of the bare conductor strand bundle 42. It is provided so as to cover the entire area along A. Here, the connecting portion is a portion for electrically connecting one linear conductor 4 to another linear conductor 4 or another conductor. In the present embodiment, the insulating coating material 46 is made of a flexible sheet-like material (tubular material) that wraps around the bare conductor wire bundle 42.

In FIG. 4, an external force (excluding gravity, the same applies hereinafter) acts on an unprocessed portion of the linear conductor 4 where a coil side pressurizing step # 01 (see FIGS. 6 and 7) described later is not performed. The shape of the cross section (henceforth an "orthogonal cross section") in the extended orthogonal plane P in the state which has not been shown is shown. Here, the extending orthogonal plane P is a plane orthogonal to the extending direction A of the bare conductor strand 42, as shown in FIG. As shown in FIG. 4, in the present embodiment, in the unprocessed portion of the linear conductor 4, the plurality of bare conductor strands 41 are in close contact with each other and gather together with high density, and the bare conductor strand bundles 42 are orthogonal to each other. The cross-sectional shape (outer shape) is a perfect circle when no external force is applied. The shape of the orthogonal cross-section of the insulating coating material 46 is a circumscribed curve that circumscribes the bare conductor wire bundle 42, and specifically, a perfect circle shape that follows the true circular shape of the bare conductor wire bundle 42. A symbol “Z” in FIG. 4 represents a “reference circumferential length” that is a circumferential length of an orthogonal cross section of the insulating coating material 46 in a state where no external force is applied to the linear conductor 4.

On the other hand, FIG. 8 shows the shape of the orthogonal cross-section of the insulating covering material 46 at the processed portion where the coil side pressurizing step # 01 (see FIGS. 6 and 7), which will be described later, is performed on the linear conductor 4. An example of the shape of the orthogonal cross section in the state deformed into the shape is shown. In FIG. 8, the number of bare conductor wires 41 is less than that in FIG. 4 for simplification. In a state where no external force is applied to the linear conductor 4, the insulating coating material 46 is stable in a state where the shape of the orthogonal cross section is a perfect circle as shown in FIG. Although details will be described later, the reference circumferential length Z of the insulating coating material 46 increases by the execution of the coil side pressurizing step # 01. Therefore, the area difference between the sum of the areas of orthogonal cross sections (hereinafter simply referred to as “cross-sectional areas”) of the plurality of bare conductor strands 41 constituting the bare conductor strand bundle 42 and the internal area of the insulating coating material 46 is When the shape of the orthogonal cross section of the insulating coating material 46 is a perfect circle, the processed part (see FIG. 8) is larger than the unprocessed part (see FIG. 4). Here, the internal area of the insulating coating material 46 is a cross-sectional area of an internal space formed inside the insulating coating material 46 in the radial direction by the inner surface of the insulating coating material 46. Since the internal area of the insulation coating material 46 is reduced by flattening the shape of the orthogonal cross section of the insulation coating material 46, illustration is omitted, but when the cross sectional shape of the linear conductor 4 shown in FIG. The above area difference is reduced.

As described above, the shape of the orthogonal cross section of the bare conductor wire 41 is circular. Therefore, as shown in FIG. 4, there is a gap G between the bare conductor strands 41 constituting the bare conductor strand bundle 42 or between the bare conductor strands 41 and the inner peripheral surface of the insulating coating material 46. Is formed. The plurality of bare conductor wires 41 constituting the unprocessed portion of the linear conductor 4 are in close contact with each other and gathered at a high density as shown in FIG. The gap G formed in is relatively small. Therefore, when a relatively large external force does not act on the linear conductor 4, the plurality of bare conductor strands 41 do not move relative to each other in the radial direction R. On the other hand, as shown in FIG. 8, the plurality of bare conductor wires 41 constituting the processed portion of the linear conductor are gathered at a lower density than the unprocessed portion (see FIG. 4). A relatively large gap G is formed inside the covering material 46. Therefore, even if a large external force does not act on the linear conductor 4, the plurality of bare conductor strands 41 can move relative to each other in the radial direction R. That is, an in-coating gap in which the bare conductor wires 41 can move relative to each other is formed inside the insulating coating material 46. In the example shown in FIG. 8, the density of the bare conductor wires 41 inside the insulating coating material 46 is shown as an example in which the radial inner region is higher than the radial outer region.

As described above, the insulating coating material 46 is made of a material having flexibility and stretchability. Therefore, the linear conductor 4 can change the shape of an orthogonal cross section, as shown in FIG.5 and FIG.7. That is, following the deformation of the insulating coating material 46, the plurality of bare conductor wires 41 move relative to each other in the inside thereof, whereby the shape of the orthogonal cross section of the linear conductor 4 is deformed. As shown in FIG. 8, the processed portion of the linear conductor 4 has a low density of the plurality of bare conductor strands 41 when the shape of the orthogonal cross section of the linear conductor 4 is a perfect circle. Have gathered. Therefore, when flattening the shape of the orthogonal cross section of the processed part, the insulation covering material 46 increases in circumference until the plurality of bare conductor wires 41 come into close contact with each other and gather together at a high density. Deforms without accompanying. Therefore, the shape of the orthogonal cross section of the linear conductor 4 can be easily changed. Note that after the plurality of bare conductor wires 41 are brought into close contact with each other and gathered at a high density, the insulating coating 46 is deformed with an increase in peripheral length due to elastic or plastic deformation. On the other hand, as shown in FIG. 4, the unprocessed portion of the linear conductor 4 has a plurality of bare conductor strands 41 in close contact with each other even when the shape of the orthogonal cross section of the linear conductor 4 is a perfect circle. Are gathered at a high density. Therefore, when flattening the shape of the orthogonal cross section of the unprocessed portion, the insulating coating material 46 is deformed with an increase in peripheral length due to elastic or plastic deformation even when the flatness is small. .

In the present embodiment, as shown in FIG. 7, the width (circumferential direction) in the circumferential direction C in a state where the shape of the orthogonal cross section of the unprocessed portion of the linear conductor 4 is a perfect circle (see FIG. 7A). Width D), that is, the diameter in a state where the cross-sectional shape of the unprocessed portion of the linear conductor 4 is a perfect circle is set to be larger than the opening width W1 of the slot 22. As shown in FIG. 7C, the linear conductor 4 has a circumferential width D having a first circumferential width D1 narrower than the opening width W1 and a second circumferential width D2 wider than the opening width W1. It can be deformed between.

3. Coil Arrangement Configuration Next, an arrangement configuration of the coil 3 according to the present embodiment will be described. As shown in FIGS. 1 and 2, the coil 3 includes a coil side portion 71 disposed in the slot 22, and a transition portion 72 that connects the two coil side portions 71 to each other outside in the axial direction L of the stator core 2. It has. The coil side portion 71 is formed in a straight line parallel to the axial direction L. The crossover portion 72 is arranged outside the stator core 2 in the axial direction L to form a coil end portion, and in the example shown in FIG. 1, the two coil side portions 71 arranged at a distance of 6 slots are connected to each other. Are arranged as follows.

As shown in FIG. 2, a plurality of coil side portions 71 are arranged inside the slot 22. Specifically, the coil side portions 71 are arranged in a plurality of layers B so as to be arranged in a line along the radial direction R at the same position in the circumferential direction C. Here, the layer B represents the position (arrangement region) in the radial direction R of each coil side portion 71 in the slot 22. In the present embodiment, the coil side portion 71 is divided into an odd number of layers B, and specifically, is divided into five layers B. Hereinafter, the layer B closest to the second radial direction R2 in the slot 22 is defined as a first layer B1, and the second layer B2, the third layer B3, and the fourth layer are sequentially formed from the first layer B1 toward the first radial direction R1. Let B4 be the fifth layer B5. In the present embodiment, the linear conductor 4 constituting the coil 3 is wound around the stator core 2 so as to be included in one linear conductor 4 in which a plurality of coil side portions 71 are continuous. That is, in the present embodiment, a plurality of processing target parts to be pressed by the coil side pressing step # 01 described later are included in one continuous linear conductor 4. Here, “continuous” for the linear conductor 4 means that the bare conductor wire 41 or the insulating coating material 46 is integrally formed in the extending direction A without a seam.

As shown in FIG. 2, the shape of the orthogonal cross section of each coil side portion 71 has a contact surface that is in surface contact with the inner wall surface of the slot 22 (in this example, in surface contact via the slot insulating portion 24), It has a rectangular shape having a contact surface in surface contact with the outer peripheral surface of the coil side portion 71 adjacent in the radial direction R. Thereby, both the clearance gap between the coil side part 71 and the inner wall face of the slot 22, and the clearance gap between coil side parts 71 can be restrained small, As a result, the space factor of the coil 3 is raised. Is possible. Each slot 22 is formed so that the slot width W varies depending on the position in the radial direction R, and the shape of the slot 22 varies depending on the layer B. Therefore, the plurality of coil side portions 71 arranged in the same slot 22 are different from each other in the shape of the orthogonal cross section. In the present embodiment, as shown in FIG. 2, each slot 22 is formed so that the slot width W gradually becomes wider toward the second radial direction R <b> 2. That is, assuming that the layer B at the position in the radial direction R having the largest slot width W is a “specific layer”, in the present embodiment, the first layer B1 is the specific layer.

As will be described later, in the present embodiment, the plurality of coil sides 71 arranged in the same slot 22 are configured to have substantially the same cross-sectional area. Therefore, in the present embodiment, as shown in FIG. 2, the plurality of coil sides 71 arranged in each of the slots 22 is based on the position (region) in the radial direction R where each of the coil sides 71 is arranged. Thus, as the slot width W increases, the aspect ratio (= the width in the circumferential direction C / the width in the radial direction R) is a ratio of the width in the circumferential direction C to the width in the radial direction R in the orthogonal cross section of the coil side portion 71. (Width) is larger. That is, the plurality of coil side portions 71 arranged in each of the slots 22 have a flattened degree of orthogonal cross section formed in a rectangular shape as the slot width W increases. In the present embodiment, each slot 22 is formed so that the slot width W gradually becomes wider toward the second radial direction R2 side, so that the Nth layer (N = 1, 2,... 4) is formed. The aspect ratio in the orthogonal cross section of the coil side portion 71 disposed is larger than the aspect ratio in the orthogonal cross section of the coil side portion 71 disposed in the (N + 1) th layer. When the aspect ratio in the orthogonal cross section of the linear conductor 4 is 1 or more, if the aspect ratio increases, the absolute difference in dimension between the width in the circumferential direction C and the width in the radial direction R in the orthogonal cross section of the linear conductor 4 The value increases. Therefore, in the present embodiment, the plurality of coil sides 71 arranged in each of the slots 22 has a large slot width W based on the position (region) in the radial direction R where each of the coil sides 71 is arranged. Accordingly, the absolute value of the dimensional difference between the width in the circumferential direction C and the width in the radial direction R in the orthogonal cross section of the coil side portion 71 increases.

As described above, in the present embodiment, the plurality of coil sides 71 arranged in the same slot 22 are configured so that the cross-sectional areas are substantially the same. The reason for adopting such a configuration is as follows. That is, in order to increase the space factor of the coil 3, as shown schematically in FIG. 5, a plurality of coil side portions 71 that are arranged in the slot 22 are configured as a plurality. It is desirable that the bare conductor wires 41 of each other are in close contact with each other and are gathered at a high density. Here, FIG.5 (b) shows the shape of the orthogonal cross section of the coil side part 71 arrange | positioned at 1st layer B1, FIG.5 (c) shows the coil side part 71 arrange | positioned at 5th layer B5. The shape of an orthogonal cross section is shown. FIG. 5A shows the shape of the orthogonal cross section of the unprocessed portion of the linear conductor 4 as in FIG. In FIG. 5, the number of bare conductor wires 41 is less than that in FIG. 4 for simplification.

Since the number of bare conductor wires 41 included in the insulation coating material 46 is constant, the sum of the cross-sectional areas of the plurality of bare conductor wires 41 is constant regardless of the shape of the orthogonal cross section of the coil side portion 71. become. Therefore, a plurality of coils arranged in the same slot 22 by making the cross-sectional area of the coil side portion 71 (that is, the internal area of the insulating coating material 46) substantially equal regardless of the shape of the orthogonal cross section of the coil side portion 71. For each of the side portions 71, the sum of the cross-sectional areas of the gaps G formed inside the insulating coating material 46 can be kept small, and the space factor of the coil 3 can be increased.

By the way, the internal area of the insulation coating material 46 is maximized when the shape of the orthogonal cross section of the linear conductor 4 is a perfect circle (see FIG. 5A) if the circumference of the insulation coating material 46 is constant. . Further, when the shape of the orthogonal cross section of the linear conductor 4 is rectangular, the inner area of the insulating coating material 46 is as long as the peripheral length of the insulating coating material 46 is constant. As is clear from the comparison with (c), the aspect ratio decreases as the aspect ratio increases. In addition, the two-dot chain line in FIG.5 (c) has the same aspect-ratio as the insulation coating material 46 of the coil side part 71 of 1st layer B1 shown in FIG.5 (b) with the insulation coating material 46 of 5th layer B5. This shows a state of being deformed. FIG. 5A shows a state in which the insulation coating material 46 of the coil side portion 71 of the first layer B1 shown in FIG. 5B is deformed into a perfect circle by a two-dot chain line. A state where the insulating coating material 46 of the coil side portion 71 of the fifth layer B5 shown in 5 (c) is deformed into a perfect circle is indicated by another two-dot chain line. As is apparent from FIG. 5, in order to make the cross-sectional area of the coil side portion 71 substantially equal regardless of the shape of the orthogonal cross section of the coil side portion 71, the insulating coating material 46 in the state shown in FIG. It is necessary to make the perimeter of the orthogonal cross section longer than the perimeter of the orthogonal cross section of the insulation coating material 46 in the state shown in FIG. 5A, and further, the insulation coating in the state shown in FIG. It is necessary to make the circumference of the orthogonal cross section of the material 46 longer than the circumference of the orthogonal cross section of the insulating coating material 46 in the state shown in FIG.

It is conceivable as one method to realize the above-described relationship between the circumferential lengths of the orthogonal cross sections of the insulating coating material 46 only by elastically deforming the insulating coating material 46. However, in this case, as the aspect ratio of the orthogonal cross section of the insulating coating material 46 increases, the elastic extension amount (elastic extension amount) of the peripheral length of the insulating coating material 46 becomes longer, and the restoration generated in the insulating coating material 46. Depending on the magnitude of the force (tension), it may be difficult to make the shape of the orthogonal cross section of the coil side portion 71 a desired shape in the slot 22. That is, in such a method, there is a possibility that the process of winding the linear conductor 4 around the stator core 2 may be complicated.

In view of this point, in the present embodiment, the reference peripheral length Z of the insulating coating material 46 of the coil side portion 71 is determined based on the aspect ratio in a state where the coil side portion 71 is disposed in the slot 22. The length is set longer as the ratio increases. In other words, in the present embodiment, the reference circumferential length Z of the insulating coating material 46 of the coil side portion 71 is set to the width and diameter in the circumferential direction C in the orthogonal cross section in a state where the coil side portion 71 is disposed in the slot 22. The absolute value of the dimensional difference from the width in the direction R is increased as the absolute value increases. Here, the reference circumferential length Z is the circumferential length of the orthogonal cross section of the insulating coating material 46 in a state where no external force is applied to the linear conductor 4 as described above with reference to FIG. . Even when no external force is applied to the linear conductor 4, a certain amount of force is required to change the shape of the orthogonal cross section of the bare conductor strand 42. Therefore, even when no external force is applied to the linear conductor 4, it is assumed that the peripheral length of the insulating coating material 46 is elastically extended by the force received from the bare conductor strand 42. . In this case, the elastic extension amount of the circumferential length can be a different value depending on the shape of the orthogonal cross section of the bare conductor strand 42. In this regard, in the state where no external force is acting on the linear conductor 4, the linear conductor 4 is generally considered to be stable in a state where the shape of the orthogonal cross section is a perfect circle. Therefore, in this specification, the reference circumferential length Z is the circumferential length of the orthogonal cross section of the insulating coating material 46 when the shape of the orthogonal cross section of the linear conductor 4 is a perfect circle. That is, the reference circumference Z basically matches the circumference (natural circumference) of the orthogonal cross section of the insulation coating material 46 when the bare conductor wire bundle 42 does not exist inside the insulation coating material 46. .

In this embodiment, as described above, the aspect ratio increases as the slot width W increases. Therefore, in the present embodiment, the plurality of coil side portions 71 arranged in each of the slots 22 have the slot width W increased based on the position in the radial direction R where each of the coil side portions 71 is arranged. Accordingly, the reference circumferential length Z of the insulating coating material 46 is increased. Specifically, each slot 22 is formed such that the slot width W gradually becomes wider toward the second radial direction R2. Therefore, the reference peripheral length Z of the insulating coating material 46 of the coil side portion 71 arranged in the Nth layer (N = 1, 2,... 4) is the coil side portion 71 arranged in the (N + 1) th layer. It is longer than the reference circumferential length Z of the insulating coating material 46. That is, the insulating coating material 46 of the coil side portion 71 disposed in the first layer B1 that is the layer B in the radial direction R where the slot width W is the largest is at least one of the layers B other than the first layer B1. The reference circumferential length Z is longer than the insulating covering material 46 of the coil side portion 71 arranged in the coil. In this embodiment, the insulating coating of the coil side portion 71 arranged in all the layers B other than the first layer B1 is used. The reference circumferential length Z is longer than that of the material 46. In other words, one of the plurality of coil side portions 71 and at least one other coil side portion 71 arranged in the same slot 22 are different in the reference circumferential length Z of the insulating coating material 46. In the present embodiment, one of the plurality of coil side parts 71 and the other coil side parts 71 arranged in the same slot 22 have different reference peripheral lengths Z of the insulating covering material 46.

By adopting the configuration as described above, in the state where the shape of the orthogonal cross section of the coil side portion 71 is deformed to the shape arranged in the slot 22, the insulating coating material 46 of the coil side portion 71 is changed. The amount of elastic extension of the circumference can be kept short, and as a result, the process of winding the linear conductor 4 around the stator core 2 can be simplified. The amount of elastic extension is determined according to the difference between the reference circumference Z and the design circumference having a value equal to or greater than the reference circumference Z. Here, the design circumference is a design circumference of an orthogonal cross section of the insulating coating material 46 in a state where the coil side portion 71 is disposed in the slot 22 (see FIG. 2), and varies depending on the layer B. Set to a value. In the present embodiment, the reference peripheral length Z of the insulating coating material 46 is set to the same value as the design peripheral length for each of the plurality of coil side portions 71 disposed in the slot 22. Here, “same” includes a state where there is a difference due to an error (an error that is acceptable in manufacturing). As a result, the restoring force (tension) generated in the insulating coating material 46 due to the elastic extension amount of the circumference of each coil side portion 71 is substantially suppressed to zero, and the linear conductor 4 is fixed to the stator core 2. It is possible to further simplify the winding process.

As described above, in this embodiment, the reference circumferential length Z of the insulating coating material 46 is set to the same value as the design circumferential length. Therefore, each configuration described above regarding the setting of the length of the reference circumference Z is similarly established for the setting of the length of the design circumference. Specifically, one of the plurality of coil side portions 71 and at least one other (all other in this example) coil side portion 71 disposed in the same slot 22 are formed of the insulating coating material 46. Design circumference is different. In the present embodiment, the design peripheral length of the coil side portion 71 is set longer as the aspect ratio in the state where the coil side portion 71 is disposed in the slot 22 is increased. In other words, in this embodiment, the design peripheral length of the coil side portion 71 is the width between the circumferential direction C and the radial direction R in the orthogonal cross section when the coil side portion 71 is disposed in the slot 22. It is set longer as the absolute value of the dimensional difference increases. Further, in the present embodiment, the plurality of coil side portions 71 arranged in each of the slots 22 has a slot width W that increases based on the position in the radial direction R where each of the coil side portions 71 is arranged. Accordingly, the design circumference of the insulating coating material 46 is increased.

For at least one of the coil side portions 71 of the plurality of coil side portions 71 arranged in the slot 22, the reference peripheral length Z of the insulating coating material 46 of the coil side portion 71 is set shorter than the above-described design peripheral length. It is also possible to adopt a configuration. In this case, it is necessary to apply a pressing force in the radial direction R to the coil side portion 71 to elastically extend the circumferential length of the orthogonal cross section of the insulating coating material 46 to the design circumferential length. Therefore, in this case, the coil side portion 71 maintains a shape in a state where the coil side portion 71 is pressed by the pressing force in the radial direction R according to the difference between the reference circumferential length Z and the design circumferential length, and is in the slot 22. Be placed. As described above, when the reference circumferential length Z of the insulating coating material 46 is set to be shorter than the design circumferential length, at least a part of the configurations described above regarding the setting of the length of the reference circumferential length Z is the reference circumferential length. It is also possible to adopt a configuration that does not hold for the length Z but only holds for the design circumference.

4). Next, a method for manufacturing the rotating electrical machine 100 according to the present embodiment will be described with reference to the flowchart shown in FIG. As shown in FIG. 6, the process of manufacturing the rotating electrical machine 100 includes a coil side pressurizing step # 01 and a coil side inserting step # 02, and the coil 3 constituted by the linear conductors 4 is a stator core. The rotating electrical machine 100 wound around 2 is manufactured. Here, the coil side pressurizing step # 01 is a crossing direction E in which a portion corresponding to the coil side portion 71 in the linear conductor 4 (hereinafter referred to as “processing target portion”) intersects the extending direction A. This is a process of pressurizing (pressurizing process). That is, the part to be processed is set to a covered conductor wire bundle formed by covering the periphery of a bare conductor wire bundle 42 in which a plurality of bare conductor wires 41 are assembled with a flexible insulating coating material 46. This is a region along the extending direction A. In this coil side pressurizing step # 01, the insulating coating material 46 at the site to be processed is plastically deformed to increase the circumferential length of the insulating coating material 46. At this time, since the circumferential length of the insulating coating material 46 is plastically extended, the coil side pressing step # 01 is a step of increasing the reference circumferential length Z of the insulating coating material 46. In the present embodiment, as shown in FIG. 3, the intersecting direction E is set to a direction orthogonal to the extending direction A. In addition, the coil side insertion step # 02 is a step (insertion step) of inserting the processing target portion after being pressurized in the coil side pressurization step # 01 into the slot 22 from the opening 22b.

In the coil side pressurizing step # 01, the pressure in the crossing direction E exceeding the elastic limit is applied to the insulation coating material 46 at the site to be processed in the linear conductor 4 to the insulation coating material 46 Causes plastic deformation. At this time, it is possible to adopt a configuration in which the heat treatment for the insulating coating material 46 is also performed. In the present embodiment, as described above, the portion to be processed before the coil side pressurizing step # 01 is performed, as shown in FIG. 4, the shape of the orthogonal cross section of the bare conductor strand 42 is a perfect circle. The plurality of bare conductor strands 41 assembled in this way, and a perfectly circular insulating covering material 46 whose shape of the orthogonal cross section circumscribes the bare conductor strand bundle 42 are configured. Due to this plastic deformation, the reference circumferential length Z of the insulating coating material 46 increases, and the increase amount of the reference circumferential length Z increases as the amount of pressurization in the cross direction E increases. This coil side pressurizing step # 01 is a step of manufacturing the linear conductor 4 for the coil of the rotating electrical machine, and the manufacturing method of the rotating electrical machine 100 according to the present embodiment includes the manufacturing process of the linear conductor 4. A coil side pressurizing step # 01 is included.

In the present embodiment, in the coil side pressurizing step # 01, the reference circumferential length Z of the insulating coating material 46 of the coil side 71 is set to the slot width W based on the position in the radial direction R where the coil side 71 is disposed. The amount of pressure applied to each of the plurality of processing target sites is set so that the length of the coil side portion 71 corresponding to each processing target site is positioned in the radial direction R (layer) in the slot 22 so as to increase as the size increases. Different depending on B). In the present embodiment, as described above, the aspect ratio of the orthogonal cross section of the coil side portion 71 increases as the slot width W increases, and the width in the circumferential direction C of the orthogonal cross section of the coil side portion 71 increases. The absolute value of the dimensional difference from the width in the radial direction R increases. Therefore, in the present embodiment, a plurality of reference peripheral lengths Z of the insulating coating material 46 of the coil side portion 71 are increased as the absolute value of the dimensional difference in the orthogonal cross section of the coil side portion 71 increases. The amount of pressure applied to each of the processing target parts is varied according to the absolute value of the dimensional difference of the coil side portion 71 corresponding to each processing target part. In other words, pressure is applied to each of the plurality of processing target parts so that the reference peripheral length Z of the insulating coating material 46 of the coil side 71 increases as the aspect ratio in the orthogonal cross section of the coil side 71 increases. The amount is varied according to the aspect ratio in the orthogonal cross section of the coil side portion 71 corresponding to each processing target portion. In the present embodiment, the amount of pressurization in the cross direction E with respect to each processing target part is set so that the reference peripheral length Z of the insulating coating material 46 at the processing target part has the same value as the design peripheral length described above. Here, “same” includes a state where there is a difference due to an error (an error that is acceptable in manufacturing).

In the present embodiment, in the coil side pressurizing step # 01, as shown schematically in FIG. 7B, the processing target site in the linear conductor 4 is placed in the crossing direction E using the pressurizing jig 51. Pressurize. The pressing jig 51 abuts on the linear conductor 4 from the one side in the cross direction E, and a first pressing portion having a contact surface that abuts on the linear conductor 4 from the other side in the cross direction E. A second pressing portion having a contact surface. The pressing jig 51 is inserted into the pressing gap 51a between the first pressing portion and the second pressing portion in the linear conductor 4 by bringing the first pressing portion and the second pressing portion closer to each other in the crossing direction E. The formed portion is flattened to such an extent that plastic deformation occurs. In this embodiment, as shown in FIG.7 (b), the pressurization amount with respect to the process target site | part in the linear conductor 4 is adjusted by adjusting the width | variety of the crossing direction E of the press gap 51a. That is, as the pressing gap 51a becomes narrower, the reference circumferential length Z of the insulating coating material 46 becomes longer. The pressing portion of the pressing jig 51 has, for example, the same length in the axial direction L as the slot 22.

The increase of the reference circumferential length Z by the execution of the coil side pressing step # 01 is realized by reducing the thickness of the portion pressed by the pressing jig 51 in the insulating coating material 46. That is, as the reference circumferential length Z increases, the average value of the thickness of the insulating coating material 46 on the entire circumference decreases. Here, in the present embodiment, as described above, the plurality of coil side portions 71 arranged in each of the slots 22 is based on the position in the radial direction R where each of the coil side portions 71 is arranged. As W increases, the reference circumferential length Z of the insulating coating material 46 increases. Therefore, in the present embodiment, the plurality of coil side portions 71 arranged in each of the slots 22 have the slot width W increased based on the position in the radial direction R where each of the coil side portions 71 is arranged. Accordingly, the average value of the thickness of the insulating coating material 46 is reduced.

As shown in FIGS. 6 and 7, after executing the coil side pressurizing step # 01, the coil side inserting step # 02 is executed. In the present embodiment, in the coil side portion insertion step # 02, the processing target portion pressed in the coil side pressurizing step # 01 is moved to the second radial direction R2 side so that the processing target portion is opened in the opening 22b. Into the slot 22. At this time, as shown in FIG. 7C, the part to be processed was inserted into the slot 22 in a state where the circumferential width D was deformed so as to be the first circumferential width D1 narrower than the opening width W1. Then, it pushes in to the position (layer B) of the radial direction R where the said process target site | part should be arrange | positioned. Thereafter, the shape of the orthogonal cross section of the processing target portion is changed so as to match the cross sectional shape of the slot 22 by pressing the processing target portion toward the second radial direction R2 side opposite to the opening direction of the slot 22. In the present embodiment, as shown in FIG. 7, in the coil side portion insertion step # 02, a plurality of processing target parts (five in this example) are inserted into the slots 22, and the plurality of processing target parts are the slots 22. They are arranged in a line along the radial direction R inside.

In addition, although there are a plurality of processing target portions in the linear conductor 4, when the coil side pressurizing step # 01 is performed on each processing target portion, the coil side inserting step # 02 is performed on the processing target portion. It can be any time before the time when is executed. For example, the coil side portion inserting step # 02 may be performed after the coil side portion pressing step # 01 is performed on all the processing target parts included in one linear conductor 4. Or it can also be set as the structure by which the process is repeatedly performed by making the process which performs coil side part pressurization process # 01 and coil side part insertion process # 02 with respect to a single or several process object site | part as a repeating unit. .

5. Other Embodiments Finally, other embodiments of the present invention will be described. Note that the configurations disclosed in the following embodiments can be applied in combination with the configurations disclosed in other embodiments as long as no contradiction arises.

(1) In the above embodiment, in the coil side pressurizing step # 01, the insulation coating is performed in accordance with the increase in the slot width W based on the position in the radial direction R where each of the coil side 71 is disposed. The amount of pressurization in the cross direction E with respect to the processing target site is set in accordance with the position (layer B) in the radial direction where the processing target site is arranged in the slot 22 so that the reference circumferential length Z of the material 46 increases. The configuration to be different has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the insulation coating material 46 is configured so that the reference circumference Z can be reduced by heating, and as shown in FIG. 9, after the coil side insertion step # 02 is performed, the coil side heating step # 03 is performed. It is also possible to adopt a configuration that further executes the above. Here, the coil side portion heating step # 03 heats the coil side portion 71 inserted into the slot 22 by the coil side portion insertion step # 02 to heat the reference peripheral length Z of the insulating coating material 46 of the coil side portion 71. This is a step (heating step) for reducing the amount of heat. The insulating coating material 46 is made of a heat-shrinkable material such as FEP (a copolymer of tetrafluoroethylene and hexafluoropropylene), so that the reference circumference Z of the insulating coating material 46 can be increased by heating. Can be reduced. At this time, the amount of decrease in the reference circumferential length Z increases as the heating amount increases.

Specifically, in such a configuration, in the coil side pressurizing step # 01, the reference circumference Z is set to at least one of the coil sides 71 arranged in the slot 22. The amount of pressurization in the intersecting direction E with respect to the portion to be processed which is a portion corresponding to the coil side portion 71 in the linear conductor 4 is set so as to be longer than the above-described design circumference. For example, the same pressurization amount for all the coil side portions 71, specifically, the same value as the design circumference having the longest reference circumference Z (design circumference of the first layer B1 in the example shown in FIG. 2). It can be set as the structure which sets the pressurization amount which becomes. Here, “same” includes a state where there is a difference due to an error (an error that is acceptable in manufacturing). In the coil side heating step # 03, the reference peripheral length Z of the insulating coating material 46 is set according to the increase in the slot width W based on the position in the radial direction R where each of the coil side parts 71 is arranged. The heating amount for the coil side portion 71 is varied according to the position in the radial direction R where the coil side portion 71 is disposed so as to be longer. For example, it is preferable to set the heating amount for each coil side portion 71 so that the reference circumferential length Z of the insulating coating material 46 of the coil side portion 71 has the same value as the design circumferential length.

The coil side heating step # 03 for the coil side 71 may be performed each time one coil side 71 is inserted in the coil side insertion step # 02. The coil side heating step # 03 is collectively performed on the plurality of coil side parts 71 inserted by # 02 (for example, all the coil side parts 71 arranged in the same slot 22). You can also. In addition, the coil side heating step # 03 is performed in a state where the coil side 71 is pressed in the second radial direction R2 side and the coil side 71 is in contact with both side surfaces of the slot 22. Can do.

(2) In the above-described embodiment, the portion to be processed after the coil side portion insertion step # 02 (insertion step) is pressurized in the coil side portion pressurization step # 01 (pressurization step) The configuration which is the process of inserting into the above has been described as an example. However, the embodiment of the present invention is not limited to this. That is, in the flowchart shown in FIG. 6, a configuration in which the coil side pressing step # 01 and the coil side inserting step # 02 are interchanged is also a preferred embodiment of the present invention. In this case, the coil side insertion step is a step of inserting the processing target site before being pressurized in the coil side pressurization step into the slot 22 from the opening 22b, and the coil side pressurization step is the coil side pressurization step. This is a step of performing a pressurizing process on the portion to be processed after being inserted into the slot 22 by the insertion step. Hereinafter, as an example of such a configuration, a first example shown in FIGS. 10 and 11 and a second example shown in FIGS. 12 to 15 will be described.

[First example]
As shown in FIG. 10, in this example, the processing target site (unprocessed site) before being pressurized by the coil side pressurizing step is inserted into the slot 22 by the coil side inserting step. In the example shown in FIG. 10, the flattening tool 52 is used to flatten the width in the circumferential direction C of the portion to be processed in the linear conductor 4 to be narrower than the width in the circumferential direction C of the opening 22 b of the slot 22. The part to be processed is inserted into the slot 22. At this time, the part to be processed in the linear conductor 4 is elastically deformed to flatten the shape of the orthogonal cross section, and after being inserted into the slot 22, the shape of the orthogonal cross section returns to a perfect circle. Next, as shown in FIG. 11, the coil side pressurizing step is executed, and the portion to be processed in the linear conductor 4 inserted into the slot 22 is the diameter opposite to the opening direction of the slot 22. Pressurize in the second direction R2 side. In the example illustrated in FIG. 11, the processing target site is pressed from the first radial direction R1 side using the pressing jig 53 to increase the reference peripheral length Z of the insulating coating material 46 of the processing target site.

In this first example, as shown in FIG. 11, the coil side pressurizing step is collectively performed on a plurality of processing target portions arranged in the radial direction R, and each insulating coating material of the plurality of processing target portions is performed. 46, the reference circumference Z is increased. Specifically, in the coil side portion insertion step, a plurality of processing target portions are sequentially inserted into the slots 22 (see FIG. 10), and in the coil side portion pressurization step, all the portions to be disposed inside the slots 22 ( In this example, the five parts to be processed are pressed together to increase the reference circumferential length Z of each insulation coating material 46 of all the parts to be processed. In the example shown in FIG. 11, the pressing jig 53 is narrower in the circumferential direction C than the opening 22 b of the slot 22, and the pressing jig 53 is inserted into the slot 22 along the radial direction R. Is done.

[Second example]
As shown in FIG. 12 to FIG. 15, in this example as well, in the coil side part insertion step, the part to be processed (unprocessed part) before being pressurized by the coil side part pressurizing step is slotted. After being inserted into the inner portion of the wire 22, the portion to be processed in the linear conductor 4 inserted into the inside of the slot 22 is subjected to the coil side pressurizing step so that the second radial direction R <b> 2 is opposite to the opening direction of the slot 22. Pressurize to the side. However, in this example, every time one processing target site is inserted into the slot 22 by the coil side inserting step, the coil side pressurizing step is executed to pressurize the processing target site. That is, as shown in FIG. 12, after inserting the processing target portion corresponding to the coil side portion 71 of the first layer B <b> 1 into the slot 22 by the coil side portion insertion step, the processing target portion as shown in FIG. On the other hand, the coil side pressurizing step is executed. Next, as shown in FIG. 14, after inserting the processing target portion corresponding to the coil side portion 71 of the second layer B <b> 2 into the slot 22, the coil side with respect to the processing target portion as shown in FIG. 15. A part pressurization process is performed. Thereafter, the coil side inserting step and the coil side pressing step are repeatedly executed until the coil side 71 of the fifth layer B5 is inserted. In the example shown in FIGS. 13 and 15, the tip of the pressing jig 53 is wider in the circumferential direction C than the opening 22 b of the slot 22, and the pressing jig 53 extends in the axial direction L. Then, it is moved along the radial direction R.

(3) In the above-described embodiment, in the coil side portion insertion step # 02 (see FIG. 7C), the configuration is such that the portion to be processed in the linear conductor 4 is arranged inside the slot 22 in an arbitrary arrangement direction. Described as an example. However, the embodiment of the present invention is not limited to this. That is, it is also a preferred embodiment of the present invention that the processing target portion is arranged in the slot 22 in a predetermined arrangement direction. Hereinafter, as an example of such a configuration, a third example shown in FIGS. 16 and 17 and a fourth example shown in FIG. 18 will be described. 16 and 18, in order to facilitate the understanding of the invention, the insulating coating material 46 is insulated against the pressing target portion 46a (see FIG. 7B) in the coil side pressing step # 01. The covering material 46 is shaded deeper than the non-pressing portion 46b other than the pressing target portion 46a. 16 and 18, for the sake of simplicity, the circumferential width C of the slot 22 is shown to be uniform along the radial direction R. As a result, the coil sides 71 are the same as each other. It is shown to have a cross-sectional shape.

[Third example]
As shown in FIG. 16, in this example, as in the above embodiment, the slot insulating portion 24 as an insulating portion that electrically insulates the coil side portion 71 and the stator core 2 (including the teeth 23) is a slot. 22 is provided along the inner surface. Here, the inner surface of the slot 22 is formed by a wall surface portion (a portion including the tooth side surface 23 a) that forms the slot 22 in the stator core 2. In this example, as shown in FIG. 17, the coil side portion insertion step # 02 is performed after the insulation step # 04 in which the slot insulating portion 24 is provided along the inner surface of the slot 22. For example, when the slot insulating portion 24 is formed by insulating powder coating, the insulating step # 04 is a step of applying the coating to the inner surface of the slot 22, and the slot insulating portion 24 is formed by the slot insulating sheet. In this case, the sheet is disposed along the inner surface of the slot 22. In the coil side portion insertion step # 02, the portion to be processed is inserted into the slot 22 in which the slot insulating portion 24 is provided in the insulating step # 04, and the portion to be processed is placed in the slot 22 in a predetermined arrangement direction. Place inside. In this example, the arrangement direction of the processing target portion is set such that the pressing target portion 46 a of the insulating coating material 46 faces the circumferential direction C with respect to the slot insulating portion 24.

As shown in FIG. 16, the coil side portion 71 has a first portion 71 a extending in the radial direction R at each end portion on both sides in the circumferential direction C, and the circumferential direction C at each end portion on both sides in the radial direction R. The second portion 71b extends in the direction. In this example, a plurality of coil side portions 71 are arranged inside the slot 22, and the plurality of coil side portions 71 include a target coil side portion 73. Here, in the target coil side portion 73, the first portion 71 a is in contact with the slot insulating portion 24 while facing the circumferential direction C, and the second portion 71 b is opposed to the other coil side portion 71 in the radial direction R. It is the coil side part 71 which touches. In this example, as described above, the portion to be processed constituting the coil side portion 71 is disposed such that the pressing target portion 46 a of the insulating coating material 46 faces the slot insulating portion 24 in the circumferential direction C. Therefore, at least a part of the first portion 71a of the target coil side portion 73 is formed by the pressing target portion 46a. On the other hand, at least a part of the second portion 71b of the target coil side portion 73 is formed by the pressing non-target portion 46b.

In the example shown in FIG. 16, with respect to the target coil side 73, the entire first portion 71a is formed by the pressing target portion 46a, and the entire second portion 71b is formed by the pressing non-target portion 46b. Moreover, in the example shown in FIG. 16, the whole connection part (arc-shaped corner | angular part in the rectangular cross section of the coil side part 71) of the 1st part 71a and the 2nd part 71b is formed of the pressing object part 46a. . That is, in the example shown in FIG. 16, the extension length of the pressing target portion 46a in the orthogonal cross section is set to be larger than the extension length of the first portion 71a in the orthogonal cross section. By setting the extension length in the orthogonal cross section of the pressing non-target portion 46b to be larger than the extension length in the orthogonal cross section of the second portion 71b, a part or the whole of the connecting portion is formed by the pressing non-target portion 46b. A formed configuration is also possible.

By the way, the pressing target portion 46a is a portion pressed in the coil side pressing step # 01 (in the example of the above embodiment, a portion pressed by the pressing jig 51 shown in FIG. 7B). Therefore, after execution of coil side part pressurization process # 01, the average value of the thickness of the pressing target part 46a becomes smaller than the average value of the thickness of the pressing non-target part 46b. This is because the pressing target portion 46a is plastically extended by the execution of the coil side pressurizing step # 01 and, as schematically shown in FIG. 16, when the coil side pressurizing step # 01 is executed. This is because the bare conductor wire 41 is pressed against the inner surface of the pressing target portion 46a, and the portion of the pressing target portion 46a into which the bare conductor strand 41 is recessed becomes thin. In this example, the first portion 71a of the target coil side portion 73 is formed by the pressing target portion 46a, and the second portion 71b of the target coil side portion 73 is formed by the pressing non-target portion 46b. Therefore, in this example, the insulation coating material 46 of the target coil side portion 73 has an average thickness value in the first portion 71a smaller than an average thickness value in the second portion 71b. For example, the average value of the thickness of the insulating coating material 46 in the first portion 71a may be about 9/10 or about 3/4 of the average thickness of the insulating coating material 46 in the second portion 71b. it can. Further, the minimum value of the thickness of the insulating coating material 46 in the first portion 71a (thickness of the thinnest portion) is two thirds of the minimum value of the thickness of the insulating coating material 46 in the second portion 71b (thickness of the thinnest portion). It can be set as the structure which is a grade or a half.

Note that the coil side portions 71 other than the target coil side portion 73 may be included in the plurality of coil side portions 71 arranged inside the slot 22. For example, in the example shown in FIG. 2 according to the above embodiment, the coil side 71 arranged in the first layer B1 and the coil side 71 arranged in the fifth layer B5 are different from the target coil side 73, Only one of the second portions 71 b on both sides in the radial direction R is disposed so as to be opposed to and contact the other coil side portion 71 in the radial direction R. As with the target coil side portion 73, such a coil side portion 71 can also be disposed so that the pressing target portion 46 a faces the slot insulating portion 24 in the circumferential direction C. In this case, a portion (hereinafter referred to as “target portion”) disposed on the second radial direction R2 side of the coil side portion 71 of the first layer B1 in the slot insulating portion 24 is more than the other portion of the slot insulating portion 24. Insulation performance can also be relaxed. That is, for example, when the slot insulating portion 24 is formed by insulating powder coating, the coating thickness of the target portion can be reduced, and when the slot insulating portion 24 is formed by a slot insulating sheet. The thickness of the sheet of the target portion can be reduced, or the number of overlapping sheets of the target portion can be reduced.

[Fourth example]
As shown in FIG. 18, in this example, unlike the above-described embodiment, the slot insulating portion 24 is not provided inside the slot 22. In this example, unlike the third example, the processing direction of the linear conductor 4 is such that the non-pressing portion 46 b of the insulating coating 46 is in the circumferential direction C with respect to the inner surface of the slot 22. The facing direction is set. In this example, according to such an arrangement direction, a plurality of processing target parts are arranged inside the slot 22 in the coil side portion insertion step # 02.

As shown in FIG. 18, in this example, the first portion 71 a is in contact with the inner surface of the slot 22 facing the inner surface of the slot 22 in the circumferential direction C, and The target coil side portion 74 is included, which is the coil side portion 71 in which the two portions 71b are in contact with the other coil side portions 71 in the radial direction R. In this example, as described above, the portion to be processed constituting the coil side portion 71 is disposed so that the non-pressing portion 46 b of the insulating coating material 46 faces the inner surface of the slot 22 in the circumferential direction C. . Therefore, at least a part of the first portion 71a of the target coil side portion 74 is formed by the pressing non-target portion 46b. On the other hand, at least a part of the second portion 71b of the target coil side portion 74 is formed by the pressing target portion 46a.

In the example shown in FIG. 18, the entire first portion 71a of the target coil side 74 is formed by the non-pressing portion 46b, and the entire second portion 71b is formed by the pressing target portion 46a. And in this example, unlike the said 3rd example, as for the insulation coating material 46 of the object coil side part 74, the average value of the thickness in the 1st part 71a is larger than the average value of the thickness in the 2nd part 71b. . For example, the average value of the thickness of the insulating coating material 46 in the second portion 71b may be about 9/10 or about 3/4 of the average thickness of the insulating coating material 46 in the first portion 71a. it can. Further, the minimum value of the thickness of the insulating coating material 46 in the second portion 71b (thickness of the thinnest portion) is two thirds of the minimum value of the thickness of the insulating coating material 46 in the first portion 71a (thickness of the thinnest portion). It can be set as the structure which is a grade or a half. In the example shown in FIG. 18, the entire connection portion between the first portion 71 a and the second portion 71 b is formed by the pressing non-target portion 46 b. A part or the whole of the connecting portion may be formed by the pressing target portion 46a.

It should be noted that the coil side portions 71 other than the target coil side portion 74 may be included in the plurality of coil side portions 71 arranged inside the slot 22. For example, unlike the target coil side portion 74, only one of the second portions 71 b on both sides in the radial direction R is disposed so as to be opposed to the other coil side portion 71 in the radial direction R. The coil side portion 71 may be included in the plurality of coil side portions 71. As with the target coil side portion 74, such a coil side portion 71 can also be arranged so that the pressing non-target portion 46 b of the insulation coating material 46 faces the inner surface of the slot 22 in the circumferential direction C. . For example, one of the second portions 71b on both sides in the radial direction R is arranged so as to be opposed to and contact the other coil side portion 71 in the radial direction R, and the other second portion 71b is the diameter of the slot 22. With respect to the coil side portion 71 arranged so as to face the radial direction R with respect to the inner surface facing the direction R, the pressing non-target portion 46 b of the insulating coating material 46 faces the circumferential direction C with respect to the inner surface of the slot 22. Can be arranged. In this case, it is also possible to adopt a configuration in which the slot insulating portion 24 is provided between the coil side portion 71 and the inner surface of the slot 22 facing the radial direction R. In this example as well, a configuration in which the slot insulating portion 24 is provided on the entire inner surface of the slot 22 is also possible.

(4) In the above-described embodiment, the plurality of coil sides 71 arranged in each of the slots 22 has a slot width W that is large based on the position in the radial direction R where each of the coil sides 71 is arranged. The configuration in which the reference circumferential length Z of the insulating coating material 46 is increased according to the above is described as an example. However, the embodiment of the present invention is not limited to this. In other words, the reference peripheral length Z of the insulating coating material 46 can be shortened as the slot width W increases between some of the coil sides 71. For example, when the cross-sectional area of the coil side portion 71 is set to be larger in the example shown in FIG. 2, the shape of the orthogonal cross section of the coil side portion 71 arranged closest to the first radial direction R1 is the circumferential direction. It is assumed that the width in the radial direction R is larger than the width of C. In such a case, the insulating coating material 46 of the coil side 71 arranged in the layer B at the position in the radial direction R where the slot width W is the smallest is the coil side 71 arranged in any other layer B. The reference circumferential length Z can be longer than that of the insulating coating material 46. That is, between these coil side parts 71, as the slot width W increases, the reference circumferential length Z of the insulating coating material 46 decreases. In other words, as the slot width W increases, the absolute value of the dimensional difference between the width in the circumferential direction C and the width in the radial direction R in the orthogonal cross section of the coil side portion 71 decreases. In such a case, the reference circumferential length Z of the insulating coating material 46 of the coil side portion 71 disposed in the layer B located in the radial direction R where the slot width W is the smallest is the radial direction where the slot width W is the largest. It can be equal to or greater than the reference circumferential length Z of the insulating coating material 46 of the coil side portion 71 disposed in the layer B (specific layer) at the position of R. In this case, unlike the above-described embodiment, the insulation coating material 46 of the coil side portion 71 arranged in the specific layer is arranged not in all the layers B other than the specific layer but in some layers B other than the specific layer. The reference circumferential length Z is longer than that of the insulation coating material 46 of the coil side portion 71 that has been made. The present invention includes such a configuration within the scope of rights.

(5) In the above embodiment, the slot 22 is formed so that the slot width W gradually increases toward the second radial direction R2, and the first layer B1 is a specific layer. did. However, the embodiment of the present invention is not limited to this. For example, the shape of the slot 22 is changed, and the layer B (the second layer B2, the third layer B3, or the fourth layer B4 in the example shown in FIG. 2) at the middle position in the radial direction R, or the The layer B (the fifth layer B5 in the example shown in FIG. 2) at the position on the one direction R1 side may be a layer B (specific layer) at the position in the radial direction R where the slot width W is the largest. Is possible.

(6) In the above-described embodiment, one of the plurality of coil side portions 71 and the other coil side portions 71 arranged in the same slot 22 have different reference peripheral lengths Z of the insulating coating material 46. The configuration has been described as an example. However, the embodiment of the present invention is not limited to this. That is, inside the slot 22, a plurality of coil side portions 71 having the same reference circumferential length Z of the insulating coating material 46 are disposed, and one of the plurality of coil side portions 71 is disposed in the same slot 22. It is also possible to adopt a configuration in which the reference peripheral length Z of the insulating coating material 46 is different from some other coil side portions 71.

(7) In the above embodiment, the configuration in which the coil side portion 71 is divided into the five layers B inside the slot 22 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the coil side portion 71 is divided into an odd number (for example, three, seven, etc.) of layers B other than “5”, and the coil side portion 71 is an even number (for example, two, four, etc.). It is also one of the preferred embodiments of the present invention to have a configuration in which the layer B is divided and disposed.

(8) In the above embodiment, the configuration in which the bare conductor wire 41 corresponds to the “conductor wire” in the present invention has been described as an example. However, the embodiment of the present invention is not limited to this. That is, a conductor wire (covered conductor wire) provided with an insulating film made of an electrically insulating material such as a resin (eg, polyamideimide resin or polyimide resin) on the surface is used as the “conductor wire” in the present invention. A configuration in which a periphery of a bundle of coated conductor strands in which a plurality of the coated conductor strands are assembled is further covered with an insulating coating material 46 may be employed.

(9) In the above embodiment, the configuration in which the circumferential protrusion 23b is formed at the tip of the tooth 23 has been described as an example. However, the embodiment of the present invention is not limited to this. That is, a configuration in which the circumferential protrusion 23b is not formed at the tip of the tooth 23, that is, a configuration in which the slot 22 is an open slot may be employed.

(10) In the above embodiment, the circumferential width D in a state where the shape of the orthogonal cross section of the unprocessed portion of the linear conductor 4 is a perfect circle is set to be larger than the opening width W1 of the slot 22. The configuration has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the circumferential width D in a state where the shape of the orthogonal cross section of the unprocessed portion of the linear conductor 4 is a perfect circle may be set to be equal to or smaller than the opening width W1 of the slot 22.

(11) In the above embodiment, the configuration in which the shape of the cross section orthogonal to the extending direction of the bare conductor wire 41 is a circular shape has been described as an example. However, the embodiment of the present invention is not limited to this. That is, the cross-sectional shape of the bare conductor wire 41 may be various polygonal shapes such as a quadrangular shape, a triangular shape, a pentagonal shape, a hexagonal shape, and an octagonal shape.

(12) In the above embodiment, the configuration in which the slot 22 has the opening 22b on the radial first direction R1 side, which is the direction toward the inner side in the radial direction R, has been described as an example. However, the embodiment of the present invention is not limited to this. That is, it is also possible to employ a configuration in which the slot 22 has an opening on the radial second direction R2 side, which is a direction toward the outside of the radial direction R. That is, the present invention can also be applied to an outer rotor type rotating electrical machine in which the rotor is disposed on the second radial direction R2 side of the stator.

(13) In the above embodiment, the configuration in which the stator core 2 is formed by laminating a plurality of annular plate-like magnetic plates 7 in the axial direction L has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the stator core 2 may have a configuration in which a compact material formed by pressing a magnetic material powder is formed as a main component. In this case, the stator core 2 can be formed integrally in both the radial direction R and the axial direction L in addition to the circumferential direction C.

(14) In the above embodiment, the configuration in which the stator core 2 corresponds to the “core” in the present invention has been described as an example. However, the embodiment of the present invention is not limited to this. For example, the present invention is applied to a fixed field type rotating electrical machine, and the core to be wound by the coil 3 is a rotor core, that is, the rotor core corresponds to the “core” in the present invention. It is also possible. Thus, the “core” according to the present invention can be applied to an armature core other than the stator core 2.

(15) In the above embodiment, in the coil side portion insertion step # 02, a configuration in which a plurality of processing target portions are inserted into the slot 22 has been described as an example. However, the embodiment of the present invention is not limited to this. In other words, the coil 3 may be configured to have a single-layer winding structure, and a single machining target site may be inserted into the slot 22 in the coil side portion insertion step # 02.

(16) In the above-described embodiment, in the coil side portion insertion step # 02, a configuration in which the processing target site is inserted into the slot 22 that is formed so that the slot width W varies depending on the position in the radial direction R. Described as an example. However, the embodiment of the present invention is not limited to this. That is, in the coil side portion insertion step # 02, it is also possible to adopt a configuration in which the portion to be processed is inserted into the slot 22 formed so that the slot width W is uniform along the radial direction R. . In such a case, the shape of the orthogonal cross section of the coil side portion 71 is the same rectangular shape for all the coil side portions 71 arranged in the same slot 22, and the insulating coating material for the coil side portion 71 is used. The circumferential length 46 (reference circumferential length Z or design circumferential length) may be the same for all the coil side portions 71 arranged in the same slot 22.

(17) In the above embodiment, the configuration in which the pressurizing step is the coil side pressurizing step # 01 in which the portion corresponding to the coil side portion 71 in the coated conductor strand bundle is the processing target portion has been described as an example. However, the embodiment of the present invention is not limited to this. For example, a portion corresponding to a coil end portion in the coated conductor wire bundle can be set as a processing target portion in the pressurizing step. In such a case, when a plurality of bare conductor wires 41 are gathered in close contact with each other such that the outer shape of the orthogonal cross section of the bare conductor strand bundle 42 is a perfect circle, the bare conductors 41 Processing so that the difference between the radius of the perfect circle circumscribing the strand of wire 42 and the radius of the circle whose circumferential length is the reference circumferential length Z of the insulation coating material 46 is at least equal to or larger than the diameter of the bare conductor strand 41. It is preferable to set the amount of pressure applied to the target part.

(18) Regarding other configurations as well, the embodiments disclosed herein are illustrative in all respects, and the embodiments of the present invention are not limited thereto. In other words, configurations that are not described in the claims of the present application can be modified as appropriate without departing from the object of the present invention.

The present invention can be suitably used in a manufacturing method for manufacturing a linear conductor for a coil of a rotating electrical machine and a manufacturing method of a rotating electrical machine including the manufacturing method.

2: Stator core (core)
3: Coil 4: Linear conductor 21: Core reference plane 22: Slot 24: Slot insulation (insulation)
41: Bare conductor wire (conductor wire)
42: Bare conductor wire bundle (conductor wire bundle)
46: Insulation coating material 46a: Press target part 46b: Press non-target part 71: Coil side part 100: Rotating electric machine A: Extension direction C: Circumferential direction E: Cross direction L: Axial direction R: Radial direction W: Slot width

Claims

A manufacturing method for manufacturing a linear conductor for a coil of a rotating electrical machine,
Using a covered conductor wire bundle formed by covering a conductor wire bundle in which a plurality of conductor wires are assembled with a flexible insulating coating material, the portion to be processed in the covered conductor wire bundle is defined as the conductor. Having a pressurizing step of pressurizing in an intersecting direction intersecting the extending direction of the wire bundle,
In the pressurizing step, a linear conductor that plastically deforms the insulating coating material at the site to be processed and increases the peripheral length of the insulating coating material in an orthogonal cross section that is a cross section orthogonal to the extending direction. Manufacturing method.
A coil comprising the manufacturing method according to claim 1, wherein a plurality of slots extending in the axial direction of a cylindrical core reference surface are arranged in a distributed manner in a circumferential direction of the core reference surface, the coil being constituted by the linear conductor A method of manufacturing a rotating electrical machine for manufacturing a rotating electrical machine wound with
In the pressurizing step, a portion corresponding to a coil side portion that is a portion of the coil disposed in the slot in the coated conductor wire bundle is set as the processing target portion,
A method of manufacturing a rotating electrical machine comprising an insertion step of inserting the processing target portion into the slot.
The method of manufacturing a rotating electrical machine according to claim 2, wherein, in the insertion step, the portion to be processed after being pressurized in the pressing step is inserted into the slot.
Further comprising an insulating step of providing an insulating portion for electrically insulating the coil side portion and the core along the inner surface of the slot;
In the inserting step, the processing target portion is inserted into the slot in which the insulating portion is provided in the insulating step, and the processing target portion is disposed in the slot in a predetermined arrangement direction. ,
4. The method of manufacturing a rotating electrical machine according to claim 3, wherein the arrangement direction is a direction in which a portion to be pressed in the pressing step in the insulating coating material faces the circumferential direction with respect to the insulating portion.
In the inserting step, a plurality of the processing target parts are inserted into the slot, and a plurality of the processing target parts are arranged in the slot in a predetermined arrangement direction.
The rotation according to claim 3, wherein the arrangement direction is a direction in which a non-pressing target portion other than a pressing target portion in the pressurizing step in the insulating coating material faces the circumferential direction with respect to an inner surface of the slot. Electric manufacturing method.
In the inserting step, a plurality of the processing target sites are inserted into the slot,
In the pressurizing step, the coil according to an increase in an absolute value of a dimensional difference between the circumferential width in the orthogonal cross section of the coil side portion and the radial width of the core reference surface in the orthogonal cross section. The pressurization amount for each of the plurality of processing target parts is set to the absolute value of the dimensional difference of the coil side part corresponding to each processing target part so that the peripheral length of the insulating coating material on the side part becomes long. The method for manufacturing a rotating electrical machine according to any one of claims 2 to 5, wherein the rotating electrical machine is made different depending on the method.
The method for manufacturing a rotating electrical machine according to claim 6, wherein, in the insertion step, the portion to be processed is inserted into the slot formed so that the slot width in the circumferential direction differs according to the radial position.
In the inserting step, a plurality of the processing target sites are inserted into the slots formed so that the circumferential slot widths differ according to the radial position of the core reference surface, and a plurality of the processing The target parts are arranged in a row along the radial direction inside the slot,
In the pressurizing step, the peripheral length of the insulating covering material of the coil side portion is increased as the slot width is increased based on the radial position where the coil side portion is disposed. The pressurization amount with respect to each of the plurality of processing target parts is made different according to the radial position where the coil side portion corresponding to each processing target part is arranged. The manufacturing method of the rotary electric machine of description.
The insulating coating material is configured to reduce the circumference by heating,
9. The heating process according to claim 2, further comprising a heating step of heating the processing target portion inserted into the slot by the insertion step to reduce the peripheral length of the insulating coating material of the processing target portion. The manufacturing method of the rotary electric machine as described in any one of.