JP2010166682A - Method of manufacturing coil, method of manufacturing stator, coil manufacturing device, and stator manufacturing device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To form a coil by bending a magnet wire made of a rectangular wire and the like in a complex shape like a distributed winding. <P>SOLUTION: Shape grooves 11 made to fit a coil shape and guide grooves 12a, 12b provided along the shape grooves are formed on the surface of a mandrel 10. A magnet coil 3a is guided into the guide grooves while being supplied, and bending rollers 21 and a press roller 23 are moved. The magnet wire 3a is bent by a pair of bending rollers 21 so that it goes along each shape groove 11. The bent wire is pressed by the press roller 23 and inserted into each shape groove 11. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method and apparatus for manufacturing a coil in a rotating electrical machine such as a motor, a generator, and a motor / generator, and a method and apparatus for manufacturing a stator using the same. More specifically, the present invention relates to a method and apparatus for bending a magnet wire, particularly a magnet wire made of a flat wire, into a predetermined shape and mounting it on a stator core.

  In general, rotating electrical machines such as induction motors and direct current motors (including generators) are widely used as power sources for industrial or vehicle use, and distributed winding with high specific output is often used for the layout of the stator coils. ing. Recently, as a motor used in a hybrid drive vehicle and an electric vehicle, it has been proposed to use a rectangular wire having a high slot space factor as a magnet wire because of output / size requirements.

  Conventionally, a rectangular wire material is bent into a predetermined shape using a plurality of bending dies, and segments are formed. The ends of each segment are joined sequentially by welding or the like at one end of the core to form a coil as a whole. It has been proposed (see Patent Document 1).

JP 2003-264964 A

  The above method for forming a coil segment requires many molds and requires many other processes such as a joining process for each segment in order to form a stator by attaching it to a core as a coil. In addition, a long coil (magnet wire) having a complicated shape cannot be formed, and it is difficult to ensure sufficient performance as a coil, particularly a coil composed of a flat wire and a stator having the coil.

  Therefore, the present invention is a method and apparatus for manufacturing a coil of a rotating electrical machine, which makes it possible to continuously bend a magnet wire into a complex predetermined shape and further attach it to a stator core, thereby solving the above-mentioned problems. It is another object of the present invention to provide a stator manufacturing method and a manufacturing apparatus using the stator.

The method for manufacturing a coil according to the present invention includes:
Bending to bend the magnet wire along the groove while supplying the magnet wire (3a) to the mandrel (10) having a coil (3) -shaped groove (11) wound around the stator core (2) on the outer peripheral surface Process,
An insertion step of inserting the magnet wire bent in the bending step into the groove,
In the bending step, the magnet wire is sandwiched and bent by a pair of bending rollers (21, 21) that move relative to the mandrel along the groove,
In the inserting step, the magnet is inserted into the groove by a presser roller (23) that moves relative to the mandrel along the groove.

The coil manufacturing apparatus according to the present invention includes:
A mandrel (10) having a coil (3) shaped groove (11) wound around the stator core (2) on the outer peripheral surface;
A pair of bending rollers (21, 21) that move relative to the mandrel along the shape groove;
A pressing roller (23) that moves following the bending roller, has a rotation axis perpendicular to the depth direction plane of the shape groove, and inserts a magnet wire (3a) into the shape groove,
The magnet wire is sandwiched by the bending roller and bent along the shape groove of the mandrel, and the bent magnet wire is inserted into the shape groove by the pressing roller. To do.

The mandrel (10) has guide grooves (12a, 12b) formed along the shape groove (11),
The pressing roller (23) is supported by a pair of guide rollers (22) guided by the guide groove.

The groove (11) on the surface of the mandrel (10) has a rectangular wave shape and an endless continuous shape,
The magnet wire is continuously inserted into the groove (11) a plurality of times.

The mandrel (10) includes a small diameter portion (10a), a large diameter portion (10b), a step portion (10c) that smoothly connects the small diameter portion and the large diameter portion, and a round surface ( 10d) and an end face part (10e) connected via
The shape groove (11) includes an axial linear groove (11a) formed in the small diameter portion (10a), a circumferential groove (11b) formed in the large diameter portion (10b), and the end surface portion. (10e) a circumferential groove (11d) and connecting grooves (11c) for connecting the linear grooves to the stepped portion (10c) and the circumferential grooves (10d) formed on the circumferential grooves. 11e)
One end side coil which forms the slot conductor part (33) of the coil by the linear groove (11a) and expands in the outer diameter direction at one end part of the coil by the circumferential groove (11b) of the large diameter part. The end portion (31) is formed, and the other end side coil end portion (32) bent in the inner diameter direction at the other end portion of the coil is formed by the circumferential groove (11d) of the end face portion.

The method for manufacturing a stator according to the present invention includes:
The mandrel (10) has an axial groove (11f) through which the linear groove (11a) passes through the end surface of the mandrel in the large diameter portion (10b), and the linear groove and the axial groove have a predetermined depth. It consists of a cut groove (13),
Insert the payment plate (15) into the cut groove so as to be axially movable,
The stator core (2) is arranged with the mandrel (10) aligned with the axial center and aligned in the axial direction,
The coil (3) inserted into the shape groove (11) of the mandrel is molded into the stator core (2) by pushing the displacing plate (15) in the stator core direction (A) by the pushing operation member (17). ).

The stator manufacturing apparatus according to the present invention includes:
The mandrel (10) has an axial groove (11f) through which the linear groove (11a) passes through the end surface of the mandrel in the large diameter portion (10b), and the linear groove and the axial groove have a predetermined depth. It consists of a cut groove (13),
A payout plate (15) inserted into the cut groove so as to be axially movable;
A push actuating member that moves the payment plate along the cut groove,
The stator core is arranged by aligning the axial core with the mandrel and arranging them in the axial direction,
A coil formed by being inserted into a groove of the mandrel is attached to the stator core by moving the paying plate in the direction of the stator core by a pushing operation member.

  The magnet wire is a rectangular wire having a rectangular cross section.

  In addition, although the code | symbol in the said parenthesis is for contrast with drawing, this does not have any influence on the structure of a claim.

  According to the present invention according to claim 1, 7, or 8, even a thick magnet wire such as a flat wire can be easily and reliably bent into a coil having a complicated shape such as distributed winding, and the magnet wire can be bent in the bending process. The high-quality coil can be efficiently manufactured.

  According to the second or ninth aspect of the present invention, the magnet wire can be bent and formed by using the same mandrel for a plurality of times, and the end face joining operation or the like can be reduced to improve productivity.

  According to the present invention according to claim 3 or 10, the slot conductor portion has a linear shape in the axial direction, the coil end portion at one end is disposed in the outer diameter direction, and the coil end portion at the other end is disposed in the inner diameter direction, A coil that can be easily and reliably inserted into and attached to the stator core can be manufactured.

  According to the present invention of claim 4 or 11, the coil that can be easily inserted into and mounted on the stator core described above can be manufactured by superimposing a plurality of magnet wires, and one end and the other end side coil end are Since the plurality of magnet wires overlap in the radial direction, it is possible to easily manufacture a compact coil and a stator that are particularly compact in the axial direction.

  According to the present invention according to claim 5 or 12, the above-described coil can be removed from the mandrel and attached to the stator core, and damage to the coil is reduced during the attachment, so that a high-quality stator can be made highly productive. Can be manufactured.

  According to the present invention of claim 6 or 13, a rectangular coil is used as a magnet wire, a coil having an appropriate shape and a stator using the coil are manufactured, and high performance such as an electric vehicle or a hybrid drive vehicle is required. It becomes possible to manufacture the rotary electric machine.

The perspective view which shows the stator manufactured by this invention. The perspective view which shows the coil (U phase). The perspective view which shows the mandrel of the bending machine of the magnet wire which concerns on this invention. The perspective view which shows the linear part insertion of a magnet wire. The perspective view which shows the bending start part of the inner diameter direction of a magnet wire. The perspective view which shows the bending end part of the inner diameter direction of a magnet wire. The perspective view which shows the bending start part to the circumferential direction in the internal diameter side of a magnet wire. The perspective view which shows the completion | finish part of the circumferential bending in the inner diameter side of a magnet wire. The perspective view which shows the bending start part to the outer-diameter direction of a magnet wire. The perspective view which shows the bending end part of the outer diameter direction of a magnet wire. It is a figure which shows the stator manufacturing apparatus which added the coil insertion machine to the bending machine, (a) is front sectional drawing which shows the state which inserted the coil in the stator core, (b) is front sectional drawing which shows the state before insertion, (C) is the side view. The perspective view which shows the state before insertion of a stator core manufacturing apparatus. The perspective view which shows the state after the coil insertion of a stator core manufacturing apparatus.

  Embodiments of the present invention will be described with reference to the drawings. First, a rotary electric (motor, generator, etc.) stator manufactured according to the present invention will be described with reference to FIGS. The stator 1 constitutes an electric motor (including a generator) together with a rotor, and the electric motor is suitable for application to an electric motor (including a generator) serving as a drive source for electric vehicles and hybrid vehicles, particularly a brushless DC motor. is there. As shown in FIG. 1, the stator 1 includes a stator core 2 in which a large number of thin silicon steel plates are laminated and a coil 3 around which a magnet wire (conductor) 3a is wound. The stator core 2 is formed in a ring shape, and a plurality of slots 5 and teeth 6 that are open on the inner diameter side are alternately formed. The three-phase U, V, and W coils 3 (3U, 3V, and 3W) are wound between the two slots 5 separated by a predetermined pitch by distributed winding.

  The magnet wire 3a is a rectangular wire having a rectangular cross section, and an insulating coating such as an insulating resin is formed on the entire circumference of the conductor portion made of copper or the like. The three-phase coils 3U, 3V, and 3W made of the wire 3a are arranged in a plurality of in-phase (for example, four) wires 3a side by side in the radial direction of the stator core 2 in the in-phase slot 5. In addition, in the one end side coil end portion 31 protruding from the one end face 2 a in the axial direction L of the stator core 2, a plurality of in-phase wires 3 a are arranged side by side in the radial direction (or axial direction) of the stator core 2. In the other end side coil end portion 32 protruding from the other end surface 2b in the axial direction, a plurality of wires 3a having the same phase are bent to the radial direction radial side of the stator core 2 and arranged side by side in the radial direction of the stator core 2. .

  As a representative example, the U-phase coil 3U is adjacent to the coil 3U in such a way that two sets 3U1 and 3U2 occupy two adjacent slots 5 and 5 as shown in FIG. The two slots are connected so that the closer and far sides of the two slots are connected at a predetermined interval, and the two sets are connected alternately. Each set of coils 3U1 and 3U2 extends in the circumferential direction C so as to connect the slot conductor portion 33 disposed in the slot 5 and the slot conductor portion 33 protruding from the one end surface 2a of the stator core and spaced apart from each other. The one end side coil end portion 31 and the other end side coil end portion 32 that protrudes from the other end surface 2b of the stator core and bends in the inner diameter direction R1 and extends in the circumferential direction C so as to be connected to the slot conductor portion 33 spaced apart by a predetermined distance. And consist of Both coil end portions 31 and 32 are bent in a plurality of circumferential directions (for example, Y) or axial directions (for example, X) so that they are arranged without interfering with each other in the axial direction L or the radial direction R. .

  Next, a magnet wire bending machine M for bending the magnet wire 3a of the stator 1 into the above-described coil shape will be described. As shown in FIG. 3, the bending molding machine has a mandrel 10, and the mandrel 10 has a hollow cylindrical shape, and its outer peripheral surface has a relatively long small diameter portion 10 a and a relatively short large diameter. It has the step part 10c which connects the part 10b, the small diameter part and the large diameter part with the smooth slope, and the end surface 10e connected with the small diameter part 10a by the smooth round surface 10d. On the surface of the mandrel 10, a winding groove 11 having a shape corresponding to two rounds of the coil 3 is formed, and a pair of guide grooves 12 a and 12 b are formed so as to sandwich the groove 11. Yes.

  That is, a linear groove 11a extending in the axial direction for forming the slot conductor portion 33 of the coil is formed in the small diameter portion 10a of the mandrel, and one end side coil end portion 31 is formed in the large diameter portion 10b. A circumferential groove 11b is formed, and an inclined groove (connecting groove) 11c serving as a transition portion from the slot conductor portion 33 to the coil end portion 31 is formed in the stepped portion 10c. The end surface 10e is formed with a circumferential groove 11d for forming the other end side coil end portion 32 bent toward the inner diameter side. From the rounded surface 10d to the end surface 10e, the slot conductor portion 33 to the end portion 32 are formed. A step-shaped connecting groove 11e having a complicated shape is formed.

  The bending machine M has a roller unit 20 as shown in FIG. The roller unit 20 includes a pair of bending rollers 21 and 21, a pair of guide rollers 22 and 22, and a direction orthogonal to the guide rollers 22 (a direction orthogonal to a depth direction plane of the shape groove). The wire pressing rollers 23 having the rotation shafts are supported so as to be rotatable and the relationship between the rollers can be moved in the up-down direction and in the tertiary direction. The left and right rollers of the pair of bending rollers 21 and 21 and the guide rollers 22 and 22 have their respective shafts 21a and 22a fitted into the pair of guide grooves 12a and 12b of the mandrel, respectively, and move along the guide grooves. It is guided to do.

  The mandrel 10 is appropriately driven in the rotation direction, and the roller unit 20 is driven so that the rollers 21 and 22 can move along the guide grooves 12a and 12b. Although not shown, the roller unit 20 is preferably provided with a magnet wire 3a supply device.

  The pair of bending rollers 21 has a small-diameter portion 21b and a large-diameter portion 21c in addition to the rotating shaft 21a, and the magnet wire 3a made of a rectangular wire is sandwiched between the pair of small-diameter portions 21b. The upper surface of the wire can be pressed at the step portion with respect to the large diameter portion 21c, and the wire 3a can be bent three-dimensionally along the winding groove 11 of the mandrel. A presser roller 23 supported by a portion between the pair of guide rollers 22 and having an orthogonal rotation axis allows the wire 3a bent along the shape groove 11 by the bending guide roller 21 from the upper surface thereof. The wire is inserted into the shape groove 11 by pressing. 3 and 4, the axially-shaped groove 11f formed in the large-diameter portion 10b of the mandrel 10 is necessary for starting the supply of the magnet wire 3a and for extruding and inserting a coil to be described later into the stator core. It is a groove.

  Next, a manufacturing method for forming a coil by bending the magnet wire 3a into a predetermined shape using the bending machine M will be described with reference to FIGS.

  First, as shown in FIG. 4, the magnet wire 3a held by the roller unit 20 and the like is supplied from the axially-shaped groove 11f to the winding-shaped groove 11 while the rotation of the mandrel 10 is stopped. The roller unit 20 moves relatively along the axially-shaped groove 11f, the inclined groove 11c, and the linear groove 11a. In the roller unit 20, the bending rollers 21 and 21 and the guide rollers 22 and 22 are guided through the shafts 21a and 22a by the left and right guide grooves 12a and 12b, respectively, and each shaft is at a predetermined angle with the surface of the mandrel 10. The both bending rollers 21 and 21 move while rotating so as to sandwich the magnet wire 3a. Then, the guide roller 22 moves so as to follow the bending roller 21, and the wire pressing roller 23 supported by the guide roller 22 presses the magnet wire 3 a located on the shape groove 11 from above to form the shape. It inserts in the groove | channel 11 (The axial direction shape groove | channel 11f, the inclination groove | channel 11c, and the linear groove | channel 11a). At this time, the roller unit 20 moves along the mandrel surface so that the shaft 22a of the guide roller 22 is held perpendicular to the surface, and moves to the inclined groove 11c located in the step portion 10c of the mandrel 10. At this time, the magnet wire 3a is bent in the radial direction to form a bending inclined portion G (see FIG. 2) of the other end side coil end portion 32 of the coil 3 in the outer radial direction.

  The roller unit 20 moves along the linear groove 11a while supplying the magnet wire 3a, and inserts the wire into the linear groove. Thereby, the slot conductor part 33 (refer FIG. 2) of the coil 3 is formed.

  Next, as shown in FIG. 5, the roller unit 20 reaches the vicinity of the round surface 10 d of the mandrel 10. In this state, the preceding bending rollers 21 and 21 are positioned in the guide grooves 12a and 12b on the rounded surface, and the subsequent guide roller 22 and the pressing roller 23 are in the guide grooves 12a and 12b on the small diameter cylindrical portion 10a. For a certain relationship, the magnet wire 3a sandwiched between the small-diameter portion 21b of the bending roller 21 and having its upper surface pressed by a stepped portion with the large-diameter portion 21c is bent in the inner diameter direction, and the roller unit 20 is placed on the mandrel surface. The wire 3a is sequentially inserted into the shape groove 11 by proceeding along the line. As a result, a rounded shape H (see FIG. 2) is formed which becomes a connection portion between the other end side coil end portion 32 bent in the inner diameter direction of the coil 3 and the throttle conductor portion 33.

  Further, the roller unit 20 advances while supplying the wire 3a, and as shown in FIG. 6, the subsequent guide roller 22 and presser roller 23 also reach the one end surface 10e from the round surface 10d of the mandrel, and the presser roller 23 causes the magnet to move. The wire 3a is bent in the inner diameter direction. And it will be in the state just before the bending roller 21 which tapers bends the wire 3a along the circumferential groove | channel 11d.

  In the present embodiment, the magnet wire 3a is bent so as to make two rounds. Therefore, the circumferential groove 11d is wide so that two magnet wires 3a made of rectangular wires are arranged in the radial direction. In addition, the linear groove 11a, the inclined groove 11c, and the circumferential groove 11b of the large diameter portion have such a depth that two wires are arranged in the depth direction of these grooves. As shown in detail in FIGS. 6 to 8, the first round wire and the second round wire are deflected in the depth direction of the linear groove 11 a and the width direction of the circumferential groove 11 d, so that And a step-shaped groove 11e that forms different bent portions (see X and Y in FIG. 2) in the second round.

Next, as shown in FIG. 7, the other end side coil end portion 32 is bent in the circumferential direction. As described above, since the circumferential groove 11d is wide, both the left and right rollers are guided by the guide grooves 12a and 12b in order to sandwich the wire 3a by the pair of rollers 21, 21, 22, and 22. The pair of rollers is guided by only one guide groove. In the first round of work, since the wire 3a passes outside, both the rollers 21 and 22 are guided only by the outside guide groove 12b. Therefore, to become bending roller 21 ₁ and the guide roller 22 ₁ is inside, as shown in FIGS. 6 to 10, the shaft 21a, 22a is moved upward, disengaged from the guide groove 12a.

  In this state, the roller unit 20 further advances, and the mandrel 10 rotates in the clockwise direction T as shown in FIG. As a result, the magnet wire 3 a having the supply upstream side sandwiched between the bending roller 21 and the guide roller 22 and the downstream side inserted into the shape groove 11 is bent in the circumferential direction, and the circumferential roller 11 d is pressed by the pressing roller 23. Is inserted along the outer wall a. Further, as the mandrel 10 rotates, the magnet wire 3a extends in the circumferential direction on the inner diameter side, and the other end side coil end portion 32 is formed, as shown in FIG.

  As shown in FIG. 9, when the magnet wire 3a reaches the end of the circumferential groove 11d, the roller unit 20 is deflected so as to face in the outer diameter direction. Accordingly, the magnet wire 3a is bent in the outer diameter direction by the bending roller 21 guided in the guide groove 12b, and the rotation of the mandrel 10 is stopped at the place where the wire is on the extension line of the linear groove 11a.

Roller unit 20, as shown in FIG. 10, the roller ₂₁ 2, 22 ₂ proceeds while being guided by the guide groove 12b, and pushing the pressing roller 23 is a wire 3a on the recessed side of the stepped groove 11e, thereby the other end An axial bent portion X of the side coil end portion 32 is formed. Magnet wire 3a is inserted into the stepped groove 11e, the roller 21 reaches the groove on the extension of the straight grooves 11a (arranged in rounded surface 10d), the inside of the roller ₂₁ 1, 22 ₂ also sequentially inside the guide groove 12a The rollers 21 and 22 are guided by the left and right guide grooves 12a and 12b, and the roller unit 20 moves along the mandrel surface.

  The roller unit 20 advances so that the magnet wire 3a is pushed into the linear groove 11a, and the adjacent slot conductor part 33 is formed. Further, when the roller unit 20 reaches the circumferential groove 11b portion of the large diameter portion 10b via the inclined groove 11c, the roller unit 20 is guided by the guide grooves 12a and 12b and sequentially moves in the circumferential direction with the bending roller 21 and the guide roller 22. The magnet wire 3a is inserted into the circumferential groove 11b by the presser roller 23, and the one end side coil end portion 31 is formed. This is repeated for one round along the mandrel 10 to form the four rectangular-wave-shaped annular coils 3 in the first round.

  Next, the second round wire is superimposed on the wires already inserted in the linear grooves 11a, the inclined grooves 11c, and the circumferential grooves 11b on the large diameter side, thereby forming a continuous coil in the second round.

In the circumferential groove 11d on the end surface of the mandrel, the rotating shafts 21a and 22a are lifted so that the outer rollers 21 ₂ and 22 ₂ out of the pair of bending rollers 21 and guide rollers 22 are disengaged from the guide grooves 12b. This time, the rotation shafts of the inner rollers 21 ₁ and 22 ₁ are guided in the guide groove 12a, and the pair of rollers 21 and 22 are guided. Therefore, the magnet wire 3a of the second round is pushed into the wide circumferential groove 11d along the inner wall b inside the first round wire already installed. At this time, in the step groove 11e, the second-round wire is placed in the portion c on the same side as the circumferential groove 11d to form the radial bent portion Y of the coil end portion 32, and the first-round wire The second round rectangular wave-shaped annular coil 3 is formed without interfering with the coil.

  The coil shown in FIG. 2 can be formed by stacking two sets of two coils 3 formed by bending a magnet wire (flat wire) by the bending machine M and connecting one end thereof.

  In the present embodiment, the coil 3 consisting of two rounds is formed. However, the end face circumferential groove 11d of the mandrel is not widened, but a coil consisting of one round is formed, and a plurality of these are formed with different mandrels. Then, the end faces may be connected to each other, and a coil having an appropriate number of turns may be formed. Further, the two-round coil may be formed so that the rollers 21 and 22 can be adjusted with respect to the guide groove by using a plurality of eccentric shafts or the like. A coil having a large number of turns such as a loop may be formed by one mandrel.

  The bending machine M may be an automatic machine that rotates the mandrel 10 and moves the roller unit 20 along the mandrel surface by an XY driving device. The roller unit 20 may be a semi-automatic or manual machine that is provided separately from the unit and manually moves the roller unit 20 while rotating the mandrel for a predetermined period.

  Next, a stator manufacturing apparatus N and a manufacturing method in which a coil insertion machine is attached to the bending machine described above will be described with reference to FIGS. The linear groove 11a, the inclined groove 11c, and the axial groove 11f extending in the axial direction of the mandrel 10 are cut grooves 13 that are deeper than the number of turns of the magnet wire 3a and penetrate in the axial direction. Further, in the portion of the mandrel 10 where the large-diameter circumferential groove 11b is located, the large-diameter portion 10b 'on the stepped portion 10c side of the circumferential groove is freely removable from the mandrel body.

  And the payment plate 15 is inserted in the said notch groove 13 so that axial movement is possible. There are eight wiping plates 15 fitted in the notch groove 13 in the circumferential direction, and are fixed to the pressing collar 16 on the base end side thereof, and the pressing collar 16 and the pressing operating member 17 to which the pressing collar 17 is fixedly mounted are provided. By operating in the axial direction, the full payout plate 15 can move in the axial direction all at once.

  The displacing plate 15 has a radially upper surface 15a on the tip side constituting the bottom surface of the linear groove 11a and the inclined groove 11c, and a tip surface 15b constituting a part of the step groove 11e and the small diameter side circumferential groove 11d. And the part corresponding to the inclination groove | channel 11c is the enlarged diameter part 15c. Therefore, as shown in FIG. 11 (b), the magnet wire 3 a is fitted into the shape groove 11 of the mandrel 10 in a state where it is on the payment plate 15.

  Next, a stator manufacturing method using the stator manufacturing apparatus N will be described. The point of forming the coil 3 by bending a magnet wire using the mandrel 10 is as described above (see FIGS. 11B and 12). Then, in a state where the coil 3 having a predetermined shape is molded, the large-diameter portion 10b 'of the predetermined inclined surface of the mandrel is removed from the mandrel body. Thereby, there is no part that obstructs the removal of the coil toward the tip side of the mandrel 10.

  In this state, the stator core 2 is arranged in alignment with the mandrel 10 and the tip side of the mandrel in a state where the axis is aligned, and the push actuating member 17 is moved in the arrow A direction. Then, as shown in FIGS. 11A and 13, the eight paying plates 15 are moved in the direction of the arrow A by the push collar 16 in the direction of arrow A, and the coil inserted in the coil-shaped groove 11 of the mandrel 10. 3 is moved in the direction of the stator core 2 in a state of being placed on these paying plates 15, and is inserted into the slot 5 of the stator core 2. Thereby, the coil 3 has its slot conductor portion 33 inserted into the slot 5, the other end side coil end portion 32 arranged in the radial direction on the inner diameter side is located on the left side of the drawing of the core, and One end side coil end portion 31 arranged side by side in the axial direction on the outer diameter side is positioned on the right side in the drawing of the core and is attached to stator core 2.

  As in the embodiment, in the case of the two-turn coils (3U1, 3U2), the mounting operation of the coil to the stator core is performed twice, the end faces of the magnet wire 3a are connected to each other, and the three-phase U, V , W are similarly bent and mounted on the stator core, and the stator 1 as shown in FIG. 1 is manufactured.

  Note that, as described above, the operation of attaching the coil to the stator core may not be performed simultaneously with the operation of removing the coil from the mandrel 10, but the coil may be simply detached from the mandrel and the coil may be attached to the stator core in a separate operation thereafter. In this case as well, it is necessary to remove the large diameter portion 10b 'of the mandrel 10 in order to remove the coil. Moreover, you may comprise so that this one part large diameter part may sink to an internal diameter side like a collet chuck. Further, the shape groove of the mandrel is not limited to the above-described embodiment. For example, the circumferential groove (11b) of the large diameter portion (10a) is formed wide like the circumferential groove of the end surface (10e). A plurality of magnet wires may be arranged in the axial direction in the one end side coil end portion (31).

1 Stator 2 Stator Core 3 Coil 3a Magnet Wire (Flat Wire)
5 slot 10 mandrel 10a small diameter portion 10b large diameter portion 10c stepped portion 10d rounded surface 10e end surface 11 (shape) groove 11a circumferential groove 11c of straight groove 11b (large diameter side) connecting groove (inclined groove)
11d (end face) circumferential groove 11e connecting groove (step groove)
12a, 12b Guide groove 20 Roller unit 21 Bending roller 22 Guide roller 23 Pressing roller 31 One end side coil end portion 32 Other end side coil end portion 33 Slot conductor portion M Coil manufacturing apparatus (bending molding machine)
N stator manufacturing equipment

Claims (13)

A bending step of bending the magnet wire along the groove while supplying the magnet wire to a mandrel having a coil-shaped groove wound around the stator core on the outer peripheral surface;
An insertion step of inserting the magnet wire bent in the bending step into the groove,
In the bending step, the magnet wire is sandwiched and bent by a pair of bending rollers that move relative to the mandrel along the groove,
In the insertion step, the magnet is inserted into the groove by a press roller that moves relative to the mandrel along the groove.
A method for manufacturing a coil, characterized in that: The groove on the surface of the mandrel has a rectangular wave shape and an endless continuous shape,
The magnet wire is continuously inserted into the groove a plurality of times,
The manufacturing method of the coil of Claim 1. The mandrel includes a small diameter portion, a large diameter portion, a step portion that smoothly connects the small diameter portion and the large diameter portion, and an end surface portion that is connected to the small diameter portion via a rounded surface,
The groove includes an axial linear groove formed in the small-diameter portion, a circumferential groove formed in the large-diameter portion, a circumferential groove formed in the end surface portion, and the step portion and the rounded surface. A connecting groove for connecting the circumferential groove and the linear groove formed,
The linear groove forms a slot conductor portion of the coil, the circumferential groove of the large-diameter portion forms an end-side coil end portion that extends in the outer diameter direction at one end portion of the coil, and the end face portion The other end side coil end portion bent in the inner diameter direction at the other end portion of the coil is formed in the circumferential groove.
The manufacturing method of the coil of Claim 1 or 2. The linear groove and the circumferential groove of the large diameter portion have a depth at which a plurality of the magnet wires can be stacked in the depth direction of the groove,
The circumferential groove on the end face has a width that allows a plurality of magnet wires to be stacked in the radial direction,
The connection groove on the rounded surface has a step shape in which each magnet wire can be bent in a radial direction or an axial direction,
In the slot conductor portion and the one end side coil end portion, a plurality of magnet wires are stacked in a radial direction,
In the other end side coil end portion, a plurality of magnet wires are stacked in the radial direction,
Each magnet wire between the other end side coil end portion and the slot conductor portion is formed so as to intersect without interference,
The manufacturing method of the coil of Claim 3. In the manufacturing method of the coil according to claim 3 or 4,
The mandrel has an axial groove through which the linear groove passes through the end surface of the mandrel in the large diameter portion, and the linear groove and the axial groove are formed by a cut groove having a predetermined depth.
Insert the payment plate into the cut groove so as to be axially movable,
The stator core is arranged by aligning the axial core with the mandrel and arranging them in the axial direction,
A coil formed by being inserted into the groove of the mandrel is attached to the stator core by moving the displacing plate in the direction of the stator core by a pressing member.
Stator manufacturing method. The magnet wire is a rectangular wire having a rectangular cross section,
A method for manufacturing a coil or a method for manufacturing a stator according to any one of claims 1 to 5. A mandrel having a coil-shaped groove wound around the stator core on the outer peripheral surface;
A pair of bending rollers that move relative to the mandrel along the shape groove;
A pressing roller that moves following the bending roller, has a rotation axis that is perpendicular to the depth direction plane of the shape groove, and inserts a magnet wire into the shape groove,
The magnet wire is sandwiched by the bending roller and bent along the shape groove of the mandrel, and the bent magnet wire is inserted into the shape groove by the pressing roller.
A coil manufacturing apparatus. The mandrel has a guide groove formed along the shape groove,
The presser roller is supported by a pair of guide rollers guided in the guide groove.
The coil manufacturing apparatus according to claim 7. The shape groove of the mandrel has a rectangular wave shape and an endless continuous shape,
The coil manufacturing apparatus according to claim 7 or 8. The mandrel has a small diameter portion, a large diameter portion, a step portion that smoothly connects the small diameter portion and the large diameter portion, and an end surface portion that is connected to the small diameter portion via a rounded surface. ,
The shape groove includes an axial linear groove formed in the small diameter portion, a circumferential groove formed in the large diameter portion, a circumferential groove formed in the end surface portion, the step portion, and the round surface Connecting grooves that respectively connect the linear grooves to the circumferential grooves formed in
The coil manufacturing apparatus according to any one of claims 7 to 9. The linear groove and the circumferential groove of the large diameter portion have a depth at which a plurality of the magnet wires can be stacked in the depth direction of the groove,
The circumferential groove on the end face has a width that allows a plurality of magnet wires to be stacked in the radial direction,
The connecting groove of the rounded surface has a step shape in which each magnet wire can be bent in a radial direction or an axial direction.
The coil manufacturing apparatus according to claim 10. In the coil manufacturing apparatus according to claim 10 or 11,
The mandrel has an axial groove through which the linear groove passes through the end surface of the mandrel in the large diameter portion, and the linear groove and the axial groove are formed by a cut groove having a predetermined depth.
A payment plate that is inserted into the cut groove so as to be axially movable;
A push actuating member that moves the payment plate along the cut groove,
The stator core is arranged by aligning the axial core with the mandrel and arranging them in the axial direction,
A coil formed by being inserted into the shape groove of the mandrel is attached to the stator core by moving the displacing plate in the direction of the stator core by a pressing member.
Stator manufacturing equipment. The magnet wire is a rectangular wire having a rectangular cross section,
The coil manufacturing apparatus or the stator manufacturing apparatus according to claim 7.

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