JP2010259215A - Method of manufacturing stator, and stator manufacturing apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing stators capable of reliably inserting insulators into teeth, even if a large warpage is produced at a tooth section of any stator core formed of laminated steel plates, and to provide a stator manufacturing apparatus. <P>SOLUTION: In the method of manufacturing stators, the insulator 20 includes a projection 20d at an edge that is at a base side of the tooth section 26a and is orthogonal to a direction in which the laminated steel plate is stacked out of edges for forming an engaging hole 20e. The method of manufacturing stators includes: a first process for moving the insulator 20 so that a coil inserting device 34 grips the insulator 20 and the projection 20d is placed at a position separating from a tip-upper face or a lower face of the tooth section 26a; a second process for moving the projection 20d in a direction abutting against a tip-upper surface or the lower surface of the tooth section 26a by a prescribed distance; a third process for inserting the insulator 20 into the tooth section 26a by a prescribed length; and a fourth process for allowing the coil inserting device 34, to insert the insulator 20 to a fixed position of the tooth section 26a, while abutting against the tip surface of the tooth section 26Aa positioned at the opposite side of the stator section 26a. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a stator manufacturing method in which an engagement hole of the insulator is engaged with a tooth portion of a stator core formed of a laminated steel plate by a robot having a head holding an insulator having a conductor wound on the outer periphery, and The present invention relates to a stator manufacturing apparatus.

In the patent document 1, the applicant of the present invention engaged the engagement hole of the insulator with the teeth portion of the stator core formed of the laminated steel plate by a robot having a head that holds the insulator with a conductor wound around the outer periphery. In the stator manufacturing method, a stator structure in which an insulator has a convex portion at an edge portion which is on the root side of the teeth and is orthogonal to the direction in which the laminated steel plates are laminated among the edge portions forming the engagement holes. Has proposed. According to this, it is possible to prevent an assembling failure due to the steel plate being rolled or rolled up.
Further, the present applicant has proposed a stator structure in which a concave portion is formed on the side surface of the tooth portion and a convex portion formed on the outer periphery of the insulator is engaged with the concave portion in Patent Document 2 to suppress assembly play. ing.
Both applications were filed in the early stages of development, and in both cases, a stator manufacturing method and a stator manufacturing apparatus suitable for the stator structure have not been developed and are not specifically described.

JP 2008-178223 A JP 2008-263719 A

However, when manufacturing a stator having a stator structure proposed by the present applicant, the following problems occur.
That is, when the stator core is formed by laminating about 100 steel sheets having a thickness of 0.3 mm, for example, the steel sheet punched out by the press may have a slight warp. In some cases, the upper surface or the lower surface of the tooth portion warps outward by about 1 mm with respect to the upper surface or the lower surface of the annular yoke portion.
When an insulator is gripped by the robot head and a convex portion formed on the insulator is inserted into contact with the lower surface of the teeth portion, for example, an unexpected reaction force is received from the teeth portion via the insulator. In some cases, the robot head is tilted, and the trouble that the engagement hole of the insulator cannot be properly engaged with the tooth portion has occurred with a small probability.
In particular, on the lower surface of the stator core, the weight of the steel plate itself is added, and the warp of the tip of the steel plate located at the bottom is further increased, so that the frequency of defective insertion has increased.

  The present invention is for solving the above-mentioned problems, and a stator manufacturing method and a stator manufacturing capable of reliably inserting an insulator into a tooth even when a warp generated in a tooth portion of a stator core formed of laminated steel plates is large. An object is to provide an apparatus.

In order to achieve the above object, the stator manufacturing method of the present invention has the following configuration.
(1) A stator that engages an engagement hole of an insulator with a tooth portion of a stator core formed of a laminated steel plate by a robot in which an insulator holding means for holding an insulator having a conductive wire wound on its outer periphery is mounted on the robot head. In the manufacturing method, the insulator has a convex portion at an edge that is at the root side of the teeth portion and is orthogonal to the direction in which the laminated steel plates are laminated, of the edges forming the engagement holes, and the insulator holding means Grips the insulator and moves the insulator so that the convex portion is located away from the top or bottom surface of the tip of the tooth portion, and a predetermined direction in which the convex portion comes into contact with the top or bottom surface of the tip of the tooth portion. A second step of moving the distance, a third step of inserting the insulator into the teeth portion by a predetermined length, and an insulator holding means While contact with the tooth tip on the opposite side of the stator core person, and having a fourth step of inserting an insulator into position of the tooth portion.
Here, the convex portion may be formed on the lower side of the stator core or on the upper side. However, considering the warpage due to the weight of the steel plate, it is better to form it on the lower side.

Moreover, in order to achieve the said objective, the stator manufacturing apparatus of this invention has the following structure.
(2) Engage the engagement hole of the insulator with the teeth portion of the stator core formed of laminated steel sheets by a robot in which an insulator holding means for holding an insulator with a conductor wire wound on the outer periphery is mounted on the robot head. In the stator manufacturing apparatus, the insulator has a convex portion at an edge that is orthogonal to the direction in which the laminated steel plates are laminated, on the base side of the tooth portion, of the edge portion that forms the engagement hole, and retains the insulator The means grips the insulator, and inserts the insulator into the tooth part for a predetermined length while the convex part is in contact with the top or bottom surface of the tip of the tooth part, and the tip of the tooth part where the insulator holding means is located on the opposite side of the stator core It has a reaction force receiving mechanism that inserts the insulator to a fixed position of the teeth part while abutting And, characterized by.

Next, the operation and effect of the stator manufacturing method and the stator manufacturing apparatus of the present invention having the above-described configuration will be described.
In a stator manufacturing method of engaging an engagement hole of an insulator with a tooth portion of a stator core formed of a laminated steel plate by a robot in which an insulator holding means for holding an insulator having a conductive wire wound around an outer periphery is attached to a robot head. The insulator has a convex portion at the edge of the tooth portion, which is the root side of the teeth portion, perpendicular to the direction in which the laminated steel plates are laminated, and the insulator holding means has the insulator. The first step of gripping and moving the insulator so that the convex portion is located away from the upper surface or lower surface of the tip of the tooth portion, and the convex portion is moved by a predetermined distance in a direction in contact with the upper surface or lower surface of the tooth portion The second step, the third step of inserting the insulator into the teeth portion for a predetermined length, and the insulator holding means And a fourth step of inserting the insulator to a fixed position of the teeth portion while abutting the tip of the teeth portion located on the opposite side of the taco, and in the first step, the first end face of the laminated steel plate Even if the steel plate located at is greatly warped, the convex portion of the insulator is positioned outside the tip of the outermost steel plate of the teeth.
And in a 2nd process, it contacts with the front-end | tip of the outermost steel plate of teeth, and moves a little inside (direction approaching the laminated steel plate). Thereby, the distance of the front-end | tip of the steel plate located in the end surface side of teeth and the front-end | tip of the steel plate located in the uppermost side of teeth can be made close.
In the third step, the insulator is inserted into the teeth portion by a predetermined length by the movement of the robot.
And, in the fourth step, when the insulator is inserted to the fixed position of the tooth portion, the reaction force receiving mechanism of the insulator holding means comes into contact with the tooth portion located on the opposite side of the stator core, so that the steel plate is interposed via the insulator. Even if the head receives an unexpected reaction force, the insulator holding means does not tilt, so that the engagement hole of the insulator can be reliably attached to the outer periphery of the teeth.

2 is a front view of a coil insertion device 34 attached to a robot head 11. FIG. It is a figure which shows the AA cross section and stator core 26 of FIG. FIG. 3 is a view showing a state where the coil insertion device 34 grips the trapezoidal coil 20 with a pair of chuck claws 23 and is located on the inner periphery of a tooth portion 26 a of the stator core 26. It is a figure which shows the state which the convex part 20d of the insulator 20 lifted the front-end | tip of the steel plate located in the lowest part of the teeth part 26a to the height of the upper surface of a mounting base. It is a figure which shows the state which inserted the engagement hole 20e of the insulator 20 in the outer periphery of the teeth part 26a to the position just before the front end surface of the chuck | zipper claw 23 and the holder 36 does not contact the front end surface of the teeth part 26a. It is a figure which shows the state which the press part 16a of the insulator press member 16 presses the edge part around the engagement hole 20e of the insulator 20, and has further inserted the insulator 20 to the root of the teeth part 26a. It is the front view and side view of the insulator 20 for trapezoidal coils 22. FIG. 4 is a diagram showing a relationship among an insulator 20, a chuck claw 23, and a holder 36.

Hereinafter, a stator and a stator manufacturing method according to an embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a front view of the coil insertion device 34 attached to the robot head 11. FIG. 1 shows a state where the coil insertion device 34 grips the trapezoidal coil 22 in which the conducting wire 21 is wound around the outer periphery of the insulator 20. A part is shown in a sectional view. FIG. 2 shows the AA cross section of FIG. 1 and the stator core 26. A state in which the coil insertion device 34 is disposed on the inner periphery of the tooth portion 26a of the stator core 26 is shown.
As shown in FIG. 2, the stator core 26 of the present embodiment has 12 tooth portions 26a. Six rectangular coils 28 and six trapezoidal coils 22 are alternately mounted. As a manufacturing method, first, six trapezoidal coils 22 are mounted, and then six rectangular coils 28 are mounted. All the coils are inserted by the coil insertion device 34 shown in FIG. A trapezoidal coil 22A in FIG. 2 indicates the position of the trapezoidal coil after mounting.
On the upper surface of the stator core 26, a bus bar 25 is annularly arranged. A bus bar terminal 25a for connecting to the conductor terminal portion 21a of the conductor 21 protrudes from the bus bar 25 at a position corresponding to each coil. The bus bar 25 is connected to three stator terminals 27 for connecting the U phase, the V phase, and the W phase.

As shown in FIG. 1, the center line of the robot head 11 is indicated by L. A base plate 12 is fixed to the robot head 11. A slide guide 13 is fixed to the base plate 12. A cylinder slider 14 and a chuck slider 33 are slidably held on the slide guide 13, respectively. The coil insertion device 34 includes all the components below the base plate 12.
In FIG. 1, the cylinder slider 14 and the chuck slider 33 are in contact with each other. A cylinder bracket 35 is fixed to the cylinder slider 14. The main body of the insertion cylinder 17 is fixed to the cylinder bracket 35. The rod 17a of the insertion cylinder 17 is connected to a chuck bracket 15 described later. The cylinder bracket 35 is deformed into a U shape from the portion where the insertion cylinder 17 is attached, and a reaction force receiving portion 35a is formed at the tip.

On the other hand, the chuck bracket 15 has a substantially U-shape in which two bracket plates 15a and 15b are suspended. Both ends of the four guide rods 18 are fixed to the bracket plates 15a and 15b, respectively. A chuck base plate 19 is slidably held on the four guide rods 18. A chuck cylinder 24 that can move a pair of chucks 24 a is fixed to the chuck base plate 19. Each of the pair of chucks 24 a is provided with a substantially L-shaped chuck claw 23. The chuck base plate 19 is provided with a holder 36 that engages with the inner periphery of the engagement hole 20 a of the insulator 20.
FIG. 8 shows the relationship between the insulator 20, the chuck claw 23, and the holder 36. On both side surfaces of the holder 36, a space in which the tip of the chuck claw 23 enters and can be operated is formed. The tip of the chuck claw 23 enters the space.
An insulator pressing member 16 that contacts the front surface of the insulator 20 and presses the insulator 20 is attached to the right side surface of the bracket plate 15 a at a position corresponding to the edge of the engagement hole of the insulator 20. The insulator pressing member 16 is formed with a square ring-shaped pressing portion 16a corresponding to an edge portion forming the engagement hole 20e of the insulator 20.
A position sensor 30 is attached to the bracket plate 15 by a position sensor bracket 31.

In FIG. 7, the front view of the insulator 20 for the trapezoidal coil 22 is shown in (b), and the side view is shown in (a).
The insulator 20 has an outer wall 20a formed on the root side of the tooth portion and an inner wall 20b formed on the tip side of the tooth portion at both ends of the cylindrical portion 20c around which the conducting wire 21 is wound. An engaging hole 20e for engaging with the tooth portion 29 passes through the outer wall 20a, the cylindrical portion 20c, and the inner wall 20b. On the inner surface of the engagement hole 20e, four convex portions 20f are formed. A convex portion 20d is formed at an edge portion of the edge portion forming the engagement hole 20e of the outer wall 20a perpendicular to the direction in which the laminated steel plates are laminated.

Next, an operation of the coil insertion device 34 of the present invention, that is, a method for inserting the trapezoidal coil 22 into the tooth portion 26a of the stator core 26 will be described.
FIG. 3 shows a state in which the coil insertion device 34 grips the trapezoidal coil 22 with the pair of chuck claws 23 and is positioned on the inner periphery of the tooth portion 26 a of the stator core 26. In the figure, the tooth portion 26a is specified by hatching. The pair of chuck claws 23 grips the inner surface of the engagement hole 20e of the insulator 20 of the trapezoidal coil 22 in a state of being opened left and right in FIG.
The robot head 11 descends and stops at the position shown in FIG. 3 with the coil insertion device 34 gripping the trapezoidal coil 22. In FIG. 3, the annular portion of the stator core 26 is mounted on a mounting table (not shown). The tip of the steel plate positioned at the bottom of the tooth portion 26a may be lowered by 1 or 2 mm from the upper surface of the mounting table. This is due to the warpage of the steel sheet and the weight of the steel sheet.
The robot head 11 is stopped so that the upper surface of the convex portion 20d of the insulator 20 is positioned by a length M = 3 mm below the upper surface of the mounting table. Thereby, even if the front-end | tip of the steel plate located in the lowest part of the teeth part 26a is a case where it is about 1 mm lower than the upper surface of a mounting base, the upper surface of the convex part 20d of the insulator 20 is ensured of the teeth part 26a. It is located below the tip of the steel plate located at the bottom.

Next, the robot head 11 moves in the horizontal direction, and the engagement hole 20e of the insulator 20 is not yet in a position to engage with the tooth portion 26a. Only the upper surface of the convex portion 20d of the insulator 20 is below the tooth portion 26a. Move to the position at and stop. Next, the robot head 11 moves up 3 mm, and moves to a position where the upper surface of the convex portion 20d of the insulator 20 is at the same height as the upper surface of the mounting table. Even if the tip of the steel plate positioned at the bottom of the tooth portion 26a is lowered by about 1 mm from the upper surface of the mounting table due to this rise, the convex portion 20d of the insulator 20 is lowered to the bottom of the tooth portion 26a. Lift the tip of the steel plate located at the height of the top surface of the mounting table. This is the first step. This state is shown in FIG. Thereby, since the tip of the steel plate located at the bottom is lifted, the distance between the tip of the steel plate located at the bottom and the tip of the steel plate located at the top is set to the length of the engagement hole 20e. In contrast, the tooth portion 26a can be reliably inserted into the engagement hole 20e.
Next, the robot head 11 moves horizontally, and the engagement hole 20e of the insulator 20 is moved to the outer periphery of the tooth portion 26a until the front end surface of the chuck claw 23 and the holder 36 does not contact the front end surface of the tooth portion 26a. insert. The inserted state is shown in FIG. This is the third step.
When the robot head 11 moves horizontally, the robot head is lowered by about 0.3 mm. The reason is that the tip of the lead wire terminal portion 21a of the trapezoidal coil 22 is appropriately inserted into the guide of the bus bar holding means.

Next, the robot head 11 is stopped and the gripping by the chuck claws 23 is released. At this time, as shown in FIG. 5, the engagement hole 20e of the insulator 20 is inserted to a length of about 2/3 of the entire length, which is the predetermined length in the claims. The insulator 20 is stable, and the insulator 20 does not move even when the chuck pawl 23 is released.
Next, the insertion cylinder 17 is driven while the robot head 11 is stopped. The insertion cylinder 17 is a single-acting cylinder, and when not driven, the cylinder slider 14 and the chuck slider 33 are in contact with each other by a built-in return spring, and the chuck bracket 15 and the cylinder bracket 35 are shown in FIG. It is in the position shown in FIG.
By driving the insertion cylinder 17, first, the pressing portion 16a of the insulator pressing member 16 comes into contact with the edge portion of the insulator 20, and the engaging hole 20e of the insulator 20 is connected to the outer periphery of the tooth portion 26a and 2/3 of the whole. Since it is engaged for a certain length, the engagement becomes resistance, and the chuck bracket 15 does not move.

On the other hand, since the cylinder bracket 35 is in a free state, the cylinder slider 14 moves to the left while being guided by the slide guide 13 by driving the insertion cylinder 17. When the reaction force receiving portion 35a of the cylinder bracket 35 comes into contact with the tip surface of the teeth portion 26Aa located on the opposite side of the teeth portion 26a of the stator core 26, the cylinder slider 14 stops.
Next, under the force of the insertion cylinder 17, the chuck slider 33 moves to the right along the slide guide 13. And the press part 16a of the insulator press member 16 presses the edge part around the engagement hole 20e of the insulator 20, and further inserts the insulator 20 to the root of the teeth part 26a. The state at that time is shown in FIG. This is the fourth step.

At this time, the coil insertion device 34 receives a reaction force due to the insertion, but the reaction force receiving portion 35a of the cylinder bracket 35 is in contact with the distal end surface of the tooth portion 26Aa, so that an inclination or the like does not occur. The engagement hole 20e of the insulator 20 can be stably inserted into the outer periphery of the tooth portion 26a. At the same time, the conductor terminal portion 21a of the trapezoidal coil 22 can be engaged with the bus bar terminal 25a of the bus bar 25 through the guide of the bus bar terminal holding means 32.
The chuck base plate 19 is always urged by a spring (not shown) in a direction in which the chuck base plate 19 abuts on the tooth portion 26a. When the insertion cylinder 17 is driven to change from the state of FIG. 5 to the state of FIG. 6, the chuck claw 23 and the tip of the holder 36 are in contact with the tip surface of the tooth portion 26 a. The chuck base plate 19 moves to the left along the guide rod 18 to the position shown in FIG.

Here, as shown in FIG. 2, a pair of side surface recesses 26 b and 26 b are formed on both side surfaces of the tooth portion 26 a of the stator core 2, and the side surface recesses 26 b and 26 b are connected to the engagement hole 20 e of the insulator 20. The four formed protrusions 20f are engaged and positioned.
Further, the amount of insertion of the engagement hole 20e of the insulator 20 into the tooth portion 26a is measured by the position sensor 30 every time, and it is confirmed that the engagement hole 20e has been inserted to the proper position. If it is not inserted to the proper position, an alarm is given.
At this time, the convex portion 20d of the insulator 20 is located on the lower surface of the tooth portion 26a and does not get in the way.
Although the method for inserting the trapezoidal coil 22 has been described above, the same applies to the case of the rectangular coil 28.

  As described above in detail, according to the stator manufacturing method and the stator manufacturing apparatus of the present embodiment, the robot head 11 to which the coil insertion device 34 that holds the insulator 20 around which the conductive wire 21 is wound is mounted is mounted. In the stator manufacturing method in which the engagement hole 20e of the insulator 20 is engaged with the teeth portion 26a of the stator core 26 formed of a laminated steel plate by the robot provided, the insulator 20 has an edge portion that forms the engagement hole 20e. Among them, the root portion of the tooth portion 26a, which has a convex portion 20d at the edge perpendicular to the direction in which the laminated steel plates are laminated, the coil insertion device 34 grips the insulator 20, and the convex portion 20d is the teeth portion. The robot head 11 moves the insulator 20 so as to be at a position away from the upper surface or the lower surface of the distal end of 26a. One step, a second step in which the robot head 11 moves the convex portion 20d by a predetermined distance in a direction in contact with the upper surface or the lower surface of the tip portion 26a, and the robot head 11 has a predetermined length in the insulator portion 26a. A third step of inserting, and a fourth step of inserting the insulator 20 to a fixed position of the tooth portion 26a while the coil insertion device 34 is in contact with the tip surface of the tooth portion 26Aa located on the opposite side of the stator portion 26a. In the first step, even if the steel plate located on the outermost end surface of the laminated steel plate is greatly warped, the convex portion 20d of the insulator 20 is positioned outside the front end of the outermost steel plate of the teeth. Is done.

And in a 2nd process, the robot head 11 contact | abuts with the front-end | tip of the outermost steel plate of the teeth part 26a, and moves a little inside (direction approaching the laminated steel plate). Thereby, the distance of the front-end | tip of the steel plate located in the most end surface side of a teeth part and the front-end | tip of the steel plate located in the uppermost side of a teeth part can be shortened. In the third step, the insulator 20 is inserted into the tooth portion 26a up to a predetermined length (about 2/3 of the total length in this embodiment) by the movement of the robot head 11.
And in the 4th process, when insulator 20 is inserted to the fixed position of teeth part 26a, reaction force receiving mechanisms 17 and 16 of coil insertion device 34 contact teeth part 26Aa located on the opposite side of a stator core. Therefore, even if the robot head 11 receives an unexpected reaction force from the steel plate via the insulator 20, the robot head 11 does not tilt, so the engagement hole 20e of the insulator 20 is securely attached to the outer periphery of the tooth portion 26a. can do.

In addition, this invention is not limited to the said embodiment, A part of structure can also be changed suitably and implemented in the range which does not deviate from the meaning of invention.
For example, in this embodiment, the convex portion 20d of the insulator 20 is brought into contact with the lower surface of the tip of the steel plate positioned at the bottom of the tooth portion 26a and the teeth portion 26a is lifted upward. 20d may be formed in the upper edge part of the engagement hole 20e, and the lower surface of the convex part 20d may be contact | abutted to the front-end | tip upper surface of the steel plate located in the top of the teeth part 26a, and the teeth part 26a may be pushed down.
In the present embodiment, the robot performs the first, second, and third steps, and the dedicated mechanism performs the fourth step. However, any one of the first, second, and third steps may be performed by the dedicated mechanism.

DESCRIPTION OF SYMBOLS 11 Robot head 16 Insulator press member 16a Press part 17 Insert cylinder 20 Insulator 20d Protrusion part 20e Engagement hole 22 Trapezoid coil 23 Chuck claw 24 Chuck cylinder 25 Bus bar 26 Stator core 26a Teeth part 34 Coil insertion apparatus

Claims (2)

A stator manufacturing method in which an engagement hole of the insulator is engaged with a tooth portion of a stator core formed of a laminated steel plate by a robot in which an insulator holding means for holding an insulator having a conductive wire wound on an outer periphery is attached to a robot head. In
The insulator has a convex portion at an edge perpendicular to the direction in which the laminated steel sheets are laminated, on the root side of the teeth portion among the edges forming the engagement hole,
A first step of moving the insulator so that the insulator holding means grips the insulator and the convex portion is positioned away from the top surface or the bottom surface of the tip of the tooth portion;
A second step of moving the convex portion by a predetermined distance in a direction in contact with the upper surface or the lower surface of the tip of the teeth portion;
A third step of inserting the insulator into the teeth portion for a predetermined length;
A fourth step of inserting the insulator to a fixed position of the teeth portion while the insulator holding means is in contact with the tip of the teeth portion located on the opposite side of the stator core;
The stator manufacturing method characterized by having. A stator manufacturing apparatus for engaging an engagement hole of the insulator with a tooth portion of a stator core formed of a laminated steel plate by a robot in which an insulator holding means for holding an insulator having a conductive wire wound around its outer periphery is mounted on a robot head. In
The insulator has a convex portion at an edge perpendicular to the direction in which the laminated steel sheets are laminated, on the root side of the teeth portion among the edges forming the engagement hole,
The insulator holding means grips the insulator and inserts the insulator into the tooth portion for a predetermined length while the convex portion is in contact with the top or bottom surface of the tip of the tooth portion;
A stator manufacturing apparatus, comprising: a reaction force receiving mechanism that inserts the insulator to a fixed position of the teeth portion while the insulator holding means is in contact with a tip of the teeth portion positioned on the opposite side of the stator core.

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