JP2007006677A - Winding method and winding device for stator core - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a winding method and a winding device for a stator core that enable single equipment to execute winding work process. <P>SOLUTION: The winding device 100 is provided with a holder 202 for holding the stator core 3, an index motor 203 for rotating the holder 202 by a prescribed angle, a winding nozzle 121, a winding nozzle driving part 120 for moving the winding nozzle 121 in the stator axial direction, and for oscillating the winding nozzle around the stator axis, a winding-former attaching/detaching and replacing part 140 for attaching/detaching a winding former 150 to/from the stator core 3, a winding arm driving part 160 for controlling the drive of winding arms 161-164, an inspection part 220 for inspecting the state of the formed coil 7, and an interphase insulator assembly part 260 for mounting an interphase insulator 261 to the coil 7. The winding-former attaching/detaching and replacing part 140, winding arm driving part 160, inspection part 220, and interphase insulator assembly part 260 are arranged, in turn so as to surround the vicinity of the holder 202. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a winding method and a winding device for a stator core in which a coil is formed by directly winding a winding around a stator core.

  Conventionally, in the winding work process in the case of manufacturing a distributed winding stator, the winding is wound in advance to form a coil, and this is sandwiched between blades, and the winding sandwiched using a stripper is pushed up, A so-called inserter system in which a stator is formed by inserting a coil into a slot of a stator core is generally employed. (See Patent Document 1).

However, in the inserter method, it is necessary to provide a dedicated facility for each process in order to perform winding, so that there is a problem that the facility cost and the installation space for the facility are large. Furthermore, a device for moving or reversing the stator core between facilities in each process is also required.
In the inserter method, when changing the specifications of the stator to be produced (work change), it is necessary to replace or newly manufacture tools, jigs, and pallets for each process equipment. Efficiency will decrease.

  On the other hand, it is also considered that the winding operation process of the distributed winding stator is performed not by the inserter method but by a direct winding method in which a coil is formed by directly winding a winding around a stator core. Here, as the direct winding method, for example, when winding the stator core having a skew angle of the core groove (slot) of the stator core (stator core), the wire nozzle is advanced and retracted along the core groove by a spindle. In addition, there is a method in which the position of the wire nozzle and the stator core is relatively changed by swinging the stator core, and the winding is wound in the core groove (see Patent Document 2).

  Further, Patent Document 3 discloses a method of winding a plurality of cores composed of a base portion and salient pole portions. In this winding method, the first core that is wound first and the second core that is wound later have a predetermined distance, the projecting direction of the salient pole portions is different, and the winding end line of the first core does not collapse. As described above, the second coil is wound with the tension applied.

JP 2003-164122 A JP-A-61-173650 JP 2004-96894 A

  However, even in the conventional direct winding method, as in the inserter method, the actual situation is that a production line is made by providing dedicated equipment for each step in order to perform winding. That is, the inspection of the state of the coil and the installation of the interphase insulating paper are performed in a facility separate from the winding device. For this reason, an apparatus for moving or reversing the stator core between facilities in each process is also required. Therefore, the problem that equipment cost and installation space of equipment are large has not been solved.

  Therefore, the present invention has been made to solve the above-described problems, and it is an object of the present invention to provide a winding method and a winding device for a stator core capable of performing a winding work process with a single facility. To do.

  The stator core winding method according to the present invention made to solve the above-described problems is a stator core winding method in which a winding is wound directly around a plurality of slots opened in the inner peripheral surface of the stator core, A winding step of forming a coil by winding a winding in a first slot and a second slot of the plurality of slots; and, after indexing the stator core, the coil formed in the winding step An inspection step for inspecting the state, and an insulating step for attaching an interphase insulator to the coil that has been inspected in the inspection step after the stator core is indexed, and the winding step, the inspection step, and the insulation The processes are performed in parallel.

In this winding method, in the winding process, a winding is wound by direct winding in the first slot and the second slot among the plurality of slots formed in the stator core to form a coil. Further, the state of the coil formed in the winding process is inspected by the inspection process. In addition, an interphase insulator is attached to the coil that has been inspected in the inspection step by the insulating step. The winding process, the inspection process, and the insulation process are performed in parallel while indexing the stator core on which the winding is performed.
In other words, the winding process, the inspection process, and the insulation process are performed simultaneously (in parallel) when looking at the entire stator manufacturing, while focusing on one coil, the winding process, the inspection process, and the insulation process are in order. To be implemented.

  In this way, each step is performed in order by indexing the stator core, so there is no need to move or reverse the stator core for each step, so there is no need for a device or the like for moving or reversing the stator core. become. For this reason, since the apparatus for implementing each process of a winding process, an inspection process, and an insulation process can be integrated, a winding work process can be implemented by a single installation.

In the winding method of the stator core according to the present invention, in the winding step, a plurality of windings are discharged from a winding nozzle that can move up and down and swing in the inner peripheral portion of the stator core, and Winding a winding around the first slot and the second slot via a winding former detachably attached to both end faces of the circumference;
The winding wound around the first slot and the second slot may be drawn into the first slot and the second slot by each winding arm disposed so as to be able to contact and be separated from both side surfaces of the former. desirable.

  Further, in the winding method of the stator core according to the present invention, each winding arm is separated from the winding former when the winding nozzle passes, and the winding former is passed to the winding former after the winding nozzle passes. More preferably, they abut.

  In this winding method, the windings discharged from the nozzle are inserted into the slots by reciprocating in the vertical direction (stator axial direction). Specifically, for example, when the winding is inserted into the first slot on the forward path, the coil swings in the circumferential direction by the coil opening angle, and on the return path, the winding is inserted into the second slot. Thereafter, the coil swings in the circumferential direction opposite to the previous time by the coil opening angle, and the winding is inserted into the first slot again. For this reason, part of the winding inserted into the first slot may protrude from the inside of the stator core during the period after the winding is inserted into the first slot until the next insertion of the winding into the first slot. . In particular, when the space factor of the windings in the slot is high, there is a high risk of this. The same applies to the second slot.

  In this case, once the winding jumps out of the slot, the work and productivity are lowered, for example, it is necessary to return the winding into the slot with an operator's finger. In addition, when the space factor is high, the presence of the winding already inserted into the slot may make it difficult to insert the winding later when trying to insert the winding into the slot.

  On the other hand, in the winding method of the present invention, the windings wound in the first slot and the second slot are arranged in the first slot by the winding arms arranged so as to be able to contact and separate from both side surfaces of the former. And retracts into the second slot. Each winding arm is separated from the winding former before the winding nozzle passes, and abuts against the winding former after the winding nozzle passes.

  Therefore, for example, in the case described above, after the winding nozzle inserts the winding into the first slot (outward path), the winding arm arranged on the first slot side contacts the winding former. . For this reason, it can prevent that the coil | winding inserted in the 1st slot protrudes inside from the inner surface of a stator core. Then, the winding inserted in the first slot is drawn into the first slot (outside of the stator core diameter) by the winding arm arranged on the first slot side. As a result, the winding in the first slot is deformed so as not to protrude. For this reason, the protrusion of the winding from the first slot is prevented. Moreover, since the winding is pulled in, a space for inserting the winding into the first slot can be formed. For this reason, even when a stator (coil) having a high space factor of the winding in the slot is formed, the winding can be surely arranged in the slot.

  Next, after the winding nozzle swings in the circumferential direction and the winding nozzle inserts the winding into the second slot (return path), the winding arm disposed on the second slot side contacts the winding former. Touch. For this reason, it can prevent that the coil | winding inserted in the 2nd slot protrudes inside from the inner surface of a stator core. Then, the winding inserted in the second slot is drawn into the second slot (outward direction of the stator core) by the winding arm disposed on the second slot side. As a result, the winding in the second slot is deformed into a shape that is difficult to protrude. For this reason, the protrusion of the winding from the second slot is prevented. Moreover, since the winding is pulled in, a space for inserting the winding into the second slot can be formed next. For this reason, even when a stator (coil) having a high space factor of the winding in the slot is formed, the winding can be surely arranged in the slot.

  In particular, when the stator is formed by distributed winding, the cross-sectional area of the slot of the stator core tends to be small, so that the space factor of the winding in the slot tends to be high and insertion is often difficult. Further, the winding easily protrudes from the slot to the inside of the stator core. Therefore, it is preferable to use this winding method. In other words, it is particularly preferable to use the winding method of the present invention when the stator core has a form in which another slot exists between the first slot and the second slot.

  In the stator core winding method according to the present invention, it is desirable that the winding nozzle individually discharges the windings from a plurality of discharge ports arranged linearly in the stator axial direction.

  Here, a winding discharge device that discharges a plurality of windings from an elongated nozzle such as a linear nozzle is used, and this winding discharge device or stator core is moved in the stator axial direction, and the winding is inserted into the slot. There is a case to try. In this case, when the winding discharged from the long and narrow nozzle receives tension, it gathers at the end of the nozzle opposite to the traveling direction of the winding discharge device, and the arrangement of the windings in the nozzle can be biased. For this reason, friction may occur between the windings or between the winding and the wall surface of the nozzle, which may damage the insulating coating of the windings. Further, it may be difficult to smoothly discharge the winding due to friction. In addition, since a force is applied to push the nozzle in the width direction (short direction), the nozzle may be deformed.

  Therefore, in the winding method of the present invention, each of the windings is individually discharged from the discharge ports arranged linearly in the stator axial direction. Thereby, since only one winding is discharged from each discharge port, the arrangement of the windings at each discharge port (nozzle) can hardly be biased. For this reason, almost no force is generated to push and spread each discharge port in the short direction, so that each discharge port is not easily deformed. Further, since there is no friction between the windings, there is no risk of damaging the insulation coating of the windings. In addition, since each winding is discharged individually, there is no friction from other windings, so that the windings can be discharged very smoothly. Therefore, the winding can be smoothly discharged without damaging the insulation coating of the winding.

  Moreover, in the winding method of the stator core according to the present invention, when supplying a plurality of windings to the winding nozzle, the slack generated in the whole of the plurality of windings due to the operation of the winding nozzle is eliminated. In order to adjust the overall length and tension of the plurality of windings, and to eliminate the slack of each winding caused by the winding discharge position of the winding nozzle due to the operation of the winding nozzle, It is desirable to adjust the length and tension for each line.

  In the winding method of the present invention, the winding nozzle is moved up and down and swung while the winding is individually discharged from the discharge ports arranged linearly in the stator axial direction, and the winding is wound around the stator core. For this reason, when the length of the winding supplied to the winding nozzle is kept constant, the winding is slackened, or conversely, the winding is pulled. If it does so, there exists a possibility that a winding may not be wound around a stator core well, or there exists a possibility that a winding may be damaged.

  Therefore, in the winding method of the present invention, the length and tension of the whole of the plurality of windings are adjusted in order to eliminate the slack that occurs in the whole of the plurality of windings due to the operation of the winding nozzle. The length and tension of each winding are adjusted in order to eliminate the slack of each winding caused by the difference in winding discharge position. Thereby, slack does not generate | occur | produce in the whole winding and each winding, and moderate tension is given. For this reason, the winding shape of the winding in the stator core can be stabilized and damage to the winding can be prevented.

  In this case, when the operation of the winding nozzle changes from swinging to vertical movement, the length and tension of the whole of the plurality of windings are adjusted, and the winding nozzle is swinging. The length and tension for each winding may be adjusted.

  Further, in the stator core winding method according to the present invention, the operation timing of the winding arm and the adjustment timing of the length and tension of the winding are determined in advance based on the movement trajectory of the winding nozzle, It is desirable to adjust the operation of the winding arm and the length and tension of the winding in conjunction with the operation of the winding nozzle.

  By doing so, it is possible to prevent the damage of the winding wire and the winding wire from protruding from the slot, stabilize the winding shape of the winding wire in the stator core, and form a coil with a high space factor.

  The stator core winding device according to the present invention, which has been made to solve the above problems, is a stator core winding device in which a winding is wound directly around a plurality of slots opened in the inner peripheral surface of the stator core, A holder for holding the stator core, an index mechanism for rotating the holder by a predetermined angle, a winding nozzle disposed on an inner peripheral portion of the stator core and discharging a plurality of windings to be inserted into the slot; A winding nozzle drive unit that moves the winding nozzle in the stator axial direction and swings around the stator axis, a winding former attaching / detaching unit that attaches / detaches a winding former to the inner peripheral surface of the stator core, and the slot A winding arm that prevents the inserted winding from protruding outside the slot and controls the driving of the winding arm that pulls the winding into the slot. A drive unit, an inspection unit that inspects a state of a coil formed on the stator core, and an interphase insulator assembly unit that mounts an interphase insulator on the coil formed on the stator core, the former demounting unit, The winding arm drive unit, the inspection unit, and the interphase insulator assembly unit are sequentially arranged so as to surround the holder.

  This winding device is provided with an index mechanism for rotating the holder by a predetermined angle. And since each part is arrange | positioned around a holder, the operation | work in each part can be implemented in order and in parallel by indexing a holder with an index mechanism. That is, when attention is paid to one coil, winding of the winding around the stator core (coil formation), inspection of the coil, and assembly of the interphase insulator to the coil are sequentially performed. On the other hand, as a whole, the winding of the winding around the stator core (coil formation), the inspection of the coil, and the assembly of the interphase insulator to the coil are performed simultaneously (in parallel).

  For this reason, since it is not necessary to move or reverse the stator core when the operation in each part is completed, an apparatus for moving or reversing the stator core is not necessary. For this reason, it is possible to consolidate devices for carrying out the winding process, the inspection process, and the insulation process, so that the winding work process is carried out with a single facility (one winding apparatus of the present invention). Can do. Moreover, in the winding apparatus of this invention, since the apparatus for implementing each process is integrated and arrange | positioned, size reduction of the apparatus is achieved.

  In this winding device, the winding nozzle is reciprocated in the vertical direction (stator axial direction) by the winding nozzle driving unit, and the winding discharged from the nozzle is inserted into the slot. Specifically, for example, when the winding is inserted into the first slot on the forward path, the coil is swung in the circumferential direction by the coil opening angle, and on the return path, the winding is inserted into the second slot. Thereafter, the coil is swung in the circumferential direction opposite to the previous time by the coil opening angle, and the winding is inserted into the first slot again. For this reason, part of the winding inserted into the first slot may protrude from the inside of the stator core during the period after the winding is inserted into the first slot until the next insertion of the winding into the first slot. . In particular, when the space factor of the windings in the slot is high, there is a high risk of this. The same applies to the second slot.

  In this case, once the winding jumps out of the slot, the work and productivity are lowered, for example, it is necessary to return the winding into the slot with an operator's finger. In addition, when the space factor is high, the presence of the winding already inserted into the slot may make it difficult to insert the winding later when trying to insert the winding into the slot.

  On the other hand, in the winding device of the present invention, the winding arms wound around the first slot and the second slot are arranged so that the winding arms arranged so as to contact and be separated from both side surfaces of the former are winding arms. Driven by the drive unit, it is pulled into the first slot and the second slot. That is, the winding inserted in the first slot is drawn into the first slot (outside of the stator core diameter) by the two winding arms arranged on the first slot side. As a result, the winding in the first slot is deformed so as not to protrude. For this reason, the protrusion of the winding from the first slot is prevented. Moreover, since the winding is pulled in, a space for inserting the winding into the first slot can be formed. For this reason, even when a stator (coil) having a high space factor of the winding in the slot is formed, the winding can be surely arranged in the slot.

  Further, the winding inserted in the second slot is drawn into the second slot (outward direction of the stator core) by the two winding arms arranged on the second slot side. As a result, the winding in the second slot is deformed into a shape that is difficult to protrude. For this reason, the protrusion of the winding from the second slot is prevented. Moreover, since the winding is pulled in, a space for inserting the winding into the second slot can be formed next. For this reason, even when a stator (coil) having a high space factor of the winding in the slot is formed, the winding can be surely arranged in the slot.

  In particular, when the stator is formed by distributed winding, the cross-sectional area of the slot of the stator core tends to be small, so that the space factor of the winding in the slot tends to be high and insertion is often difficult. Further, the winding easily protrudes from the slot to the inside of the stator core. Therefore, it is preferable to use this winding device. That is, when the stator core has another slot between the first slot and the second slot, it is particularly preferable to use the winding device of the present invention.

  In the stator core winding device according to the present invention, the winding arm drive unit separates the winding arm from the winding former and moves the winding nozzle to the winding arm and the winding former. Preferably, the winding arm is brought into contact with the winding former when the winding nozzle passes between the winding arm and the winding former.

Thus, for example, in the case described above, after the winding nozzle inserts the winding into the first slot (outward path), the winding arm arranged on the first slot side contacts the winding former. . For this reason, it can prevent that the coil | winding inserted in the 1st slot protrudes inside from the inner surface of a stator core.
Next, after the winding nozzle swings in the circumferential direction and the winding nozzle inserts the winding into the second slot (return path), the winding arm disposed on the second slot side contacts the winding former. Touch. For this reason, it can prevent that the coil | winding inserted in the 2nd slot protrudes inside from the inner surface of a stator core.

  Here, there is a winding apparatus that uses an elongated nozzle such as a linear nozzle as the winding nozzle. In such a winding device, when the winding discharged from the long and narrow nozzle receives a tension, it gathers at the end of the nozzle opposite to the traveling direction of the winding discharge device, and the arrangement of the winding in the nozzle Can be biased. For this reason, friction may occur between the windings or between the winding and the wall surface of the nozzle, which may damage the insulating coating of the windings. Further, it may be difficult to smoothly discharge the winding due to friction. In addition, since a force is applied to push the nozzle in the width direction (short direction), the nozzle may be deformed.

  Therefore, in the stator core winding device according to the present invention, it is preferable that the winding nozzle has a plurality of discharge ports arranged linearly in the stator axial direction and individually discharging the windings.

  Thereby, since only one winding is discharged from each discharge port, the arrangement of the windings at each discharge port (nozzle) can hardly be biased. For this reason, almost no force is generated to push and spread each discharge port in the short direction, so that each discharge port is not easily deformed. Further, since there is no friction between the windings, there is no risk of damaging the insulation coating of the windings. In addition, since each winding is discharged individually, there is no friction from other windings, so that the windings can be discharged very smoothly. Therefore, the winding can be smoothly discharged without damaging the insulation coating of the winding.

  The stator core winding device according to the present invention further includes a winding supply unit that supplies a winding to the winding nozzle while adjusting the length and tension of the winding, and the winding supply unit includes: It is desirable to have a first adjustment mechanism that adjusts the length and tension of the entire plurality of windings, and a second adjustment mechanism that adjusts the length and tension of each winding.

  In this case, the first adjustment mechanism adjusts the length and tension of the entire plurality of windings when the operation of the winding nozzle changes from swing to vertical motion, and the second adjustment mechanism The adjustment mechanism may adjust the length and tension of each winding when the winding nozzle is swinging.

  In the winding device of the present invention, the winding nozzle is moved up and down and swinged while individually discharging the windings from the discharge ports arranged linearly in the stator axial direction, and the winding is wound around the stator core. For this reason, when the length of the winding supplied to the winding nozzle is kept constant, the winding is slackened, or conversely, the winding is pulled. If it does so, there exists a possibility that a winding may not be wound around a stator core well, or there exists a possibility that a winding may be damaged.

  Therefore, in the winding device of the present invention, the winding supply unit has a first adjustment mechanism that adjusts the length and tension of the entire plurality of windings, and a second adjustment that adjusts the length and tension of each winding. Mechanism. For this reason, the slack which arises in the whole several winding by the operation | movement of a winding nozzle is eliminated by the 1st adjustment mechanism. Further, the slack for each winding caused by the difference in the winding discharge position in the winding nozzle is eliminated by the second adjustment mechanism. Thereby, slack does not generate | occur | produce in the whole winding and each winding, and moderate tension is given. For this reason, the winding shape of the winding in the stator core can be stabilized and damage to the winding can be prevented.

  According to the winding method and the winding device for the stator core according to the present invention, as described above, the stator core is indexed and the respective processes are processed in parallel, so that the winding work process can be performed by a single facility.

  BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a most preferred embodiment in which a stator winding method and a winding device of the present invention are embodied will be described in detail with reference to the drawings. In the present embodiment, the present invention is applied to a manufacturing process of a stator used for a motor for driving a hybrid vehicle.

  First, a motor provided with a stator manufactured by using the winding technique according to the present embodiment will be described with reference to FIG. FIG. 1 is a schematic diagram schematically showing the configuration of a motor. The motor 1 is a three-phase motor including a rotor 9 and a stator 2. Among these, the rotor 9 is an eight-pole permanent magnet rotor composed of a cylindrical rotor body 92 centering on the rotation shaft 91 and a permanent magnet 93. The permanent magnet 93 is fixed to the rotor body 92 in a zigzag manner along the vicinity of the outer peripheral surface like a petal in a plan view. On the other hand, the stator 2 is disposed so as to surround the rotor 9.

Subsequently, a stator manufactured using the winding technique according to the present embodiment will be described with reference to FIGS. FIG. 2 is a schematic diagram schematically showing the configuration of the stator.
FIG. 3 is a perspective view showing a schematic configuration of the stator. FIG. 4 is a connection diagram showing the connection of each phase coil. 5A and 5B are diagrams showing a schematic configuration of the stator core, wherein FIG. 5A is a plan view of the stator core, and FIG. 5B is a longitudinal sectional view of the stator core. FIG. 6 is a partially enlarged perspective view showing a state in which the U-phase winding is wound around the stator core. FIG. 7 is a partially enlarged perspective view showing a state in which the U-phase winding and the V-phase winding are wound around the stator core. FIG. 8 is a partially enlarged perspective view showing a state in which the U-phase winding, the V-phase winding, and the W-phase winding are wound around the stator core.

  As shown in FIGS. 2 and 3, the stator 2 is a three-phase eight-pole distributed winding stator. As shown in FIG. 5, the stator 2 includes a stator core 3 having a ring shape in a plan view and having 48 teeth (inner teeth) 4 and 48 slots 5 constituted by adjacent teeth 4. . The stator 2 includes eight U-phase coils 7u, V-phase coils 7v, and W-phase coils 7w, respectively. These coils use a winding bundle 6P with 16 windings as one set for each phase of U phase, V phase, and W phase, and U phase winding 6u, V phase winding 6v, W phase winding. The wire 6w is inserted into a predetermined slot 5 (U-phase, V-phase, W-phase slots 5u, 5v, 5w) and wound around each tooth 4 by distributed winding.

  Specifically, as shown in FIGS. 2 and 6 to 8, the U-phase coil 7 u is inserted into the U-phase slot 5 u of the slots 5 and wound around the teeth 4 therebetween. Similarly, the V-phase coil 7v is inserted into the V-phase slot 5v and wound around the teeth 4, and the W-phase coil 7w is inserted into the W-phase slot 5w and wound around the teeth 4 therebetween. Accordingly, the U-phase, V-phase, and W-phase slots 5u, 5v, and 5w are divided into two U-phase slots 5u, two V-phase slots 5v, and two W-phase slots 5w in this order in the stator 2 (stator core 3). They are arranged repeatedly in the circumferential direction (clockwise in FIG. 2).

  Further, in this motor 1 (stator 2), the windings of each phase are so-called double star connection as shown in FIG. For this reason, among the U-phase windings 6u, one U-phase winding 6Au causes four U-phase coils 7u forming one U-phase coil array 7Au in order in the circumferential direction of the stator 2 (stator core 3) (FIG. 2). In the clockwise direction). Further, four U-phase coils 7u forming the other U-phase coil array 7Bu are formed side by side in the circumferential direction of the stator 2 (clockwise in FIG. 2) by the other U-phase winding 6Bu. Similarly, one V-phase winding 6Av among the V-phase windings 6v forms a V-phase coil 7v forming a V-phase coil array 7Av in order in the circumferential direction of the stator 2 (clockwise in FIG. 2). The other V-phase winding 6Bv forms a V-phase coil 7v forming the V-phase coil array 7Bv in order in the circumferential direction of the stator 2. Further, the W-phase winding 6w is also formed such that one of the W-phase windings 6Aw includes the W-phase coil 7w forming the W-phase coil array 7Aw in order in the circumferential direction of the stator 2 (clockwise in FIG. 2). The other W-phase winding 6Bw forms a W-phase coil 7w forming a W-phase coil array 7Bw in order in the circumferential direction of the stator 2.

  As shown in FIG. 2, U-phase external connection ends 61Au and 61Bu which are one ends of the U-phase windings 6Au and 6Bu are connected to each other to form a U-phase external connection terminal 65u. Similarly, V-phase external connection terminals 61Av and 61Bv, which are one ends of the V-phase windings 6Av and 6Bv, are connected to each other to serve as a V-phase external connection terminal 65v. Furthermore, the W-phase external connection ends 61Aw and 61Bw, which are one ends of the W-phase windings 6Aw and 6Bw, are connected to each other to serve as a W-phase external connection terminal 65w.

  On the other hand, U-phase neutral connection ends 62Au and 62Bu that are the other ends of the U-phase windings 6Au and 6Bu, V-phase neutral connection ends 62Av and 62Bv that are the other ends of the V-phase windings 6Av and 6Bv, and a W-phase winding. The W-phase neutral connection ends 62Aw and 62Bw, which are the other ends of the lines 6Aw and 6Bw, are connected to each other by a connection 66 to be a neutral point N. Thus, the applied voltage at the time of driving the motor 1 is lowered by making the connection of each phase coil a double star connection.

  2 and 3 show the U-phase coil end portion 7Hu and the V-phase coil end portion 7Hv located outside the both end surfaces of the stator core 3 among the U-phase coil 7u, the V-phase coil 7v, and the W-phase coil 7w. , W-phase coil end portion 7Hw is also shown in the mutual positional relationship when viewed from one end surface side of the stator core. Specifically, as shown in FIGS. 6 to 8, the stator core 3 is arranged in the order of the U-phase coil 7u (see FIG. 6), the V-phase coil 7v (see FIG. 7), and the W-phase coil 7w (see FIG. 8). It is rolled up. In addition, each U-phase coil 7u is formed such that the U-phase coil end portion 7Hu of the U-phase coil 7u is positioned radially outward from the V-phase slot 5v and the W-phase slot 5w. Further, each V-phase coil 7v is formed such that the V-phase coil end portion 7Hv of the V-phase coil 7v is disposed radially inward from the U-phase coil end portion 7Hu of the U-phase coil 7u. Furthermore, each W-phase coil 7w is formed such that the W-phase coil end portion 7Hw of the W-phase coil 7w is disposed radially inward of the V-phase coil end portion 7Hv of the V-phase coil 7v. Thus, the U-phase coil end portion 7Hu, the V-phase coil end portion 7Hv, and the W-phase coil end portion 7Hw are arranged in this order from the radially outer side of the stator core 3 toward the radially inner side.

  In FIGS. 1 and 2, the windings 6u, 6v, 6w of each phase in the U-phase coil 7u, the V-phase coil 7v, and the W-phase coil 7w (clockwise and counterclockwise, forward and reverse winding) In order to show the difference, “dot (•)” and “cross (×)” are shown on the sides of the coils 7u and the like of each phase. Of the coils 7u and the like of each phase, the side indicated by “cross” indicates that they are close to the external connection terminals 65u, 65v, and 65w of each phase, and the side indicated by “dot” indicates that they are close to the neutral point N. Yes. As can be understood from this, the eight coils 7u, 7v, 7w of each phase are alternately reversely wound, and it is understood that the magnetic fields generated in the adjacent coils have opposite polarities. .

Further, in the stator 2, the coils 6u, 6v, 6w of the respective phases are formed by winding the windings 6u, 6v, 6w of the respective phases as described above, so that one of the U phase, the V phase, and the W phase is formed. The coil winding directions in the coil rows 7Au, 7Av, 7Aw and the other coil rows 7Bu, 7Bv, 7Bw are all the same. For example, when looking at the U-phase coil array 7Au, the winding is in the order of normal winding, reverse winding, normal winding, and reverse winding from the side close to the external connection terminal 65u. The same applies to the V-phase coil group 7Av and the W-phase coil group 7Aw. The same applies to the coil arrays 7Bu, 7Bv, and 7Bw. When each coil is viewed from the inside of the core, the winding method for winding counterclockwise is forward winding, and the winding method for winding clockwise is reverse winding.
Therefore, since the coils of each phase can be formed in the same pattern, the stator can be manufactured easily and inexpensively.

  As already described, the stator core 3 shown in FIG. 5 has a ring shape in plan view and 48 teeth 4 extending inward in the radial direction and the 48 teeth 4 positioned between these teeth 4. A slot 5 is provided. The stator core 3 is configured by stacking steel plates 39 formed by, for example, stamping directional silicon steel plates and fixing them together.

  The U-phase winding 7u, the V-phase winding 7v, and the W-phase winding 7w are wound around the teeth 4 of the stator core 3, respectively. In the present embodiment, the winding of the stator core as schematically shown in FIGS. A winding is wound around the stator core 3 using the wire device 100. FIG. 9 is a perspective view showing a schematic configuration of the winding device 100. FIG. 10 is a perspective view showing a main part that performs a winding operation in the winding apparatus 100.

  Here, when the stator core 3 is set, the winding device 100 automatically performs winding to form a three-phase (U, V, W phase) coil. For this purpose, the winding device 100 includes a winding nozzle driving unit 120, a winding former attaching / detaching / exchanging unit 140, a winding on the upper surface of a table 103 supported by four legs 102 erected on a base 101. An arm driving unit 160, a coil end forming unit 180, a work pallet unit 200, an inspection unit 220, crossover processing units 240a and 240b, an interphase insulator assembly unit 260, and a winding supply unit 280 are provided. Note that the winding nozzle driving unit 120, the winding former attaching / detaching / exchanging unit 140, the winding arm driving unit 160, the coil end forming unit 180, the work pallet unit 200, and the interphase insulator assembling unit 260 are described below. A part of the device is also arranged on the side. In addition, a wedge paper insertion unit 300 is provided on the lower surface of the table 103.

  The winding former attaching / detaching / exchange unit 140, the winding arm driving unit 160, the coil end forming unit 180, the inspection unit 220, the crossover processing unit 240, and the interphase insulator assembly unit 260 surround the holder 202. Are arranged. As will be described later, the holder 202 accommodates and holds the stator core 3 set on the winding device 100. Thereby, each process in each part can be executed in parallel while indexing the stator core 3. Focusing on one coil, the winding of the winding 6 around the stator core 3, the forming of the wound winding 6 (coil 7), the inspection of the formed coil 7, and the insulation of the coil 7 may be sequentially performed. it can.

  Thus, in the winding apparatus 100, it is not necessary to move (move between apparatuses) or reverse the stator core 3 for each process. Therefore, the winding device 100 does not require a device for moving or reversing the stator core 3. Therefore, in the winding apparatus 100, the above-described parts can be arranged so as to surround the holder 202, and the winding work process can be carried out with a single facility.

  The winding nozzle driving unit 120 controls driving of the winding nozzle 121 that discharges the winding wound around the stator core 3. As shown in FIG. 11, the winding nozzle driving unit 120 has a winding nozzle 121 that discharges the winding, a nozzle holder 130 that holds the winding nozzle 121, and a ball spline in which the nozzle holder 130 is inserted. 131, a ball screw 132, a detent shaft 133, and two servo motors 134 and 135 are provided. FIG. 11 is a perspective view illustrating a schematic configuration of the winding nozzle driving unit 120.

  The servo motor 134 and the ball spline 131 are connected via a belt, and the winding nozzle 121 can be swung in the circumferential direction of the stator core by controlling the drive of the servo motor 134. Yes. The servo motor 135 and the ball screw 133 are connected via a belt, and the winding nozzle 121 can be moved up and down (moved in the Z-axis direction) by controlling the drive of the servo motor 135. ing.

  Thereby, the winding nozzle 121 can be wound between two predetermined slots in the stator core 3 by distributed winding of the winding discharged from the winding nozzle 121. Then, by adjusting the drive control contents of the two servo motors 134 and 135, the winding nozzle 121 can be moved in an arbitrary curve.

  Such a winding nozzle driving unit 120 is provided on a support 136 fixed on the table 103 so as to be movable in the Z-axis direction. Accordingly, the winding nozzle driving unit 120 arranges the winding nozzle 121 (nozzle holder 130, ball spline 131, ball screw 132, and rotation stopper shaft 133) inside the stator core 3 or retracts from the inside of the stator core 3. It can be made to. Such an operation is necessary, for example, when the stator core 3 is replaced.

  Here, inside the winding nozzle 121, as shown in FIG. 12, there are sixteen winding tubes 122, and a first holding portion 123 that holds and holds the eight winding tubes 122 by eight, A second holding portion 124 that holds the twisted winding tubes 122 held in the first holding portion 123 in a row; and a tip portion 125 that enters the slot 5 of the stator core 3 and discharges the winding 6. It has. A discharge port 126 for discharging the winding 6 individually is formed in the tip portion 125 in a straight line in the stator axial direction. As a result, the winding bundle 6P (16 windings 6) supplied from the upper part of the winding nozzle 121 via the winding supply part 280 is transferred to the tip part 125 by the winding tube 122 disposed in the winding nozzle 121. The discharge ports 126 are discharged in one vertical row. The winding tube 122 and the tip end portion 125 are formed of a material that does not damage the coating of the winding 6, so that the coating of the winding 6 is not damaged in the winding nozzle 121. FIG. 12 is a perspective view showing the internal configuration of the winding nozzle 121.

  The winding former attaching / detaching / exchanging unit 140 attaches / detaches / replaces the winding formers 150 u, 150 v, 150 w having different shapes for the U, V, W phases to / from the stator core 3. As shown in FIG. 13, the winding former attaching / detaching / exchanging unit 140 includes an upper receiving portion 141 ua and a lower receiving portion 141 ub for receiving an upper winding former 150 ua and a lower winding former 150 ub for forming a U-phase coil, respectively. I have. Further, an upper accommodating portion 141va and a lower accommodating portion 141vb for accommodating an upper winding former 150va and a lower winding former 150vb for forming a V-phase coil are provided. Further, an upper accommodating portion 141wa and a lower winding former 141wb for accommodating an upper winding former 150wa and a lower winding former 150wb for forming a W-phase coil are provided. FIG. 13 is a side view showing a schematic configuration of the winding former attachment / detachment / exchange unit 140.

  These accommodating portions are provided above and below the table 103, respectively. Specifically, the upper housing parts 141 ua, 141 va, 141 wa are arranged on the upper surface side of the table 103, and the lower housing parts 141 ub, 141 vb, 141 wb are arranged on the lower surface side of the table 103. The winding formers 150u, 150v, and 150w are separated into upper and lower parts and are accommodated in the accommodating portions. Specifically, the upper winding former 150ua is accommodated in the upper accommodating portion 141ua, and the lower winding former 150ub is accommodated in the lower accommodating portion 141ub. Further, the upper winding former 150va is accommodated in the upper accommodating portion 141va, and the lower winding former 150vb is accommodated in the lower accommodating portion 141vb. Further, the upper winding former 150wa is accommodated in the upper accommodating portion 141wa, and the lower winding former 150wb is accommodated in the lower winding former 141wb.

  Further, the winding former attaching / detaching / changing unit 140 includes a holding part 142a for holding any one of the separately housed upper winding formers 150ua, 150va, and 150wa and a separately housed lower winding former 150ub, 150vb. , 150wb, and gripping portions 142b, 142b, and actuator portions 143a, 143b for moving the gripping portions 142a, 142b in the three-axis (X, Y, Z) directions. Therefore, the gripping portions 142a and 142b and the actuator portions 143a and 143b are also arranged above and below, respectively, with the table 103 as a boundary. Specifically, the grip portion 142 a and the actuator portion 143 a are provided on the upper side of the table 103, and the grip portion 142 b and the actuator portion 143 b are provided on the lower side of the table 103. Then, by controlling the driving of the gripping portions 142a and 142b and the actuator portions 143a and 143b, the winding former is taken out from the housing portion and attached to the stator core 3, or the winding former attached to the stator core 3 is removed. So that it can be stored again in the storage section.

  Here, the winding former will be described. Each winding former is different only in the shape of the former part and has the same basic configuration. Therefore, a winding former 150u for forming a U-phase coil will be described as a representative example. As shown in FIGS. 14A and 14B, the winding former 150u has an upper and lower separation structure of an upper winding former 150ua and a lower winding former 150ub. FIG. 14 is a perspective view showing a schematic configuration of the U-phase winding former 150u in a separated state (in a state where the U-phase winding former 150u is held), wherein (a) shows the front side, and (b) ) Indicates the back side.

  The upper winding former 150ua is provided at a former portion 151ua around which the winding 6 is wound, a former support portion 152ua that supports the former portion 151ua, and a lower portion of the former support portion 152ua, and is coupled to the lower winding former 150ub. And a coupling portion 153ua. The former part 151ua is formed in the shape of the U-phase coil end part 7Hu. Thereby, by winding the winding 6 along the former part 151ua, the U-phase coil end part 7Hu can always have a constant shape. A protrusion 350 is formed on the lower surface of the former portion 151ua. The protrusion 350 is adapted to fit into an assembly hole provided in a cuff attached to the stator core 3.

  On both side surfaces and the upper surface of the former support portion 152ua, fitting holes 351 for fitting the respective protrusions formed on the grip portion 142a are formed. As a result, when the gripping part 142a grips the upper winding former 150ua, each protrusion of the gripping part 142a is fitted into each fitting hole 351, so that the upper winding former 151ua is firmly gripped by the gripping part 142a. be able to.

  In addition, a positioning member 354 that engages with the teeth 4 of the stator core 3 to position the upper winding former 150ua with respect to the stator core 3 when attached to the stator core 3 is attached to the former support portion 152ua. Engaging portions 352 are formed on both side surfaces of the coupling portion 153ua to engage the clamp claws 356 of the lower winding former 150ub. In addition, a fitting convex portion 353 that fits into the fitting concave portion 363 of the lower winding former 150 ub is formed on the lower surface of the coupling portion 352.

  On the other hand, the lower winding former 150ub is coupled to a former part 151ub around which the winding 6 is wound, a former support part 152ub that supports the former part 151ub, and an upper winding former 150ua provided on the former support part 152ub. Connecting portion 153ub. The former part 151ub is formed in the shape of the U-phase coil end 7Hu. Thereby, by winding the winding 6 along the former part 151ub, the U-phase coil end part 7Hu can always have a constant shape. Further, a protrusion 350 is formed on the upper surface of the former portion 151ub. The protrusion 350 is adapted to fit into an assembly hole provided in a cuff attached to the stator core 3.

  The former support portion 152ub is provided with rods 360 and 360 and a bottom plate 361 to which the lower ends of these rods 360 are fixed. The bottom plate 361 is provided so as to be movable up and down in the former portion 151ub. On the other hand, an engagement piece 362 that engages with the flat portion 358 a of the cam 358 is formed at the upper end of the rod 360. The rods 360 and 360 incorporate springs, and these springs are fixed to the bottom plate 361 and the cam 358.

  In addition, on both side surfaces of the former support portion 152ub, fitting holes 351 into which the respective protrusions formed on the grip portion 142b are fitted are formed. Further, a fitting hole 351 is formed in the lower surface of the bottom plate 361. As a result, when the gripping part 142b grips the lower winding former 150ub, the protrusions of the gripping part 142b fit into the fitting holes 351, so that the upper winding former 151ua is firmly gripped by the gripping part 142b. can do. Further, a positioning member 354 that engages with the teeth 4 of the stator core 3 and positions the lower winding former 150 ub with respect to the stator core 3 when attached to the stator core 3 is attached to the former support portion 152 ub.

  The coupling portion 153ub is provided with clamps 355 and 355 for coupling to the coupling portion 153ua of the upper winding former 150ua. These clamps 355 are fixed to the former support part 152 ub so as to be rotatable by pins 357. Thereby, since the clamp 355 rotates around the pin 357, the clamp 355 can perform an opening / closing motion. A clamp claw 356 that engages with the engagement portion 352 in the coupling portion 153 ua of the upper winding former 150 ua is formed at the tip of the clamp 355. At the lower end of the clamp 355, a cam 358 having an upward convex taper portion is disposed. In a normal state (a state where the grip part is not gripped), the bottom plate 361 is biased downward by the spring, so that the engagement piece 362 of the rod 360 is engaged with the flat part 358a of the cam 358. Since the cam 358 and the clamps 355 and 355 are separated from each other, the clamps 355 and 355 are in a closed state (see FIG. 16). In addition, the coupling portion 153ub is provided with a fitting recess 363 between the clamps 355 and 355, into which the fitting projection 353 of the upper winding former 150ua is fitted.

  When the lower winding former 150ub is gripped by the gripping portion 142b, the bottom plate 361 moves upward. Then, the rods 360 and 360 move upward, and the engaging pieces 362 and 362 are separated from the flat portions 358a and 358a of the cam 358. As a result, the cam 358 rises and comes into contact with the bottom surfaces of the clamps 355 and 355. As a result, the clamps 355 and 355 are opened.

  In this state, in order to couple the upper winding former 150ua and the lower winding former 150ub, as shown in FIGS. 15A and 15B, the fitting convex portion 353 of the coupling portion 153ua and the coupling portion 153ub are connected. The fitting recess 363 is fitted. In this state, the clamps 355 and 355 remain open. FIG. 15 is a perspective view showing a state in which the upper winding former 150ua and the lower winding former 150ub are in contact with each other, wherein (a) shows the front side and (b) shows the rear side. .

Thereafter, when the lower winding former 150ub is released from the gripping portion 142b in the state shown in FIGS. 15A and 15B, the bottom plate 361 moves downward as shown in FIGS. 16A and 16B. To do. Note that the release timing of the upper winding former 150ua from the gripping portion 142a may be the same as or different from the releasing timing of the lower winding former 150ub from the gripping portion 142b. When the bottom plate 361 moves downward, the rods 360 and 360 move downward and the engaging pieces 362 and 362 engage with the flat portions 358a and 358a of the cam 358. As a result, the cam 358 is lowered and separated from the clamps 355 and 355. As a result, the clamps 355 and 355 are closed, and the claw 356 of the clamp 355 is engaged with the engagement portion 352 of the coupling portion 153ua. Thus, the upper winding former 150ua and the lower winding former 150ub are coupled. FIG. 16 is a perspective view showing a state in which the upper winding former 150 ua and the lower winding former 150 ub are coupled, wherein (a) shows the front side and (b) shows the rear side.
In this way, the phase winding former 150 has a vertically separated structure, so that the winding former 150 is automatically attached to and removed from the stator core 3.

  The winding arm driving unit 160 controls driving of the four winding arms 161 to 164 that perform winding with respect to the stator core 3 together with the winding nozzle 121. As shown in FIG. 17, the winding arm driving unit 160 includes first to fourth driving units 171 to 174 that control driving of the first to fourth arms 161 to 164. These arm driving units 171 to 174 can move the first to fourth arms 161 to 164 forward and backward in the stator core radial direction and move in the vertical (Z-axis) direction. FIG. 17 is a perspective view showing a schematic configuration of the winding arm drive unit 160.

Here, since the first to fourth arms 161 to 164 are basically the same in configuration and operation, the first arm 161 will be described as a representative example below.
The first arm 161 is fixed to the distal end portion of the first drive unit 171 at the first root portion 161a so as to be swingable on the stator core horizontal plane (XY plane). The first arm 161 is attached to the first drive unit 171 so that the second base portion 161b slides in the cam groove 171a. Note that by raising the first arm 161, the engagement between the second root portion 161b and the cam groove 171a can be released. Then, when the first arm 161 is advanced inward in the stator core diameter, the cam groove 171a first advances along the winding former 150 (150u or the like) at the end of the first arm 161, and finally the winding. The shape swings in a direction away from the former 150.

  In such a winding arm drive unit 160, the movements of the first to fourth arms 161 to 164 are controlled by the first to fourth drive units 171 to 174. The movement of the first to fourth arms 161 to 164 will be described with reference to FIG. 18 using the first winding arm 161 as a representative example. FIG. 18 is an explanatory diagram showing each operation state of the winding former.

  First, from the initial position shown in FIG. 18A, the first arm 161 is advanced in the stator core radial inward direction by the first drive unit 171. Then, as shown in FIG. 18 (b), the first winding arm 161 swings away from the winding former 150 due to the restriction of the cam groove 171a, and interference (collision) with the winding nozzle 121 occurs. Move to the nozzle retract position to avoid.

  When the winding nozzle 121 passes, the first arm 161 is retracted outwardly by the first drive unit 171 in the stator core diameter direction. Then, as shown in FIG. 18 (c), the first winding arm 161 swings due to the restriction of the cam groove 171a and comes into close contact with the winding former 150. For this reason, it is possible to prevent the winding 6 inserted into the slot 3 of the stator core 3 from protruding from the slot 3.

  Then, while the first arm 161 is in close contact with the winding former 150, as shown in FIG. Thus, the winding 6 discharged from the winding nozzle 121 and inserted into the slot 5 of the stator core 3 is drawn into the slot 5 by the first arm 161. Thereby, the coil | winding 6 in the slot 5 is deform | transformed into the shape which is hard to protrude. For this reason, the protrusion of the winding 6 from the slot 5 is prevented. Moreover, since the winding 6 is pulled in, a space for inserting the winding 6 into the slot 5 can be formed next. For this reason, even when a stator (coil) having a high space factor of the winding in the slot is formed, the winding can be surely arranged in the slot.

  In addition, since a coil formation position differs in each phase coil, the amount of winding 6 by the 1st arm 161 differs for every phase. Specifically, the pull-in amount when winding the U-phase coil 7u is the largest, and the pull-in amount decreases as the V-phase coil 7v and the W-phase coil 7w are obtained. For this reason, the first drive unit 171 variably controls the amount of movement of the first arm 161 in the outward direction of the stator core diameter for each phase. Thereby, since it can respond to each coil formation of the U-phase coil 7u, the V-phase coil 7v, and the W-phase coil 7w with one-shaped winding arms 161 to 164, the configuration of the winding device 100 is configured. It can be simplified.

The second to fourth arms 162 to 164 also perform the same operation as the first arm 161, and the first to fourth arms 161 to 164 are driven by the nozzles described above by the first to fourth driving units 171 to 174. The advance / retreat operation and the retreat operation are performed in synchronization with the unit 120.
As a result, the winding 6 discharged from the winding nozzle 121 is inserted into the slot 5 of the stator core 3, and is passed between the slots 5 over the winding former 150 mounted on the stator core 3 and the coil end portion. As a result, coils 7u, 7v, and 7w for each phase are formed. In this way, the coils 7u, 7v, and 7w for the U phase, V phase, and W phase are sequentially formed (see FIGS. 6 to 8), and the stator 2 and the motor 1 are manufactured.

  The coil end forming part 180 mainly forms the coil end part 7H (7Hu, 7Hv, 7Hw) of each phase coil 7 (7u, 7v, 7w) formed in the stator core 3. The coil end forming portion 180 also has a function of holding the winding 6 (hereinafter referred to as “crossover wire 6 </ b> C”) that is wound around the stator core 3 from the winding nozzle 121. Note that the coil end forming portion 180 is also provided on the lower surface side of the table 103. As shown in FIG. 19, the coil end molding portion 180 includes L-shaped (side view) extended claws 181 and 182 that can move (open / close operation) in the circumferential direction of the stator core. FIG. 19 is an enlarged view showing the coil end forming section 180 and the crossover processing sections 240a and 240b.

  The expansion claws 181 and 182 are moved by the drive unit 185 in the stator core radial direction and the vertical direction (Z-axis direction). Thereby, in the coil end shaping | molding part 180, the expansion claws 181 and 182 are located inside the coil end part 7H of each phase coil 7, and the expansion claws 181 and 182 are opened to retract the stator core radially outward. The coil end portion 7H of each phase coil 7 can be expanded. Further, by lowering the extension claws 181 and 182, the lower end of the arm portions 183 and 184 of the extension claws 181 and 182 can be molded to suppress the height of the coil end portion 7H.

  Further, the coil end forming part 180 not only forms the coil end part 7H of each phase coil 7 wound around the stator core 3, but also holds the jumper 6C when reversing the winding direction of the winding. It is also. That is, the coil end forming portion 180 protects the coil 7 so that the connecting wire 6C does not break the shape of the coil 7 (coil end portion 7H) during the crossover processing.

  The work pallet unit 200 holds and accommodates the stator core 3 and moves it to a predetermined position (including an index operation). As shown in FIGS. 20A and 20B, the work pallet unit 200 includes a pallet 201, a holder 202, and an index servo motor 203. FIG. 20 is a perspective view showing a schematic configuration of the work pallet unit, where (a) shows a case when viewed from above, and (b) shows a case when viewed from below.

  In the work pallet unit 200, a holder 202 is mounted on the pallet 201. On the pallet 201, a holder 202 having a size corresponding to a stator core for winding is set. That is, if the type of the stator core is changed, the holder 202 set on the pallet 201 is also changed.

  As shown in FIG. 20A, the pallet 201 is arranged on rails 205 and 205 installed in parallel on the table 103. The pallet 201 is connected to a slider 206 provided on the table 103. Thus, the pallet 201 moves on the rails 205 and 205 in the Y-axis direction. As shown in FIG. 19B, the pallet 201 is fixed at a predetermined position (winding position) by a pallet displacement prevention pin 207 installed on the lower surface of the table 103. Specifically, when one pin provided on the pallet displacement prevention pin 207 is fitted into one pin hole provided on the pallet 201, the pallet 201 is fixed at a predetermined position. ing.

  On the other hand, the holder 202 mounted on the pallet 201 is rotated (indexed) at a predetermined angle by an index servo motor 203 provided on the lower surface of the pallet 201. The holder 202 is fixed at a predetermined position (winding position) by an angle deviation prevention fixing pin 208 installed on the table 103. Specifically, the holder 202 is fixed at a predetermined position by fitting a pin provided on the angle deviation prevention fixing pin 208 into a notch formed on the outer periphery of the holder 202. In this way, by indexing the holder 202, the stator core 3 accommodated and held in the holder 202 can be indexed, and the relative position between each part of the winding device 100 and the stator core 3 can be changed in order. ing.

  The inspection unit 220 performs shape inspection of each phase coil 7 formed by the coil end forming unit 180. Therefore, as shown in FIG. 10, a CCD camera 221 is installed in the inspection unit 220. A sensor such as a laser may be installed in place of the CCD camera 221. Then, in the inspection unit 220, the coil end shape, the coil end dimensions (inner and outer diameters, etc.), the presence or absence of stray lines, and the coil surface are detected by a known method (image processing) based on the image data obtained by the CCD camera 221. It checks for the presence of scratches and manages the inspection results. Such an inspection by the inspection unit 220 is performed when the stator core 3 is indexed each time the phase coil 7 is formed on the stator core 3 and each phase coil 7 is positioned directly below. Note that when the inspection unit 220 detects an abnormality, the inspection unit 220 notifies the operator of the abnormality. When an abnormality is detected, the operator performs rework.

  The crossover processing sections 240a and 240b are for holding the winding 6 (crossover 6C) that is wound around the stator core 3 from the winding nozzle 121 and guiding the crossover 6C to the next winding position. is there. As shown in FIG. 19, the crossover processing unit 240 a is disposed next to the winding arm driving unit 160 (upstream in the index direction of the stator core). A crossover clamp 241 is provided at the tip of the crossover processor 240a. The crossover clamp 241 includes a fixed portion 242 and a movable portion 243, and can be opened and closed. Thereby, the crossover clamp 241 can hold and release the crossover 6C. Further, the crossover clamp 241 can be moved in the three-axis (X, Y, Z) directions by the drive unit 244.

  On the other hand, the crossover processing section 240b is disposed next to the coil end forming section 180 (downstream in the index direction of the stator core). The crossover processing section 240b temporarily holds the crossover 6C so that the crossover 6C does not cross the coil end 7H of the coil 7 already wound around the stator core 3 when shifting from reverse winding to normal winding. And the crossover hook 246 is provided in the front-end | tip of the crossover processing part 240b. The crossover hook 246 is movable in the three-axis (X, Y, Z) directions by the driving unit 247 and can be opened and closed.

  The interphase insulator assembly 260 assembles interphase insulators 261uv and 261vw made of resin that secure insulation between the coil phases (between the UV phase and the VW phase) to the stator core 3. Interphase insulator 261uv is assembled between U-phase coil 7u and V-phase coil 7v, and inter-phase insulator 261vw is assembled between V-phase coil 7v and W-phase coil 7w.

  The interphase insulator assembling portion 260 is provided up and down with the table 103 as a boundary in order to attach the interphase insulators 261uv and 261vw to the coil end portions 7H protruding from both end faces of the stator core 3. Further, as shown in FIG. 21, the interphase insulator assembly portion 260 includes a grip portion 270 that holds the legs 13 and 33 (see FIGS. 23 and 24) of the interphase insulators 261uv and 261vw, and an interphase insulator 261uv. , 261 vw are aligned and fixed, and a drive unit 272 that drives the gripping unit 270 in three axis (X, Y, Z) directions is provided. The grip part 270, the pallet part 271, and the drive part 272 are provided above and below the table 103 as a boundary. FIG. 21 is a perspective view showing a schematic configuration of the interphase insulator assembly.

  Two grip members 275 and 275 are arranged in parallel on the grip portion 270 so as to be openable and closable. Then, as shown in FIG. 22, a claw portion 276 is provided at the tip of each gripping member 275. FIG. 22 is a perspective view showing the grip portion 270. By opening and closing the claw portions 276 and 276, the leg portions 13 and 33 of the interphase insulators 261uv and 261vw can be grasped or released. Thereby, in the holding part 270, the interphase insulators 261uv and 261vw fixed to the pallet part 270 can be taken out from the pallet part 271, and the interphase insulators 261uv and 261vw taken out from the pallet part 270 can be assembled to the stator core 3. It has become.

  As shown in FIG. 21, the pallet part 270 has an engagement groove 277 for engaging the legs 13 and 33 of the interphase insulators 261uv and 261vw, and an opening 278 for the claw part 276 of the grip part 270 to enter. Is formed. The engaging groove 277 and the opening 278 communicate with each other and are formed for each interphase insulator. For this reason, in the present embodiment, it is necessary to set eight interphase insulators 261uv and 261vw on the pallet part 271, so that one pallet part 270 has 16 engagement grooves 277 and 16 openings 278 formed therein. ing.

  Here, the interphase insulators 261uv and 261vw will be described. First, the interphase insulator 261uv is a resin molded product formed into a shape that follows the U-phase coil 7u wound around the slot 5 of the stator core 3, as shown in FIGS. FIG. 23 is a perspective view showing an interphase insulator (between UV phases), where (a) shows the case seen from the inside of the stator core, and (b) shows the case seen from the outside of the stator core. The interphase insulator 261uv includes an insulating portion 11 for covering the coil end portion 7Hu of the U-phase coil 7u, and is formed so as to protrude and incline from the insulating portion 11 toward the inner periphery of the stator core. And a convex portion 12 covering the base of the coil end portion 7Hu of the coil 7u.

  And the leg part 13 with which the stator core side edge part (FIG. 23 lower end part) of the convex part 12 is mounted | worn between the roots of the coil end parts 7Hu and 7Hu of adjacent U-phase coil 7u and 7u is formed. . The stator core outer peripheral side end of the leg 13 is formed in a tapered shape. As a result, the leg portion 13 can be smoothly mounted between the roots of the coil end portions 7Hu and 7Hu of the adjacent U-phase coils 7u and 7u. Further, since the leg portion 13 enters between the roots of the coil end portions 7Hu and 7Hu of the adjacent U-phase coils 7u and 7u, the interphase insulator 261uv is positioned and firmly fixed by fixing the leg portion 13. It has come to be.

  The leg portion 13 has a height at which the bottom surface 13 a contacts the end surface of the stator core 3 when the leg portion 13 is attached to the stator core 3. The bottom surface 13 a of the leg portion 13 is formed smoothly so as to be attached to the end surface of the stator core 3. As a result, when the interphase insulator 261uv is mounted on the stator core 3, alignment in the stator axial direction (Z-axis direction) can be performed. Further, the leg portion 13 is also a portion that is gripped by the grip portion 270 of the interphase insulator assembly portion 260. Further, the leg portion 13 has a function of hooking and fixing to the pallet portion 271 of the interphase insulator assembly portion 260.

  Further, the insulating portion 11 includes a coil holding portion 14 that protrudes toward the inner peripheral side of the stator core and holds the V-phase coil 7v. The coil holding part 14 is formed with a protrusion (position deviation preventing part) 15 for preventing the position deviation of the V-phase coil 7v. As a result, the holding groove 16 is formed in the coil holding portion 14. For this reason, since the V-phase coil 7v in the middle of winding fits in the coil holding groove 16 and is not displaced, the arrangement and shape of the V-phase coil 7v can be reliably adjusted. Further, since the V-phase coil 7v can be wound around the predetermined position without slack, it is possible to reliably avoid the V-phase coil 7v from crossing or covering another slot.

  Next, the interphase insulator 261vw disposed between the V-phase coil 7v and the W-phase coil 7w will be described. As shown in FIGS. 24A and 24B, the interphase insulator 261vw is a resin molded product formed into a shape that follows the V-phase coil 7v wound around the slot 5 of the stator core 3. FIG. 24 is a perspective view showing an interphase insulator (between VW phases), where (a) shows the case seen from the inside of the stator core, and (b) shows the case seen from the outside of the stator core. The interphase insulator 261vw is formed to have an insulating portion 31 for covering the coil end portion 7Hv of the V-phase coil 7v, and to protrude from the insulating portion 31 toward the inner peripheral side of the stator core and to be inclined so as to be V-phase. And a convex portion 32 that covers the base of the coil end portion 7Hv of the coil 7v.

  And the leg part 33 with which the end part of the stator core side of the convex part 32 (FIG. 24 lower end part) is mounted | worn between the roots of coil end part 7Hv and 7Hv of adjacent V-phase coil 7v and 7v is formed. . The stator core outer peripheral side end portion of the leg portion 33 is formed in a tapered shape. As a result, the legs 33 can be smoothly mounted between the roots of the coil end portions 7Hv, 7Hv of the adjacent V-phase coils 7v, 7v. Further, since the leg portion 33 enters between the roots of the coil end portions 7Hv and 7Hv of the adjacent V-phase coils 51V and 51V, the interphase insulator 261vw is positioned and firmly fixed by fixing the leg portion 33. It has come to be.

  The leg 33 has a height at which the bottom surface 33 a comes into contact with the end surface of the stator core 3 when the leg 33 is attached to the stator core 3. The bottom surface 33 a of the leg portion 33 is formed smoothly so as to be attached to the end surface of the stator core 3. Accordingly, when the interphase insulator 30 is mounted on the stator core 52, alignment in the stator axial direction (Z-axis direction) can be performed. Moreover, the leg part 33 is also a part hold | gripped by the holding part 270 of the interphase insulator assembly part 260 so that it may mention later. Furthermore, the leg part 33 also has a function of hooking and fixing to the pallet part 271 of the interphase insulator assembly part 260.

  Further, the insulating portion 31 includes a coil holding portion 34 that protrudes toward the inner peripheral side of the stator core and holds the W-phase coil 7w. The coil holding portion 34 is formed with a notch 36 to prevent the W-phase coil 7w from being displaced. As a result, the W-phase coil 7w in the middle of winding fits into the notch 36 and does not shift, so that the arrangement and shape of the W-phase coil 7w can be reliably adjusted. Further, the W-phase coil 7w can be wound around the predetermined position without slack.

  The winding length / tension adjusting unit 280 adjusts the length and tension of the winding 6 supplied to the winding nozzle 121. As shown in FIG. 25, the winding length / tension adjusting unit 280 is attached to a rectangular holding frame 281 fixed on the table 103, and includes a brake unit 282, a roller unit 283, a spring mechanism unit 284, and the like. A telescopic stroke cylinder 285. FIG. 25 is a perspective view showing a schematic configuration of the winding length / tension adjusting unit.

  The brake unit 282 stops or cancels the drawing of the winding 6 from the winding length / tension adjusting unit 280. As shown in FIGS. 25 and 26, the brake portion 282 includes a stopper 291 with a spring driven by a rotating cam 290 and a winding support base 292 on which the end of the stopper 291 abuts and separates. ing. FIG. 26 is a side view showing a schematic configuration of the winding length / tension adjusting section. The stopper 291 is provided for each winding of the winding bundle 6P, and two stoppers 291 are driven by one rotating cam 290 two by two. That is, 16 stoppers 291 are provided, and 8 rotary cams 290 are provided.

  In the brake portion 282, the rotating cam 290 is rotated to lower the stopper 291 at the convex portion of the cam 290, the stopper 291 is brought into contact with the winding support base 292, and the winding 6 is connected to the stopper 291 and the winding. By pulling between the support base 292 and the winding 6, the drawing of the winding 6 is stopped. The operation of the brake unit 282 is controlled in conjunction with the operation of the winding nozzle 121.

  The roller portion 283 includes a pair of first guide rollers 293 and a pair of second guide rollers 294. Four guide rollers 293 and 294 are provided. The spring mechanism unit 284 includes a pair of rollers 295 and a set of springs 296 disposed above and below the rollers 295. The pair of rollers 295 and the set of springs 296 are provided for each winding of the winding bundle 6P. That is, 16 pairs of rollers 295 and a set of springs 296 are provided. A pair of rollers 295 and a pair of springs 296 are connected to one telescopic stroke cylinder 285 by four, and individually move up and down.

  In such a winding length / tension adjusting section 280, the winding bundle 6P is divided into four sets (four windings are divided into four) and each winding stroke 6P is generated by driving the winding nozzle 121 by each expansion / contraction stroke cylinder 285. The length and tension of the entire winding bundle 6P are controlled in order to eliminate the slack that occurs throughout. The operation of the expansion / contraction stroke cylinder 285 is also controlled in conjunction with the operation of the winding nozzle 121. Further, the winding length and tension for each winding 6 are reduced by the spring mechanism 284 in order to eliminate the slack that occurs in each winding 6 due to the difference in the winding discharge position of the winding nozzle 121 (the difference in the vertical direction). Fine adjustments are made. As a result, the winding shape of the winding 6 in the stator core 3 can be stabilized. Further, since each winding 6 can be supplied to the winding nozzle 121 with a certain tension applied to each winding 6, damage to the winding 6 can also be prevented.

  Here, the cause of the slack in the winding 6 will be described with reference to FIG. FIG. 27 is an explanatory diagram for explaining the cause of slack in the winding due to the structure and operation of the winding nozzle. The winding length necessary for winding the winding 6 around the stator core 3 is as shown by a one-dot chain line in FIG. However, in order to avoid interference between the winding nozzle 121 and the winding former 150, it is necessary to operate the winding nozzle 121 so that the winding nozzle 121 draws a locus as indicated by a broken line in FIG. For this reason, slack corresponding to “T1 + T2” and “T3 + T4” is generated in the entire winding bundle 6P. The looseness corresponding to “T1 + T2” and “T3 + T4” is eliminated by the operation of the expansion / contraction stroke cylinder 285.

  Further, since the winding nozzle 121 discharges the windings 6 aligned in a vertical row, slacks corresponding to “t1 + t2” and “t3 + t4” at maximum occur between the windings. The looseness corresponding to “t1 + t2” and “t3 + t4” is eliminated by the operation of the spring mechanism 284.

  The wedge paper insertion portion 300 is for inserting wedge paper into the two slots 5 and 5 of the stator core 3 simultaneously. As shown in FIG. 28, the wedge paper insertion unit 300 includes a wedge paper supply unit 301 and a wedge paper holding unit 302. FIG. 28 is a perspective view showing a schematic configuration of the wedge paper insertion portion.

  The wedge paper supply unit 301 is provided with semi-cylindrical wedge magazines 311 and 311 on which a plurality of wedge papers 310 are arranged, and index tables 312 and 312 for indexing the wedge magazines 311 and 311, respectively. The table 313 on which the index tables 312 and 312 are installed is movable in the X-axis direction. The wedge paper supply unit 301 includes push-in plates 314 and 314 (see FIG. 29) for supplying the wedge papers 310 and 310 set in the wedge magazines 311 and 311 one by one to the wedge paper holding unit 302, Plate driving portions 315 and 315 for driving the plates 314 and 314, respectively, are provided. Then, in the wedge paper supply unit 301, as shown in FIG. 29, the pushing plate 314 is driven by the plate driving unit 315, whereby the wedge paper 310 set in the wedge magazine 311 is provided in the holder 320 provided in the wedge paper holding unit 302. Are supplied sequentially. FIG. 29 is an explanatory diagram showing a state in which the wedge paper 310 is supplied from the wedge magazine 311 to the holder 320.

  The wedge paper holding unit 302 includes a holder 320 that holds the wedge paper 310 supplied from the wedge paper supply unit 301, and support blades 321 and 321 that insert the wedge paper 310 held by the holder 320 into the slot 5 of the stator core 3. And a drive unit 322 that moves (up and down) the holder 320 and the support blades 321 and 321 in the Z-axis direction. As shown in FIG. 30, the lower ends of the support blades 321 and 321 are fixed to a blade base 322, and the blade base 322 is coupled to a guide plate 324 by a shaft 323. The guide plate 324 is slidably attached to the ball spline 131 for driving the winding nozzle 121. Thereby, the guide plate 324 moves up and down along the ball spline 131. Therefore, the blade base 322 (support blade 321) coupled to the guide plate 324 via the shaft 323 is also moved up and down along the ball spline 131. At this time, the tips of the support blades 321 are in contact with the guide plate 324 to prevent the support blades 321 from falling. FIG. 30 is a schematic diagram schematically showing a schematic configuration in the vicinity of the support blade 321.

  In such a wedge paper insertion unit 300, the respective wedge papers 310 and 310 set in the wedge magazines 311 and 311 are supplied to the holder 320 in the state shown in FIG. Then, the holder 320 and the support blades 321 and 321 are both raised by the drive unit 322. At this time, the guide plate 324 also rises along the ball spline 131. Then, as shown in FIG. 31 (b), the holder 320 is raised to the lower surface of the stator core 3 and stopped. This is to prevent interference between the stator core 3 and the holder 320. In the state shown in FIG. 31 (b), the wedge papers 310 and 310 are held in the holder 320 and are not inserted into the slots 5 and 5 of the stator core 3.

  When the support blades 321 and 321 are further raised from this state as shown in FIG. 31 (c), the wedge papers 310 and 310 come out of the holder 320 and are inserted into the slots 5 and 5, and finally Thus, the wedge papers 310 and 310 are completely removed from the holder 320 and completely inserted into the slots 5 and 5. At this time, since the tips of the support blades 321 and 321 are always in contact with the guide plate 324, the support blades 321 and 321 do not fall down inside the stator core 3. Thereby, the wedge papers 310 and 310 are reliably inserted into the slots 5 and 5 of the stator core 3. FIG. 31 is an explanatory diagram showing each state of the wedge paper insertion portion 300 when the wedge paper 310 is inserted into the slot 5 of the stator core 3.

  Next, a method for manufacturing the stator 2 using the winding device 100 having the above configuration will be described. First, the stator core 3 is set on the work pallet unit 200. Specifically, as shown in FIG. 32, the slider 206 is driven to move the pallet 201 toward the front of the apparatus, the stator core 3 is attached to the holder 202, and then the holder 202 is attached to the pallet 201. When the mounting of the holder 202 to the pallet 201 is completed, the slider 202 is driven to move the pallet 201 to the center of the table 103. FIG. 32 is an explanatory diagram showing a state in which the stator core 3 is mounted on the work pallet unit 200.

  When the pallet 201 moves to the center of the table 103, the pallet 201 is fixed by the pallet displacement prevention pins 207. Then, a winding process for forming U-phase coil 7u is performed. First, the winding former 150 u is attached to the winding position of the stator core 3. Specifically, the gripping portion 142a of the winding former attaching / detaching / changing portion 140 grips and removes the upper winding former 150ua accommodated in the accommodating portion 141ua, and the gripping portion 142b is accommodated in the accommodating portion 141ub. The side winding former 150ub is grasped and taken out. Then, the winding formers 150 ua and 150 ub are arranged on the stator core 3 by the gripping portions 142 a and 142 b. At this time, the projections 350 provided on each of the winding formers 150 ua and 150 ub are fitted in the assembly holes formed in the cuff, and the positioning member 354 is engaged between the slots (the teeth inner peripheral surface). Thus, the respective winding formers 150 ua and 150 ub are reliably arranged at predetermined winding positions of the stator core 3.

  When the winding formers 150 ua and 150 ub are arranged on the stator core 3, as shown in FIG. 15, the fitting convex portion 353 of the coupling portion 153 ua in the upper winding former 150 ua and the coupling portion 153 ub in the lower winding former 150 ub are arranged. The fitting recess 363 is fitted. In this state, the clamps 355 and 355 of the lower winding former 150ub remain open. Thereafter, when the gripping portions 142a and 142b release the winding formers 150ua and 150ub, the clamps 355 and 355 are closed as shown in FIG. 16, and the claws 356 of the clamp 355 are engaged with the engaging portions of the coupling portion 153ua. 352 is engaged. As a result, the upper winding former 150 ua and the lower winding former 150 ub are coupled, and the winding former 150 u is attached to the stator core 3.

  When the winding former 150u is mounted on the stator core 3, the winding nozzle 121 is disposed inside the stator core 3 (standby position S). Then, the winding nozzle 121, the first to fourth arms 161 to 164, and the winding length / tension adjusting unit 280 are synchronized (linked) to wind the winding 6 around the stator core 3, and the U-phase coil 7u. Form. This winding process will be described with reference to FIGS. 33 and 34. FIG. FIG. 33 is an explanatory diagram showing an operation locus of the winding nozzle 121. FIG. 34 is a time chart showing the operating state of each part. Since the winding process is basically the same for both the normal winding and the reverse winding, the case of the normal winding will be described here. Since the winding process for forming each phase coil 7u, 7v, 7w is basically the same, the U phase coil 7u will be described as a representative example here.

  The winding nozzle 121 disposed at the standby position S starts to wind the stator core 3 after descending to the work origin O. In the winding to the stator core 3, the winding nozzle 121 first descends from the O point to the A point as shown in FIG. At this time, the winding bundle 6P is discharged into the slot 5a. The winding nozzle 121 starts turning from the point A (from left to right in the figure) and positions the tip of the nozzle below the slot 5b. By this turning operation, the winding bundle 6P is discharged along the winding former 150u (more precisely, the former portion 151ub of the lower winding former 150ub).

  The winding nozzle 121 starts to rise after the turning operation and passes through the point C. At this time, the winding bundle 6P is discharged into the slot 5b. Then, as shown in FIG. 33B, the winding nozzle 121 starts turning (from right to left in the drawing) and positions the nozzle tip above the slot 5a (point O) as shown in FIG. 33B. . By this turning operation, the winding bundle 6P is discharged along the winding former 150u (more precisely, the former portion 151ua of the upper winding former 150ua). Thus, the winding for one turn is completed. After that, the winding nozzle 121 moves to the retreat position G in the final turn after performing the above operation a plurality of times. Thus, one U-phase coil 7u is formed.

  Then, as shown in FIG. 34, the operations of the first to fourth arms 161 to 164 and the winding length / tension adjusting unit 280 are performed in synchronization (interlocking) with the operation of the winding nozzle 121. First, the operation of the first to fourth arms 161 to 164 will be described.

  When the winding nozzle 121 reaches the point O, all of the first to fourth arms 161 to 164 are open (see FIG. 18B). When the winding nozzle 121 passes between the winding former 150u and the first arm 161, the first arm 161 is closed (see FIG. 18C). Thus, the first arm 161 is in close contact with the winding former 150u. Thus, when the winding nozzle 121 passes between the winding former 150u and the first arm 161, the first arm 161 is in close contact with the winding former 150u, so that the winding 6 protrudes from the slot 5a. Can be reliably prevented.

  After that, when it passes between the winding former 150u and the second arm 162 and reaches the descending end (point A), the second arm 162 is closed (see FIG. 18C), and the winding former. Adheres to 150u. Then, the first arm 161 and the second arm 162 move outward in the stator core diameter state in close contact with the winding former 150u (see FIG. 18D). Accordingly, the winding bundle 6P discharged from the winding nozzle 121 and inserted into the slot 5a is drawn into the back side of the slot 5a by the first arm 161 and the second arm 162. This secures an insertion space for inserting the winding bundle 6P into the slot 5a in the second turn. Therefore, even when the U-phase coil 7u having a high space factor of the winding 6 in the slot 5a is formed, the winding 6 can be reliably arranged in the slot 5a. That is, the U-phase coil 7u having a high space factor can be formed.

  When the turning of the winding nozzle 121 (L → R) is completed, the winding nozzle 121 starts to rise, and the winding nozzle 121 passes between the winding former 150u and the third arm 163 and reaches the point C. When reaching, the third arm 163 is closed (see FIG. 18C). As a result, the third arm 163 comes into close contact with the winding former 150u. As described above, when the winding nozzle 121 passes between the winding former 150u and the third arm 163, the third arm 163 comes into close contact with the winding former 150u, so that the winding 6 protrudes from the slot 5b. Can be reliably prevented.

  Thereafter, when the winding nozzle 121 passes between the winding former 150u and the fourth arm 164 and reaches the rising end, the fourth arm 164 is closed (see FIG. 18C), and the winding is performed. It closely contacts the former 150u. Then, the third arm 163 and the fourth arm 164 move outward in the stator core diameter state in close contact with the winding former 150u (see FIG. 18D). Accordingly, the winding bundle 6P discharged from the winding nozzle 121 and inserted into the slot 5b is drawn into the back side of the slot 5b by the third arm 163 and the fourth arm 164. This secures an insertion space for inserting the winding bundle 6P into the slot 5b in the second turn. Therefore, even when the U-phase coil 7u having a high space factor of the winding 6 in the slot 5b is formed, the winding 6 can be reliably arranged in the slot 5b. That is, the U-phase coil 7u having a high space factor can be formed.

  Next, each operation of the winding length / tension adjusting unit 280 will be described. Until the winding nozzle 121 reaches the point A, the brake portion 282 is in a released state (a state where the stopper 291 is separated from the winding support base 292). Has been pulled out. At this time, the roller 295 is disposed at the origin position (the same height position as the rollers 293 and 294) by the expansion / contraction stroke cylinder 285.

  When the winding nozzle 121 reaches point A, the stopper 291 of the brake unit 282 descends and comes into contact with the winding support base 292 to stop drawing the winding 6. At this time, the windings 6 may be slack due to the difference in the winding discharge position of the winding nozzle 121. However, in this embodiment, since tension is applied to each winding 6 by the spring mechanism portion 284, slack of each winding 6 due to a difference in winding discharge position of the winding nozzle 121 does not occur. In this way, since tension is applied to each winding 6 when the winding nozzle 121 turns, the winding 6 can be wound around the winding former 150u without slack.

  Thereafter, the roller 295 is gradually lowered by the expansion / contraction stroke cylinder 285 until the winding nozzle 121 passes the point B and reaches the point C. At this time, since the drawing of the winding 6 is stopped by the brake unit 282, the winding bundle 6 supplied to the winding nozzle 121 is pulled back. Thereby, the slack (slack of “T1 + T2” shown in FIG. 27) generated in the winding bundle 6P is eliminated. When the winding nozzle 121 reaches the point C, no tension is applied to each winding 6 by the spring mechanism 284.

  When the winding nozzle 121 reaches the rising end, the tension is again applied to each winding 6 by the spring mechanism 284. In this state, the winding nozzle 121 starts to turn (R → L). In this way, since tension is applied to each winding 6 when the winding nozzle 121 turns, the winding 6 can be wound around the winding former 150u without slack.

  Thereafter, the roller 295 is gradually lowered by the expansion / contraction stroke cylinder 285 until the winding nozzle 121 reaches the point E after passing the point D. At this time, since the drawing of the winding 6 is stopped by the brake unit 282, the winding bundle 6 supplied to the winding nozzle 121 is pulled back. Thereby, the slack (sag of “T3 + T4” shown in FIG. 27) generated in the winding bundle 6P is eliminated.

  When the winding nozzle 121 reaches the point E, the stopper 291 of the brake unit 282 is lifted and separated from the winding support base 292. Thereby, the drawing of the winding 6 is released. Further, no tension is applied to each winding 6 by the spring mechanism 284.

  Thereafter, by repeating the above-described operation, the winding bundle 6P is wound between the slots 5a and 5b to form the U-phase coil 7u. In the present embodiment, as described above, the winding bundle 6P can be wound between the slots 5a and 5b while eliminating the slack generated in the winding bundle 6P (each winding 6). Further, since the winding bundle 6P inserted into the slots 5a and 5b is drawn into the slot by the winding arms 161 to 164 every turn, the winding bundle 6P is surely inserted into the slots 5a and 5b at each turn. can do. For these reasons, the U-phase coil 7u having a stable winding shape and a high space factor can be automatically formed. Since V-phase coil 7v and W-phase coil 7w are formed in the same manner, V-phase coil 7v and W-phase coil 7w can also be coils with a high space factor.

  When the winding bundle 6P is wound around the slots 5a and 5b as described above to form the U-phase coil 7u, the wedge papers 310 and 310 are inserted into the slots 5a and 5b by the wedge paper insertion unit 300. Specifically, the wedge papers 310 and 310 set in the wedge magazines 311 and 311 are supplied to the holder 320, and both the holder 320 and the support blades 321 and 321 are raised by the drive unit 322. Then, after the holder 320 is raised to the lower surface of the stator core 3 (see FIG. 31B), the support blades 321 and 321 are further raised. As the support blades 321 and 321 rise, the wedge papers 310 and 310 are inserted into the slots 5 a and 5 b while being removed from the holder 320. Finally, the wedge paper 310, 310 is completely removed from the holder 320 and completely inserted into the slots 5a, 5b.

  At this time, since the tips of the support blades 321 and 321 are always in contact with the guide plate 324, the support blades 321 and 321 do not fall into the stator core 3. As a result, the wedge papers 310 and 310 are inserted into the slots 5a and 5b of the stator core 3 without being inclined. Accordingly, since the wedge papers 310 and 310 do not protrude from the slots 5a and 5b, the wedge papers 310 and 310 are reliably inserted into the slots 5a and 5b without being damaged.

  Thereafter, the index servomotor 203 indexes the stator core 3 (holder 202) counterclockwise, and starts to wind the U-phase coil 7u to be formed next in the opposite direction. That is, if the U-phase coil 7u formed last time is forward winding, the U-phase coil 7u is formed by reverse winding this time, and if the U-phase coil 7u formed last time is reverse winding, the U-phase coil 7u is formed by current winding this time. To do.

  However, after the stator core 3 is indexed, when the winding former 150u is mounted at the winding position of the stator core 3, the winding bundle 6P (crossover wire 6C) that is wound around the stator core 3 from the winding nozzle 121 is obstructive. Thus, the winding former 150u may not be mounted on the stator core 3. Further, there is a possibility that the next U-phase coil 7u may be formed while the crossover wire 6C crosses the coil end portion 7Hu of the U-phase coil 7u formed last time.

  Therefore, in the present embodiment, the crossover line 6C is processed by the crossover line processing units 240a and 240b to avoid such a situation. Since the process of the crossover 6C is different between the case of shifting from the normal winding to the reverse winding and the case of shifting from the reverse winding to the normal winding, hereinafter, the case of shifting from the normal winding to the reverse winding and the case of shifting from the reverse winding to the normal winding. Separately described.

  First, the crossover process when shifting from forward winding to reverse winding will be described with reference to FIGS. FIG. 35 is an explanatory diagram showing a state where the crossover wire 6C is hooked on the crossover clamp 241. As shown in FIG. FIG. 36 is an explanatory diagram showing a state in which the crossover 6C is hooked on the crossover clamp 241 and pulled out. FIG. 37 is an explanatory diagram showing a state in which the crossover clamp 241 is retracted from the winding arm retraction interference area. FIG. 38 is an explanatory view showing a state where the winding formers 161 to 164 are retracted from the stator core 3. FIG. 39 is an explanatory diagram showing a state in which the stator core 3 is indexed. FIG. 40 is an explanatory diagram showing a state in which the winding former 150u is mounted on the stator core 3 after the stator core 3 is indexed. FIG. 41 is an explanatory diagram showing a state in which the crossover wire 6C is placed along a part of the winding former 150u attached to the stator core 3. FIG. FIG. 42 is an explanatory diagram showing a state in which reverse winding with respect to the stator core 3 is started. 35 to 42, (a) shows a state seen from above, and (b) shows a state seen from the side.

  When the formation of one U-phase coil 7u is completed by the normal winding, the winding nozzle 121 is positioned above the fourth arm 164 as shown in FIG. In the crossover processing unit 240a, as shown in FIGS. 35 (a) and 35 (b), the crossover clamp 241 is moved above the fourth arm 164 by the drive unit 244, and the crossover 6C is connected to the crossover clamp 241. To catch. At this time, as shown in FIG. 35A, the winding former attachment / detachment / exchange unit 140 is located at the retracted position.

  Then, as shown in FIGS. 36 (a) and 36 (b), the connecting wire clamp 241 is moved outwardly of the stator core by the drive unit 244, and the connecting wire 6C hooked on the connecting wire clamp 241 is pulled out. At this time, as shown in FIG. 36 (a), the winding former attachment / detachment / exchange unit 140 is located at the retracted position.

  Subsequently, as shown in FIGS. 37A and 37B, the movable portion 243 of the crossover clamp 241 is driven to close the crossover clamp 241. Thereby, the connecting wire 6C is clamped by the connecting wire clamp 241. Then, the crossover clamp 241 is retracted from the winding arm retraction interference area R by the drive unit 244 while the crossover 6C is clamped. Thereafter, the first to fourth arms 161 to 164 are moved outward from the stator core diameter by the first to fourth drive units 171 to 174.

  Further, the actuators 143a and 143b of the winding former attaching / detaching / exchanger 140 are driven to move the gripping parts 142a and 142b, and the winding former 150u is gripped by the gripping parts 142a and 142b. When the winding former 150u is gripped by the gripping portions 142a and 142b, the winding former 150u is separated vertically. At this time, the upper winding former 150ua is gripped by the gripping portion 142a and the lower winding former 150ub is gripped by the gripping portion 142b.

  Then, as shown in FIGS. 38A and 38B, the actuator unit 143 of the winding former attaching / detaching / exchanging unit 140 is driven to move the gripping portions 142a and 142b, and the gripping portions 142a and 142b grip the gripping portions 142a and 142b. The winding formers 150 ua and 150 ub are removed from the stator core 3 and retracted. At this time, the winding formers 150 ua and 150 ub (gripping portions 142 a and 142 b) are located inside the stator core 3.

  In this state, the index servo motor 203 of the work pallet unit 200 is driven to rotate the holder 202. As a result, as shown in FIG. 39A, the stator core 3 is indexed counterclockwise. Simultaneously with the index of the stator core 3, the crossover processing section 240a is moved to the position shown in FIGS.

  Then, as shown in FIGS. 40A and 40B, after the crossover processing section 240a is further moved, the actuator sections 143a and 143b of the winding former attaching / detaching / changing section 140 are driven to hold the holding sections 142a and 142b. The winding formers 150 ua and 150 ub held by the holding parts 142 a and 142 b are mounted on the stator core 3. When the gripping portions 150 a and 150 ub are released from the gripping portions 142 a and 142 b, the winding formers 150 ua and 150 ub are coupled and the winding former 150 u is attached to the stator core 3.

  When the winding former 150u (150ua, 150ub) is attached to the stator core 3, the connecting wire 6C is drawn out by the connecting wire processing unit 240a in the outer direction of the stator core, so that the connecting wire 6C does not get in the way. . That is, the connecting wire 6C does not enter between the winding former 150u and the stator core 3. Therefore, the winding former 150u can be reliably attached to a predetermined position of the stator core 3.

  At this time, the coil end molding portion 180 is moved, and the arm portions 183 and 184 are disposed above the U-phase coil 7u that has already been formed. As a result, the coil end portion 7Hu of the formed U-phase coil 7u is protected by the arm portions 183 and 184. At this time, the coil end forming portion 180 does not form the U-phase coil 7u that has already been formed on the coil end portion 7Hu.

  When the winding former 150u is attached to the stator core 3, as shown in FIGS. 41 (a) and 41 (b), the winding former attaching / detaching / exchanging portion 140 is moved to the retracted position. Further, the first arms 161 to 164 are moved inwardly in the stator core diameter by the first drive units 171 to 174. At this time, the second to fourth arms 162 to 164 are in close contact with the winding former 150u, and only the first arm 161 is not in close contact with the winding former 150u. Then, the crossover clamp 241 is moved by the drive unit 244 as shown in FIGS. 41 (a) and 41 (b), and the crossover 6C is made to follow the winding former 150u (upper winding former 150ua).

  Thereafter, as shown in FIGS. 42A and 42B, the movable portion 243 of the crossover clamp 241 is driven to release the clamp on the crossover 6C by the crossover clamp 241. Then, the connecting wire 6C is in a state along the winding former 150u. From this state, winding of the winding bundle 6P around the stator core 3 is started in order to form the next U-phase coil 7u by reverse winding.

  Thus, when the transition from the normal winding to the reverse winding is performed, when the winding core 150u is attached to the stator core 3 after the stator core 3 is indexed by performing the processing of the connecting wire 6C by the connecting wire processing unit 240a, the connecting wire 6C is processed. The line 6C does not get in the way. Thereby, the winding former 150u can be reliably attached to the stator core 3. Further, the crossover wire 6C can be reliably routed along the winding former 150u mounted on the stator core 3. Therefore, after the stator core 3 is indexed, the reversely wound U-phase coil 7u can be reliably formed by direct winding. In the winding process when forming the V-phase coil 7v and the W-phase coil 7w, the above-described crossover process is performed.

  Next, the crossover process when shifting from reverse winding to normal winding will be described with reference to FIGS. 43 to 50. FIG. 43 is an explanatory diagram showing a state where the crossover wire 6C is hooked on the crossover clamp 241. As shown in FIG. FIG. 44 is an explanatory diagram showing a state in which the crossover line 6C is hooked on the crossover line clamp 241 and pulled out. FIG. 45 is an explanatory view showing a state in which the crossover clamp 241 is retracted from the winding arm retraction interference area. FIG. 46 is an explanatory view showing a state where the winding former 150u is retracted from the stator core 3. FIG. FIG. 47 is an explanatory view showing a state in which the stator core 3 is indexed. FIG. 48 is an explanatory view showing a state in which, after the stator core 3 is indexed, the connecting wire 6C is hooked on the connecting wire hook 246 and the winding former 150u is attached to the stator core 3. FIG. 49 is an explanatory view showing a state in which the pre-formed coil 7u is held by the coil end molding portion 180. FIG. FIG. 50 is an explanatory diagram showing a state in which the normal winding with respect to the stator core 3 is started. 43 to 50, (a) shows a state seen from above, and (b) shows a state seen from the side.

  When the formation of one U-phase coil 7u is completed by reverse winding, the winding nozzle 121 is positioned above the first arm 161 as shown in FIG. Then, in the crossover processing unit 240a, as shown in FIGS. 43A and 43B, the crossover clamp 241 is moved above the first arm 161 by the driving unit 244, and the crossover 6C is connected to the crossover clamp 241. To catch. At this time, as shown in FIG. 43 (a), the winding former attaching / detaching / changing unit 140 is located at the retracted position.

  Then, as shown in FIGS. 44 (a) and 44 (b), the connecting wire clamp 241 is moved outwardly of the stator core by the drive unit 244, and the connecting wire 6C hooked on the connecting wire clamp 241 is pulled out. At this time, as shown in FIG. 44 (a), the winding former attachment / detachment / exchange unit 140 is located at the retracted position.

  Subsequently, as shown in FIGS. 45A and 45B, the movable portion 243 of the crossover clamp 241 is driven to close the crossover clamp 241. Thereby, the connecting wire 6C is clamped by the connecting wire clamp 241. Then, the crossover clamp 241 is retracted from the winding arm retraction interference area R by the drive unit 244 while the crossover 6C is clamped. Thereafter, the first to fourth driving units 171 to 174 retract the first to fourth arms 161 to 164 outward in the stator core diameter direction.

  Further, the actuators 143a and 143b of the winding former attaching / detaching / exchanger 140 are driven to move the gripping parts 142a and 142b, and the winding former 150u is gripped by the gripping parts 142a and 142b. When the winding former 150u is gripped by the gripping portions 142a and 142b, the winding former 150u is separated vertically. At this time, the upper winding former 150ua is gripped by the gripping portion 142a and the lower winding former 150b is gripped by the gripping portion 142b.

  Then, as shown in FIGS. 46 (a) and 46 (b), the actuator unit 143 of the winding former attaching / detaching / exchange unit 140 is driven to move the gripping portions 142a and 142b and are gripped by the gripping portions 142a and 142b. The winding formers 150 ua and 150 ub are removed from the stator core 3 and retracted. At this time, the winding formers 150 ua and 150 ub (gripping portions 142 a and 142 b) are located inside the stator core 3.

  In this state, the index servo motor 203 of the work pallet unit 200 is driven to rotate the holder 202. As a result, as shown in FIG. 47A, the stator core 3 is indexed counterclockwise. Simultaneously with the index of the stator core 3, the crossover processing section 240a is moved to the position shown in FIGS. 47 (a) and 47 (b).

  At this time, the connecting wire 6C crosses the coil end portion 7Hu of the U-phase coil 7u already formed with respect to the stator core 3. When the next coil formation is started in this state, the connecting wire 6C crossing the formed U-phase coil 7u is obstructed and the next-phase coils (V-phase coil 7v and W-phase coil 7w) are There is a risk that it cannot be formed well. For this reason, in this Embodiment, the crossover processing part 240b is provided so that such a situation can be avoided reliably.

  48 (a) and 48 (b), the crossover processing section 240a is further moved, and the crossover 6C positioned between the slot 5 of the stator core 3 and the crossover clamp 241 is crossed. The connecting wire hook 246 of the wire processing unit 240b is hooked and the connecting wire 6C is pulled out in the outward direction of the stator core diameter. As a result, since the connecting wire 6C hooked to the connecting wire hook 246 and the connecting wire clamp 241 is located outside the coil end portion, the connecting wire 6C crosses the coil end portion 7Hu of the formed U-phase coil 7u. Can not be. Therefore, the crossover 6C does not get in the way when the next phase coil is formed. Thereby, V-phase coil 7v and W-phase coil 7w can be formed normally.

  In this state, the actuators 143a and 143b of the winding former attaching / detaching / exchanger 140 are driven to move the gripping parts 142a and 142b, so that the winding formers 150ua and 150ub gripped by the gripping parts 142a and 142b are moved. Attached to the stator core 3. When the gripping portions 150 a and 150 ub are released from the gripping portions 142 a and 142 b, the winding formers 150 ua and 150 ub are coupled and the winding former 150 u is attached to the stator core 3.

  When the winding former 150u (150ua, 150ub) is attached to the stator core 3, the connecting wire 6C is drawn out by the connecting wire processing sections 240a, 240b in the outer direction of the stator core, so that the connecting wire 6C becomes an obstacle. There is no. That is, the connecting wire 6C does not enter between the winding former 150u and the stator core 3. Therefore, the winding former 150u can be reliably attached to a predetermined position of the stator core 3.

  When the winding former 150u is attached to the stator core 3, as shown in FIGS. 49 (a) and 49 (b), the winding former attaching / detaching / exchanging portion 140 is moved to the retracted position. In addition, the crossover clamp 241 and the crossover hook 246 are moved in the vertical direction to adjust the height position of the crossover 6C between the crossover clamp 241 and the crossover hook 246. And the coil end shaping | molding part 180 is advanced to a stator core diameter inward direction, and it arrange | positions in a predetermined position, and hold | maintains (protects) the formed U-phase coil 7u. At this time, the coil end portion 7Hu of the formed U-phase coil 7u by the coil end forming portion 180 is not implemented. Further, the third and fourth drive arms 173 and 174 cause the third and fourth winding arms 163 and 164 to advance inwardly in the stator core diameter.

   Then, as shown in FIGS. 50A and 50B, the crossover hook 246 is opened, and the crossover line 6C hung on the crossover hook 246 is released. At this time, since the already formed U-phase coil 7u is held by the coil end forming portion 180, the shape of the coil is not broken by the crossover wire 6C. Thereafter, the movable portion 243 of the jumper wire clamp 241 is driven to release the clamp on the jumper wire 6C by the jumper wire clamp 241. If it does so, the crossover 6C will be in the state along the U phase coil 7 already formed.

  At this time, the crossover processing unit 240a is returned to the initial position, and the first and second drive units 171 and 172 advance the first and second winding arms 161 and 162 in the stator core radial inward direction. From this state, the winding bundle 6P starts to be wound around the stator core 3 in order to form the next U-phase coil 7u by forward winding.

  When the winding former 150u is attached to the stator core 3 after the stator core 3 is indexed by performing the processing of the connecting wire 6C by the connecting wire processing units 240a and 240b when shifting from reverse winding to forward winding in this way. The crossover 6C does not get in the way. Thereby, the winding former 150u can be reliably attached to the stator core 3. Moreover, the crossover 6C can be made to follow the outer periphery of the coil end part 7Hu without traversing the coil end part 7Hu of the formed U-phase coil 7u. Therefore, after the stator core 3 is indexed, the positive winding U-phase coil 7u can be reliably formed by direct winding.

  Further, since the connecting wire 6C does not cross the coil end portion 7Hu of the already formed coil 7u, the connecting wire 6C does not get in the way when the next phase coil is formed. Therefore, the next phase coils (V phase coil 7v and W phase coil 7w) can be reliably formed. In the winding process when forming the V-phase coil 7v and the W-phase coil 7w, the above-described crossover process is performed.

  As described above, by repeating the coil formation while the stator core 3 is indexed, finally, eight U-phase coils 7u, eight V-phase coils 7v, and eight W-phase coils with respect to the stator core 3. Phase coils 7w are sequentially formed. Each time one coil 7 is formed and the stator core 3 is indexed, the following steps are sequentially performed at each index position.

  When the coil 7 is formed and the stator core 3 is indexed, first, the coil end portion 7H is formed on the coil 7 by the coil end forming portion 180. Specifically, the expansion claws 181 and 182 are disposed inside the coil 7 and the coil end portion 7H of the coil 7 is expanded by retracting outward in the stator core diameter state with the expansion claws 181 and 182 being opened. Molded. Further, when the extended claws 181 and 182 are lowered when they are arranged inside the coil 7, molding is performed for suppressing the height of the coil end portion 7 </ b> H on the lower surfaces of the arm portions 183 and 184 of the extended claws 181 and 182. Is done. By these processes, the shape of the coil end portion 7H of each coil 7 is made constant.

  Thus, the coil 7 which has finished forming the coil end portion 7H by the coil end forming portion 180 is positioned in the inspection portion 220 when the stator core 3 is further indexed. Then, the coil 221 is imaged by the CCD 221, and based on the imaging data, inspections are performed regarding the coil end shape, the coil end dimensions (inner and outer diameters, etc.), the presence of stray lines, and the presence or absence of scratches on the coil surface. Here, when an abnormality is detected, the operation of the winding device 100 is temporarily stopped, and the operator performs reworking. After the reworking is completed, the winding device 100 is operated to perform the subsequent steps. Is done.

  When the stator core 3 is further indexed after the inspection by the inspection unit 220 is completed, the interphase insulator 261 is assembled to the stator core 3 by the interphase insulator assembly unit 260. More specifically, the interphase insulator 261uv is assembled to the U-phase coil 7u, and the interphase insulator 261vw is assembled to the V-phase coil 7v. Thereby, the interphase insulator 261uv is disposed between the U-phase coil 7u and the V-phase coil 7v to ensure insulation between the UV phases, and the interphase insulator 261vw is interposed between the V-phase coil 7v and the W-phase coil 7w. Arranged to ensure insulation between the VW phases. The interphase insulators 261 uv and 261 vw are fixed to the pallet part 271, the leg parts 13 and 33 are gripped by the grip part 270, taken out from the pallet part 271, and assembled to the stator core 3.

  Thus, in the winding apparatus 100 according to the present embodiment, a winding process for forming the coil 7 on the stator core 3, a forming process for forming the coil end portion 7H of the coil 7, an inspection process for inspecting the state of the coil 7, In addition, the stator 2 can be manufactured by performing the insulating step of mounting the interphase insulator 261 on the coil 7 in parallel with the stator core 3 being indexed. For this reason, in the winding apparatus 100, since it is not necessary to move or reverse the stator core 3 for every process, the apparatus for moving and reversing the stator core 3 etc. become unnecessary. Thereby, in the winding apparatus 100, the apparatuses for performing the winding process, the molding process, the inspection process, and the insulating process are collectively arranged so as to surround the stator core 3. And the winding work process can be performed by a single facility. In such a winding apparatus 100, once the stator core 3 is set, it is basically unnecessary to perform manual work until the stator 2 is completed. That is, the production of the stator core 2 can be completely automated.

  Moreover, the production efficiency can be improved by installing a plurality of winding apparatuses 100. In addition, since stators having different specifications can be manufactured for each winding device, a plurality of types of stators can be manufactured simultaneously. When a plurality of types of stators are manufactured at the same time, the ratio of the number of manufactured stators can be changed very easily.

  Furthermore, by using the winding device 100, it is possible to prevent a significant reduction in production efficiency when the winding device fails. This is because when a production line is made as in the prior art, the production line is stopped due to a failure of one piece of equipment, so that the production of the stator is stopped. On the other hand, when a plurality of winding devices 100 are installed, even if one winding device fails and stops, the failure does not affect other winding devices. . Therefore, the other winding devices can continue to operate, and the stator can be manufactured.

  Further, in the winding device 100, since the devices for performing the winding process, the forming process, the inspection process, and the insulating process are collectively arranged, a plurality of winding apparatuses 100 are installed. However, the installation space for the equipment can be reduced as compared with the case of installing a production line as in the prior art.

  It should be noted that the above-described embodiment is merely an example and does not limit the present invention in any way, and various improvements and modifications can be made without departing from the scope of the invention. For example, in the above-described embodiment, the present invention is applied to a motor for driving a hybrid vehicle. However, the present invention is not limited to a motor of an automobile, and any type using a distributed winding of a direct winding system. It can be applied to motors used for applications.

It is a schematic diagram which shows the structure of a motor typically. It is a schematic diagram which shows the structure of a stator typically. It is a perspective view which shows schematic structure of a stator. It is a connection diagram which shows the connection of each phase coil. It is a figure which shows schematic structure of a stator core, (a) is a top view of a stator core, (b) is a longitudinal cross-sectional view of a stator core. It is a partial expansion perspective view which shows the state which wound the U-phase coil | winding around the stator core. It is a partial expansion perspective view which shows the state which wound the U-phase winding and the V-phase winding around the stator core. It is a partial expansion perspective view which shows the state which wound U phase winding, V phase winding, and W phase winding around the stator core. It is a perspective view which shows schematic structure of the winding apparatus which concerns on embodiment. It is a perspective view which shows the principal part which performs winding operation | movement among the winding apparatuses shown in FIG. It is a perspective view which shows schematic structure of a winding nozzle drive part. It is a perspective view which shows the internal structure of a winding nozzle. It is a side view which shows schematic structure of a winding former attachment / detachment / exchange part. It is a perspective view which shows schematic structure in the state (state currently hold | gripped by the holding part) of the winding former for U phases, Comprising: (a) shows the front side, (b) shows the back side. It is a perspective view which shows the state which contacted the upper side winding former and the lower side winding former, Comprising: (a) shows a front side, (b) shows a back side. It is a perspective view which shows the state with which the upper side winding former and the lower side winding former were couple | bonded, Comprising: (a) shows a front side, (b) shows a back side. 4 is a perspective view showing a schematic configuration of a winding arm drive unit 160. FIG. It is explanatory drawing which shows each operation state of a winding former. It is an enlarged view which shows a coil end shaping | molding part and a crossover processing part. It is a perspective view which shows schematic structure of a work pallet part, Comprising: (a) shows the case seen from upper direction, (b) shows the case seen from the downward direction. It is a perspective view which shows schematic structure of a phase insulator assembly | attachment part. It is a perspective view which shows the holding part in the interphase insulator assembly part shown in FIG. It is a perspective view which shows an interphase insulator (between UV phases), Comprising: (a) shows the case where it sees from the stator core inner side, (b) shows the case where it sees from the stator core outer side. It is a perspective view which shows an interphase insulator (between VW phases), Comprising: (a) shows the case where it sees from the stator core inner side, (b) shows the case where it sees from the stator core outer side. It is a perspective view which shows schematic structure of a coil | winding length and tension adjustment part. It is a side view which shows schematic structure of a coil | winding length and tension adjustment part. It is explanatory drawing for demonstrating the cause which a winding produces slack by the structure and operation | movement of a winding nozzle. It is a perspective view which shows schematic structure of a wedge paper insertion part. It is explanatory drawing which shows a mode that wedge paper is supplied to a holder from a wedge magazine. It is a schematic diagram which shows typically schematic structure of support blade vicinity. It is explanatory drawing which shows each state of the wedge paper insertion part at the time of inserting wedge paper into the slot of a stator core, (a) shows the state with which the wedge paper was supplied to the holder, (b) shows the holder of the stator core. A state where the paper is raised to the lower surface is shown, and (c) shows a state where the wedge paper is pulled out of the holder and inserted into the slot. It is explanatory drawing which shows a mode that a stator core is mounted | worn on a work pallet part. It is explanatory drawing which shows the operation | movement locus | trajectory of a winding nozzle. It is a time chart which shows the operation state of each part. It is explanatory drawing which shows the state which hooked the connecting wire on the connecting wire clamp. It is explanatory drawing which shows the state which hooked the connecting wire on the connecting wire clamp and pulled out. It is explanatory drawing which shows the state W which retracted the crossover clamp from the winding arm backward interference area. It is explanatory drawing which shows the state which retracted the winding former from the stator core. It is explanatory drawing which shows the state which made the stator core index. It is explanatory drawing which shows the state which mounted | wore the winding former to the stator core after indexing the stator core. It is explanatory drawing which shows the state which made the crossover line along some winding formers with which the stator core was mounted | worn. It is explanatory drawing which shows the state which starts the winding of the reverse winding with respect to a stator core. It is explanatory drawing which shows the state which hooked the connecting wire on the connecting wire clamp. It is explanatory drawing which shows the state which hooked the connecting wire on the connecting wire clamp and pulled out. It is explanatory drawing which shows the state which retracted the crossover clamp from the winding arm backward interference area. It is explanatory drawing which shows the state which retracted the winding former from the stator core. It is explanatory drawing which shows the state which made the stator core index. It is explanatory drawing which shows the state which attached the winding former to the stator core while hooking a connecting wire on a connecting wire hook after indexing a stator core. It is explanatory drawing which shows the state which hold | maintained the preformed coil by the coil end shaping | molding part. It is explanatory drawing which shows the state which starts normal winding with respect to a stator core.

Explanation of symbols

1 Motor 2 Stator 3 Stator Core 4 Teeth 5, 5a, 5b, 5u, 5v, 5w Slot 6 Winding 6P Winding Bundle 6C Crossover 7 Coil 7u U Phase Coil 7v V Phase Coil 7w W Phase Coil 7Hu, 7Hv, 7Hw Coil End Part 11, 31 Insulation part 12, 32 Protrusion part 13, 33 Leg part 100 Winding device 101 Base 102 Leg 103 Table 120 Winding nozzle drive part 121 Winding nozzle 126 Discharge port 140 Winding former attaching / detaching / replacement part 150 Winding Former 150u U-phase winding former 150v V-phase winding former 150w W-phase winding former 160 Winding arm driving section 161 First arm 162 Second arm 163 Third arm 164 Fourth arm 180 Coil end molding sections 181 and 182 Expansion Claw 183,184 Arm part 200 Work pallet part 2 01 Pallet 202 Holder 203 Index servo motor 220 Inspection unit 221 CCD camera 240a, 240b Crossover processing unit 241 Crossover clamp 246 Crossover hook 260 Interphase insulator assembly portion 261uv Interphase insulator (for UV phase)
261vw phase insulator (for VW phase)
270 Grip part 271 Pallet part 275 Grip member 280 Winding supply part 282 Brake part 283 Roller part 284 Spring mechanism part 285 Stretching stroke cylinder 300 Wedge paper insertion part 310 Wedge paper 311 Wedge magazine

Claims (12)

A stator core winding method in which a winding is wound directly on a plurality of slots opened on an inner peripheral surface of a stator core,
A winding step of forming a coil by winding a winding in a first slot and a second slot of the plurality of slots;
After indexing the stator core, an inspection process for inspecting the state of the coil formed in the winding process;
Furthermore, after indexing the stator core, including an insulating step of mounting an interphase insulator on the coil that has been inspected in the inspection step,
A winding method for a stator core, wherein the winding step, the inspection step, and the insulation step are performed in parallel. In the stator core winding method according to claim 1,
In the winding process,
A plurality of windings are discharged from a winding nozzle that can move up and down and swing at the inner periphery of the stator core, and the winding core is removably attached to both end surfaces of the inner periphery of the stator core. Winding a winding around the first slot and the second slot;
The winding wound around the first slot and the second slot is drawn into the first slot and the second slot by each winding arm disposed so as to be able to contact and be separated from both side surfaces of the former. The stator core winding method. In the stator core winding method according to claim 2,
The winding method of a stator core, wherein each winding arm is separated from the winding former before the winding nozzle passes, and abuts against the winding former after the winding nozzle passes. In the stator core winding method according to claim 2 or 3,
A winding method of a stator core, wherein the winding nozzle individually discharges the windings from discharge ports arranged linearly in the stator axial direction. In the stator core winding method according to claim 4,
When supplying a plurality of windings to the winding nozzle, the length and tension of the whole of the plurality of windings are adjusted, and the length and tension of each winding are adjusted. Winding method. In the stator core winding method according to claim 5,
Adjusting the overall length and tension of the plurality of windings when the operation of the winding nozzle is changed from swing to vertical motion;
A winding method of a stator core, wherein the length and tension of each winding are adjusted when the winding nozzle is swinging. In the stator core winding method according to claim 5 or 6,
The operation timing of the winding arm and the adjustment timing of the winding length and tension are determined in advance based on the movement trajectory of the winding nozzle, and the operation of the winding arm and the length and tension of the winding arm are determined. The stator core winding method, wherein the adjustment is performed in conjunction with the operation of the winding nozzle. A winding device for a stator core that winds a winding directly around a plurality of slots that are open on the inner peripheral surface of the stator core,
A holder for holding the stator core;
An index mechanism for rotating the holder by a predetermined angle;
A winding nozzle that is disposed on the inner peripheral portion of the stator core and discharges a plurality of windings to be inserted into the slot;
A winding nozzle drive unit that moves the winding nozzle in the stator axial direction and swings around the stator axis;
A winding former attaching / detaching portion for attaching / detaching a winding former to the inner peripheral surface of the stator core;
A winding arm driving unit that controls the driving of the winding arm that prevents the winding inserted into the slot from protruding out of the slot and draws the winding into the slot;
An inspection unit for inspecting a state of a coil formed on the stator core;
An interphase insulator assembly for attaching an interphase insulator to a coil formed in the stator core;
The stator core winding device, wherein the former attaching / detaching portion, the winding arm driving portion, the inspection portion, and the interphase insulator assembling portion are sequentially arranged so as to surround the holder. The stator core winding device according to claim 8,
The winding arm drive unit is
Separating the winding arm from the winding former and passing the winding nozzle between the winding arm and the winding former;
A winding device for a stator core, wherein the winding arm is brought into contact with the winding former when the winding nozzle passes between the winding arm and the winding former. In the stator core winding device according to claim 8 or 9,
A winding device for a stator core, wherein the winding nozzle has a plurality of discharge ports arranged linearly in a stator axial direction and individually discharging the windings. In the stator core winding device according to claim 10,
A winding supply section for supplying the winding to the winding nozzle while adjusting the length and tension of the winding;
The winding supply unit
A first adjusting mechanism that adjusts the length and tension of the entire plurality of windings;
A stator core winding device comprising: a second adjusting mechanism that adjusts the length and tension of each winding. In the stator core winding device according to claim 11,
The first adjustment mechanism adjusts the overall length and tension of the plurality of windings when the operation of the winding nozzle is changed from swinging to vertical movement,
The winding device for a stator core, wherein the second adjusting mechanism adjusts the length and tension of each winding when the winding nozzle is swinging.

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