JP2011151994A - Method and device for manufacturing stator winding, and rotary electric machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a stator winding by facilitating assembly while avoiding the interferences of mutual conductors molded in a normal size. <P>SOLUTION: A moving process for relatively moving conductor aggregates CG along a first path R1, and an assembly process moving and assembling the conductor aggregates CG along a second path R2 are conducted regarding the conductor aggregates CG. The conductor aggregates CG are moved along the first path R1 in the moving process, and clearances among the mutual conductor aggregates CG are secured. The moved conductor aggregates CG are moved and assembled along the second path R2 in the assembly process. Accordingly, the stator winding can be manufactured by facilitating assembly while avoiding the interferences among the mutual conductor aggregates CG molded in the normal size. The same applies to the case when the assembly is facilitated at each conductor in place of the conductor aggregates CG. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a method and an apparatus for manufacturing a stator winding having a plurality of conductor assemblies in which a plurality of conductors are laminated.

  Conventionally, a stator winding (an assembly of conductor assemblies) is assembled by winding and assembling a belt-like conductor assembly formed by wave winding a rectangular wire in a spiral shape while rotating a cylindrical core member. An example of the technique to manufacture is disclosed (for example, refer patent document 1).

JP 2009-247199 A

  However, according to the technique of Patent Document 1, a force (that is, a spring back) is applied to each of the conductive wires after the conductive wire assembly is wound up so as to spread in the outer diameter direction. The conductors interfere with each other due to the action of the spring back, and the insulating films may be damaged by rubbing each other. Since the insulation resistance of the film is reduced in a conductor with a damaged film, the performance of a rotating electrical machine having a stator winding assembled with a conductor assembly cannot be sufficiently exhibited.

  On the other hand, it is possible to consider a method of forming the coil into a spiral shape in consideration of the spring back, and moving and assembling each conductor wire having a normal dimension (finished dimension) after the spring back. According to this method, it is possible to avoid the action of the springback and to suppress the damage to the coating that occurs due to the interference between the conducting wires. However, since the conductors have regular dimensions, there is almost no clearance (gap) between the conductors even if the stator winding is manufactured by assembling the conductor assembly. Therefore, if the conductors are simply moved and assembled, interference between the conductors may occur during the assembly.

  The present invention has been made in view of the above points, and manufacture of a stator winding capable of manufacturing a stator winding by facilitating assembly while avoiding interference between conductive wires formed in regular dimensions. It is an object to provide a method and a manufacturing apparatus thereof. Moreover, it aims at providing the rotary electric machine manufactured with the said manufacturing method and manufacturing apparatus.

  The invention according to claim 1, which has been made in order to solve the above-described problem, is a stator winding manufacturing method for manufacturing a stator winding by stacking and assembling a plurality of conductors, and is included in the plurality of conductors. Each conducting wire is formed into a curved shape such as an arc shape or a spiral shape in the radial direction and is shaped into a convex shape in the axial direction, and the conducting wire is relative to the first path including at least the axial direction. It has a moving process to move, and an assembling process to move and assemble the conducting wire along a second path including at least the horizontal direction.

  According to this configuration, a lead wire that is shaped into a curved shape in the radial direction in consideration of the spring back and is shaped into a convex shape in the axial direction and having a normal dimension after the spring back is used. The “curved shape” mainly corresponds to an arc shape or a spiral shape, but may include a linear shape in part. Since each conducting wire has a normal dimension, in order to secure a clearance between the conducting wires, a moving process is performed to move the conducting wire along the first path. The “first path” is a moving path including at least the axial direction, and a part of the path may include another direction (for example, a radial direction, a horizontal direction, etc.). When assembling by moving a plurality of conducting wires, an assembling step is performed, and the conducting wires moved in advance are moved along the second path and assembled. The “second path” is a moving path including at least a horizontal direction, and a part of the path may include another direction (for example, a radial direction or an axial direction). Therefore, it is possible to manufacture the stator winding while facilitating the assembly while avoiding the interference between the conductive wires formed in regular dimensions.

  The invention according to claim 2 is characterized in that, in the moving step, the conducting wire is moved in one or both of a radial direction and a circumferential direction. That is, the first path includes movement in the radial direction and the circumferential direction as well as the axial direction. According to this configuration, by including the movement in the radial direction and the circumferential direction, for example, when trying to assemble a new conductor that has not yet been assembled, interference with the already assembled conductor is avoided. Therefore, in the process of assembling a plurality of conductors, interference between the conductors can be avoided more reliably.

  The invention according to claim 3 is characterized in that, in the assembling step, the conducting wire is moved in a direction opposite to the moving step. According to this configuration, when the movement in the radial direction or the circumferential direction included in the first path is performed, the normal dimension may be lost, and the movement is performed in the opposite direction to the normal dimension in order to return to the normal dimension. Therefore, in the process of assembling a plurality of conductors, the normal dimension of the conductors can be more reliably maintained.

  The invention described in claim 4 is characterized in that the conducting wire moves by the action of a moving cam. According to this configuration, the conducting wire can be easily moved by simply rotating the moving cam. Therefore, a power source such as a motor is not required, and a simple mechanism can be realized, so that the cost can be kept low.

  The invention according to claim 5 includes a grouping step of grouping the plurality of conductors into a conductor assembly composed of two or more conductors, and the conductor assembly grouped by the grouping step The moving process and the assembling process are performed. The “multiple conductors” are the number of conductors (for example, 48 wires) necessary to constitute the stator winding to be manufactured, and are grouped into two or more conductors (for example, six wires) by the grouping process. A plurality of conductive wire assemblies (for example, 8 groups) are formed. According to this configuration, the moving process and the assembling process may be performed for each conductor assembly in the same manner as the moving process and the assembling process performed for each conductor. Therefore, it is possible to manufacture the stator winding by facilitating the assembly of the grouped plurality of conductor assemblies, while avoiding the interference between the conductors formed in regular dimensions.

  According to a sixth aspect of the present invention, in the stator winding manufacturing apparatus for manufacturing a stator winding by stacking and assembling a plurality of conductors, each conductor included in the plurality of conductors is circular in the radial direction. It is formed into a curved shape such as an arc shape or a spiral shape, and is formed into a convex shape in the axial direction, and a holder member capable of holding a part of the conducting wire, and the holder member mounted so as to be movable at a plurality of positions And a table member.

  According to this configuration, in the same manner as in the first aspect of the invention, in consideration of the spring back, it is formed into a curved shape in the radial direction and is formed into a convex shape in the axial direction, and becomes a normal dimension after the spring back. Use conducting wire. Since each conducting wire has a normal dimension, in order to secure a clearance with the assembled conducting wire, the conducting wire to be assembled is held by a holder member. The conducting wire thus held moves together with the holder member at a plurality of positions on the table member. The said movement means moving along the path | route which avoids interference with the assembled conducting wire, and includes one or more directions among an axial direction, a horizontal direction, a radial direction, a circumferential direction, etc. Therefore, it is possible to manufacture the stator winding while facilitating the assembly while avoiding the interference between the conductive wires formed in regular dimensions.

  According to a seventh aspect of the present invention, the holder member moves along the first path when the conductor is moved along a first path including at least the axial direction, and along the second path including at least the horizontal direction of the conductor. And a second position when moving in a movable manner. According to this configuration, the conducting wire held by the holder member includes moving to the first position along the first path and moving to the second position along the second path. Therefore, it is possible to manufacture a stator winding as an assembly by assembling a plurality of conductors while more reliably avoiding interference between the conductors formed into regular dimensions.

  The invention according to claim 8 is characterized in that the holder member is configured to be movable to a third position that is further displaced in the radial direction or the circumferential direction than the second position. The “third position” means a position for separating a stator winding as an assembly in which a plurality of conducting wires are assembled and a holder member holding the conducting wires. According to this configuration, the stator winding as a finished product can be easily taken out simply by moving the holder member to the third position after releasing the held conducting wire at the second position. As a matter of course, when the holder member moves from the second position to the third position, the holder member moves along a path that avoids interference with the conducting wire (stator winding). Therefore, interference is avoided even when the finished product and the jig are separated.

  The invention according to claim 9 is characterized in that the holder member moves to any one of the plurality of positions by the action of a moving cam. According to this configuration, the holder member (and consequently the conducting wire) can be easily moved simply by rotating the moving cam. Therefore, a power source such as a motor is not required, and a simple mechanism can be realized, so that the cost can be kept low.

  The invention described in claim 10 is characterized in that a part of the conducting wire held by the holder member is a slot accommodating portion accommodated in a slot of the stator core. According to this structure, since the slot accommodating part of a conducting wire is shape | molded in a linear shape, the holder member for hold | maintaining a slot accommodating part is also comprised in a linear shape. Therefore, it can hold | maintain easily and cost can be restrained low compared with the case where a holder member is comprised in complicated shapes, such as a curve shape.

  The invention according to claim 11 is characterized in that a plurality of the holder members are provided with a cylindrical member that can be positioned at the second position. According to this configuration, the outer peripheral surface of the cylindrical member becomes the second position, and the plurality of holder members can be simply and uniformly positioned at the second position until they contact the outer peripheral surface of the cylindrical member. Therefore, the inner peripheral surface of the stator winding that is the finished product can be made uniform.

  The invention described in claim 12 is characterized in that the plurality of conductors are grouped into a conductor assembly comprising two or more conductors, and the holder member holds each conductor included in the conductor assembly. According to this configuration, the holder member can hold the conductor assembly (two or more conductors) as a whole and move it to a plurality of positions. When manufacturing the stator windings, it is only necessary to assemble the same number of conductor assemblies, and the possibility of interference between the conductors is greatly reduced. Therefore, it is possible to more reliably avoid the interference between the conductive wires formed in regular dimensions.

  According to a thirteenth aspect of the present invention, in a rotating electrical machine, the stator winding manufactured according to any one of the first to twelfth aspects is provided. According to this configuration, since the stator windings are assembled so as to avoid interference between the conductors molded in regular dimensions, insulation resistance between the conductors is ensured and the required performance of the rotating electrical machine is exhibited. can do.

It is a perspective view which shows the example of whole structure of the manufacturing apparatus of a stator winding | coil. It is a perspective view which shows the structural example of a holding | grip mechanism. It is a perspective view which shows the structural part of a manufacturing apparatus. It is a figure which shows the structural examples, such as a table member and a holder member. It is a perspective view which shows the structural example of a holder member. It is a disassembled perspective view of the holder member shown in FIG. It is the top view and sectional drawing of a holder member shown in FIG. It is a figure which shows the structural example of a chuck mechanism. It is a figure which shows the state which does not hold | maintain conducting wire, and the state hold | maintained. It is the side view and top view which show the structural example of a connection member. It is a figure explaining the gap expansion-contraction function and connection state change function of a chuck mechanism. It is a side view explaining the several position which a holder member can move. It is sectional drawing explaining the several position which a holder member can move. It is a figure which shows the example which shape | molds one conducting wire in an extending | stretching direction. It is a figure which shows the example of shaping | molding of the slot accommodating part and turn part of conducting wire. It is a figure which shows the example which shape | molds one conducting wire to radial direction. It is a perspective view which shows the example which combines a conducting wire assembly using a some conducting wire. It is a perspective view which shows the state which hold | maintained the several conducting wire with the chuck mechanism. It is a perspective view explaining the process of assembling a conducting wire assembly. It is a perspective view which shows the state after assembling | attaching a conducting wire assembly. It is a top view which shows the state which deform | transformed the 1st conductor assembly. It is a top view which shows the process of assembling the 2nd conducting wire assembly. It is a top view which shows the state after attaching the 2nd conductor assembly. It is a top view which shows the relationship between an attached conducting wire assembly and a to-be-attached conducting wire assembly. It is a figure which shows the example of a movement path | route of an attachment scheduled conducting wire assembly. It is a top view which shows the state immediately after assembling and releasing all the conducting wire assemblies. It is a perspective view which shows the workpiece | work (all the conductor assembly) after taking out from the manufacturing apparatus. It is a perspective view which shows the state after processing the edge part of conducting wire. It is a figure which shows the structural example of a stator core. It is a perspective view which shows the stator which assembled | attached the workpiece | work to the stator core. It is sectional drawing which shows the rotary electric machine provided with the stator shown in FIG.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. In addition, when showing directions, such as up and down, right and left, it shall follow a description of an applicable drawing. Moreover, the assembly at the time of manufacturing a stator winding | winding is an example performed for every conducting wire integrated body which consists of two or more conducting wires. Further, the hatch is not shown in the cross-sectional view for easy viewing.

  First, a configuration example of a manufacturing apparatus for manufacturing a stator winding (hereinafter referred to as “winding manufacturing apparatus”) will be described with reference to FIGS. The stator winding is provided in a rotating electrical machine MG (see FIG. 31) described later, and is an assembly that is assembled by laminating a plurality of conductive wires. FIG. 1 is a perspective view showing a configuration example of a winding manufacturing apparatus. FIG. 2 is a perspective view showing a configuration example of the gripping mechanism. An enlarged view of a part of FIG. 1 is shown in FIGS. 3 is a perspective view, FIG. 4A is a plan view, and FIG. 4B is a side view.

  The winding manufacturing apparatus 10 includes various elements on the base 18 for manufacturing a stator winding. Specifically, the core 11, the gripping mechanism 12, the table member 14, the slide plate 15, the deformation holder 16 and the like shown in FIG. 1 are provided. Moreover, the cylindrical member 13 shown in FIG. 3 and FIG. 4, the holder member 20, etc. are provided. In the following, the function and action of each component will be described.

  The base 18 may be formed in an arbitrary shape, and in this embodiment, the base 18 is formed by a cube having a circular through hole corresponding to the table member 14. The cores 11 and 17 are rod-shaped members that are both formed into a cylindrical shape, except that the diameters are different. Although the core material 11 and the core material 17 have the same rotation center (see FIG. 4B), they are individually rotatable. The core members 11 and 17 serve as support shafts for the cylindrical member 13, the table member 14, and the like.

  A configuration example of the gripping mechanism 12 will be described with reference to FIG. The gripping mechanism 12 is also called a “work gripping part” and has a function of gripping and holding the conductor assembly CG to be assembled. As shown in FIG. 2A, the gripping mechanism 12 includes an upper plate 12a, a shaft 12b, a restricting portion 12c, a gripping portion 12e, a lower plate 12f, and the like. The gripping mechanism 12 is supported by the core member 11 and the cylindrical member 13 (see FIGS. 1 and 4B). The lower plate 12f includes a plurality of shafts 12b and restricting portions 12c, and the lower surface side after being attached to the core material 11 is in contact with the upper surface of the cylindrical member 13 (see FIG. 4B). The upper plate 12a is configured to be movable in the vertical direction (axial direction Z), and includes a plurality of restricting portions 12c and gripping portions 12e on the lower surface side. The gripping mechanism 12 moves in the upward or downward direction according to the rotation direction of the core member 11 with the plurality of shafts 12b as the support shafts. The plurality of restricting portions 12c hold a state where the conductor assembly CG to be assembled is expanded (a state in which the conductor assembly 12c is deformed in the outer diameter direction). The grip portion 12e is provided at the distal end portion of the support 12d that penetrates the lower plate 12f, and holds a terminal portion 21 (see FIG. 6) described later.

  The gripping mechanism 12 configured as described above grips the conductor assembly CG held by the terminal portion 21 and the chuck mechanism 22 shown in FIG. 19 by the gripping portion 12e. At the same time as gripping, in order to avoid interference between the conductors C during assembly, the curved conductor assembly CG is held in an expanded state by the plurality of restricting portions 12c. The core material 11 is rotated in this holding state, and the conductor assembly CG is lowered within the clearance between the conductor assemblies CG. The state when it is lowered is shown in FIG. And after fixing the terminal part 21 to the corresponding base part 23, the terminal part 21 is released from the holding part 12e, and the assembly | attachment of conducting wire assembly CG is completed. After assembling, in order to prepare for the next assembling, the core member 11 is reversely rotated to return the upper plate 12a to the uppermost position shown in FIG.

  In FIG. 3, the cylindrical member 13 is supported by the core member 11 and the table member 14. That is, the core member 11 is passed through the cylinder of the cylindrical member 13, and the table member 14 is in contact with and supported by the lower surface of the cylindrical member 13 (see FIG. 4B). The outer peripheral surface of the cylindrical member 13 has a function of positioning the plurality of holder members 20 at a predetermined position (for example, a second position described later) with respect to the radial direction X by making contact (contact). The “radial direction X” corresponds to the horizontal direction and means a radial direction with the central axis of the core material 11 as a reference point (start point or end point).

  The table member 14 is also referred to as a “conductor terminal mounting plate”, is formed in a disk shape, and is rotatably attached to the base 18. Further, the table member 14 is fixed to the core member 17 described above (see FIG. 4B), and the holder member 20 is mounted on the upper surface side so as to be movable and detachable at a plurality of positions. Further, the table member 14 has a concave portion 14a, an alignment portion 14b, steps 14c, 14d, 14f, a long hole 14e, and the like. As shown in FIG. 4B, the concave portion 14a is an area on the inner peripheral side where the holder member 20 can be mounted, with the upper surface (surface) position being lower than the alignment portion 14b.

  The alignment part 14b is a region on the outer periphery side where the conductor assembly CG held by the holder member 20 is aligned in the axial direction Z, as indicated by a two-dot chain line on the right side of FIG. Since the alignment is performed in accordance with the outer shape of the stator winding (work) W that is a finished product, the alignment is not limited to a straight line but may be a curved line. In the case of a straight line, the aligned part 14b may be formed into a flat surface, and in the case of a curved line, the aligned part 14b may be formed into a curved surface.

  The step 14c is formed at the boundary between the outer peripheral side of the concave portion 14a and the alignment portion 14b. The step 14d is formed on the inner peripheral side of the concave portion 14a. These steps 14c and 14d have a stopper function for restricting the range in which the holder member 20 can move in the radial direction X. As shown in FIG. 7B, the through hole 14f has a stepped portion, and the cam portion 24b of the moving cam 24 that comes into contact with the wall surface of the stepped portion enters. As shown in FIG. 7 (B), the long hole 14e allows the fixing member S2 fixed to the holder member 20 to move.

  The slide plate 15 is provided on the upper surface side of the base 18. In the configuration example of FIG. 1, the base 18 is provided corresponding to the four corners. Each slide plate 15 is configured to be individually movable in the radial direction X, and is a regulating member that presses the assembled conductor assembly CG to a specified position. What is necessary is just to be comprised so that the space (namely, clearance) for inserting conducting wire assembly CG which will be assembled | attached after that may be ensured by pressing. That is, a member for sliding in the radial direction X, a member (for example, a screw or a bolt) that is maintained at a specified position, and the like are included.

  The deformation holder 16 is also referred to as an “expansion holder”, and can be rotated in the circumferential direction Y (arrow D1 direction) and provided on the upper surface side of the base 18 so as to be movable in the radial direction X (arrow D2 direction). The deformation holder 16 has a direction (in this embodiment) that resists a restoring force that attempts to restore one or more of the conductor aggregates CG out of the conductor aggregates CG held by the holder member 20 to a curved shape. It bears the function of being deformed and held in the radial direction X). This function aims to secure a clearance for sequentially assembling the conductor assembly CG that has not yet been assembled.

  The deformation of the conductor assembly CG is realized by forcibly moving a predetermined portion (for example, the end of the free end) in the outer diameter direction or the inner diameter direction within a deformation allowable range in which elastic deformation is allowed. The “deformation allowable range” is a range in which elastic deformation by the conductor assembly CG is allowed. Specifically, a range in which the conductor assembly CG formed into a curved shape can return to a normal dimension after deformation is desirable. However, even if the dimensions do not return to normal dimensions after deformation, a range of deformation that allows assembly of the stator winding as a finished product may be applied.

  As shown in FIG. 4A, the holder member 20 is movable in the radial direction X by the action of the moving cam 24, and is configured to be able to hold a part of the conductor assembly CG. The “part” can be set at an arbitrary part (part) in the case of the conductor assembly CG. In this embodiment, a portion accommodated in a slot 31 of a stator core 30 shown in FIG. 29A described later, that is, a slot accommodating portion Cc shown in FIG. 18B.

  Moreover, the holder member 20 can also be arbitrarily set also about a shape. In this embodiment, as shown in FIG. 4A, a plurality of (specifically, eight) holder members 20 are mounted, and thus each holder member 20 is formed in a substantially fan shape when viewed from above. That is, when a plurality of holder members 20 that are configured identically are aligned on a concentric circle, a donut shape is obtained.

  Next, a configuration example of one holder member 20 will be described with reference to FIGS. FIG. 5 is a perspective view showing the appearance of the holder member. FIG. 6 shows an exploded perspective view in which the holder member 20 is disassembled. 7A shows a plan view of the holder member 20, and FIG. 7B shows a cross-sectional view taken along line VIB-VIB in FIG. 7A. 8A shows a perspective view, FIG. 8B shows a side view seen from the direction of arrow Db in FIG. 8A, and FIG. 8C shows a configuration example of the chuck mechanism. The side view seen from the arrow Dc direction of FIG. 8 (A) is shown. FIG. 9A shows a state where the conductor C is not held, and FIG. 9B shows a state where the conductor C is held. About the structural example of 22 d of connection members, a side view is shown in FIG. 10 (A) and a top view is shown in FIG.10 (B). The gap expansion / contraction function of the connecting member 22d is shown in FIGS. 11 (A), 11 (B), and 11 (C), and the connection state changing function is shown in FIG. 11 (D). About the several position which positions the holder member 20, it shows with a side view in FIG. 12, and shows with sectional drawing in FIG.

  As shown in FIG. 5, the holder member 20 includes a terminal portion 21, a chuck mechanism 22, a pedestal portion 23, and the like. The terminal portion 21 and the pedestal portion 23 will be described with reference to FIGS. 6 and 7. The chuck mechanism 22 will be described with reference to FIGS.

  First, a configuration example of the terminal unit 21 that is also called a “terminal holder” will be described. The terminal portion 21 shown in FIG. 6 is configured to be fixed to the pedestal portion 23 using a fixing member S1 such as a bolt or a screw, and has a base portion 21a and a convex portion 21d that are integrally formed. The base 21a includes one through hole 21b, a plurality of through holes 21e (see FIG. 7B), a plurality of through holes through which the fixing member S1 passes. The convex portion 21d includes a plurality of through holes 21c.

  As shown in FIG. 7A, each of the plurality of through holes 21c and the plurality of through holes 21e is arranged along a concentric circle. Specifically, they are arranged such that the interval between the conductors C held by a piece 22T (see FIGS. 8 and 9) of the chuck mechanism 22 described later has a normal dimension. The number of through holes 21c corresponds to the number of support shafts 22a (see FIG. 8A). The number of through holes 21e corresponds to the number of operation shafts 22f (see FIG. 8A) to be described later. In this embodiment, the number of the through holes 21c and the through holes 21e is set to “6” in accordance with the number “6” of the conductive wires C held simultaneously.

  Next, a configuration example of the pedestal portion 23, which is also called a “terminal holder attachment portion”, will be described. The pedestal portion 23 shown in FIG. 6 is configured to be movable on the table member 14, and has a convex portion 23b and a base portion 23e that are integrally formed. The convex portion 23b is provided with one through hole (that is, a through hole 23g shown in FIG. 7B) through which the moving cam 24 is passed, a screw hole 23a for fastening to the fixing member S1, and the like.

  The base 23e includes a plurality of support holes 23c and 23d, a stopper 23f, a through hole 23g (see FIG. 7B), and the like. The plurality of support holes 23c are provided at positions corresponding to the plurality of through holes 21e described above. The plurality of support holes 23d are provided at positions corresponding to the plurality of through holes 21c described above. The stopper 23f is a recess provided in the lower corner portion on the outer peripheral side, and is formed into a shape corresponding to the step 14c shown in FIG. 7B (that is, a recess having an L-shaped cross section). The through hole 23g is a hole for passing the moving cam 24 as shown in FIG.

  The moving cam 24 includes an operation element 24a on one end side and a cam portion 24b on the other end side. The operation element 24a is used to rotate the movable cam 24 itself using an operation member (for example, a flathead screwdriver). The cam portion 24b enters a through hole 14f provided in the table member 14, and contacts the wall surface of the through hole 14f. The movement of the holder member 20 accompanying the operation of the moving cam 24 will be described later (see FIG. 13).

  Next, a configuration example of the chuck mechanism 22 will be described. The chuck mechanism 22 shown in FIG. 8 includes a support shaft 22a, a piece 22T, a connecting member 22d, an operation shaft 22f, and the like. The number of the support shafts 22a, the top portions 22T, and the operation shafts 22f can be arbitrarily set, but in the present embodiment, six are provided. These are connected using two sets of upper and lower connecting members 22d (see in particular FIG. 8B). As shown in FIG. 8C, one lead wire is held and released by one support shaft 22a, one piece portion 22T, and one operation shaft 22f. Therefore, while holding a part about the some conducting wire C, it bears the function to hold | maintain the space | interval of the conducting wire C so that expansion-contraction is possible.

  As shown in FIG. 7B, one end of the support shaft 22a enters the through hole 21c of the terminal portion 21, and the other end of the support shaft 22a enters the support hole 23d of the pedestal portion 23 and is supported. When the terminal part 21 is fixed to the pedestal part 23, the chuck mechanism 22 is supported by inserting the support shaft 22a into the through hole 21c and the support hole 23d. Conversely, if the fastening of the fixing member S1 is released, the chuck mechanism 22 can be taken out. Therefore, the chuck mechanism 22 can be attached to and detached from the holder member 20. Further, the support shaft 22a supports a top portion 22T described below.

  The top part 22T has a non-moving piece 22c and a movable piece 22b so as to have a function of freely holding and releasing the conducting wire C on one end side. As shown in FIG. 9, the immovable piece 22c does not move because it is supported by the support shaft 22a and the operation shaft 22f. As shown in FIG. 9A, the movable piece 22b is configured to move in the normal direction (arrow D3 direction) with respect to the surface of the conducting wire C around the support shaft 22a. Between the stationary piece 22c and the movable piece 22b, an elastic body 22h is interposed on one end side (the upper side in the drawing). For example, a spring or rubber is used for the elastic body 22h. As shown in FIG. 11, the movable piece 22 b is disposed on the center side of the chuck mechanism 22. The plurality of top portions 22T are divided into three on the left side and three on the right side, and are mounted symmetrically with respect to the center line of the chuck mechanism 22 (that is, the mounting directions are different).

  As shown in FIG. 7B, the operation shaft 22 f is supported by one end side entering the through hole 21 e of the terminal portion 21 and the other end side entering the support hole 23 c of the pedestal portion 23. As shown in FIG. 8C, the operation shaft 22f includes an operation element 22g and a holding cam 22e. The operation element 22g is provided at both ends, and the operation shaft 22f itself is rotated using an operation member. As shown in FIG. 9, the holding cam 22e is provided on the other end side (lower side in the drawing) via the support shaft 22a. The holding cam 22e is formed into a shape that contacts or does not contact the other end of the movable piece 22b in order to open and close the piece 22T in accordance with the rotation operation of the operation element 22g.

  When the operating element 22g is rotated so that the holding cam 22e does not come into contact with the other end of the movable piece 22b, the posture shown in FIG. That is, one end side of the stationary piece 22c and the movable piece 22b is opened by the urging force of the elastic body 22h, and the lead wire C is not gripped (released). On the other hand, when the operating element 22g is rotated so that the holding cam 22e contacts the other end of the movable piece 22b, the posture shown in FIG. That is, since the one end side of the stationary piece 22c and the movable piece 22b is closed against the urging force of the elastic body 22h, the conductive wire C is held (held).

  The connecting member 22d has a function of making it possible to freely change one or both of the interval between the pieces 22T and the connecting state. As shown in FIG. 10 (A), all the support shafts 22a are connected by connecting the adjacent support shafts 22a to each other. The connecting member 22d illustrated in FIG. 10A is composed of five plate-like members for connecting the six spindles 22a. One plate-like member has elongated holes 22i at both ends as shown in FIG. In the present embodiment, the long hole is formed to resemble the circuit track (track) of the athletic stadium, but may be formed in another shape such as an elliptical shape. According to this structure, it expands / contracts in the longitudinal direction D4 and bears a gap expansion / contraction function, and it bends in the short direction D5 and bears a connection state changing function.

  When expanded and contracted in the longitudinal direction D4, the position of the top portion 22T is expanded and contracted as shown in FIG. 11A, expanded and contracted width B2 shown in FIG. 11B (B2 <B1), and expanded and contracted as shown in FIG. The width can be changed to B3 (B3 <B2). Further, as shown in FIG. 11D, the frame portion 22T may be arranged in a fan shape, or the frame portion 22T may be arranged in another form (for example, zigzag shape). Therefore, the support shaft 22a connected by the connecting member 22d can be easily inserted in accordance with the arrangement of the through hole 21c and the support hole 23d (see FIGS. 5 and 6).

  The holder member 20 configured as described above is provided on the table member 14 so as to be movable. The position where each holder member 20 can move will be described with reference to FIGS. 12 and 13 illustrating some of the holder members 20 mounted on the table member 14. In FIG. 12, the example of a movement of the holder member 20 arrange | positioned at the center upper part is shown. For reference, the holder member 20 in the second position is shown on the left and right sides, and the cylindrical member 13 is shown by a two-dot chain line. In FIG. 13, the example of a movement concerning the right holder member 20 is shown. For reference, the holder member 20 in the second position is shown on the left side.

  When the operation member 24a of the moving cam 24 is rotated using the operation member, the holder member 20 can be moved to an arbitrary position within the movable range. The “arbitrary position” includes a first position, a second position, and a third position, and each position will be described below.

  As shown in FIGS. 12A and 13A, the first position is a position that is separated from the core material 11 by a distance L1. Further, as will be described later, this is also the position where the conductor assembly CG is moved along the first path including at least the axial direction (see FIG. 19). As shown in FIG. 13A, the gap G1 is substantially zero because the stopper 23f and the step 14c are in contact with each other.

  As shown in FIGS. 12B and 13B, the second position is a position away from the core material 11 by a distance L2 (L2 <L1). Further, as will be described later, this is the position where the conductor assembly CG is moved along the second path including at least the horizontal direction (see FIG. 25). As shown in FIG. 13B, the holder member 20 that contacts the outer peripheral surface of the cylindrical member 13 is a position that is shifted to the inner side in the radial direction X (that is, the side closer to the core material 11) than the first position. . A gap G2 (G2> G1) is generated between the stopper 23f and the step 14c.

  The third position is a position where the stator winding W and the holder member 20 (chuck mechanism 22) are separated. As shown in FIGS. 12C and 13C, the position is a distance L3 (L3 <L2) away from the core material 11, and is also a position shifted further inward in the radial direction X than the second position. . When positioning the holder member 20 at the third position, it is necessary to remove the cylindrical member 13 as shown in FIG. A gap G3 (G3> G2) is generated between the stopper 23f and the step 14c, and the inner peripheral side wall surface of the holder member 20 (specifically, the pedestal portion 23 shown in FIG. 7B) contacts the step 14d. .

  A process until the stator winding W is manufactured using the plurality of conductors C by operating the winding manufacturing apparatus 10 configured as described above will be described with reference to FIGS. 14 to 26. An example of forming the conductor C in the drawing direction is shown in FIG. 14 and an example of forming in the radial direction X is shown in FIG. FIG. 17 is a perspective view showing an example in which a conductor assembly CG is combined using a plurality of conductors C. FIG. 17 shows an example of forming the slot accommodating portion and the turn portion of the conductor C. FIG. 18 is a perspective view showing a state where the conductor assembly CG (the plurality of conductors C1 to C6) is held by the chuck mechanism 22. FIG. FIG. 19 is a perspective view showing a process of assembling the conductor assembly CG. FIG. 20 is a perspective view showing a state after the conductor assembly CG is assembled. FIG. 21 is a plan view showing a state where the first conductor assembly CG1 is deformed. FIG. 22 is a plan view showing the process of assembling the second conductor assembly CG2. FIG. 23 is a plan view showing a state after the second conductor assembly CG2 is assembled. FIG. 24 is a plan view showing the relationship between the installed conductor assembly and the scheduled conductor assembly. FIG. 25 is a diagram illustrating an example of a moving path of the scheduled conductor assembly. FIG. 26 is a plan view showing a state immediately after assembling and releasing all the conductor assembly CG1 to CG8.

  Before explaining each process, an example of forming the conductor C constituting the stator winding W will be described. 14A and 14B are plan views showing examples of forming in the extending direction of one conductor C. FIG. One conductor C has a length exceeding one turn, and is formed by processing one continuous conductor (that is, a flat wire) by a processing device or the like. The conducting wire C has terminal portions Ca and Cb, a slot accommodating portion Cc, a turn portion Cd, and the like. The terminal portions Ca and Cb shown in the alternate long and short dash line are formed into respective shapes shown by a solid line or a two-dot chain line in accordance with the connection between the conducting wires C or the connection with an external device. The slot accommodating portion Cc and the turn portion Cd are repeated between the end portions Ca and Cb. The slot accommodating portion Cc is formed linearly in the axial direction Z (the vertical direction in the drawing). The turn part Cd is formed in a convex shape in the axial direction Z.

  A configuration example of the turn part Cd described above will be described with reference to FIG. The turn portion Cd shown in FIG. 15A is formed between the slot accommodating portions Cc, and is formed into a mountain shape (triangular shape) as a whole. The turn portion Cd has stepped portions Cd1 and Cd3 and a crank portion Cd2. The stepped portions Cd1 and Cd3 are each formed in a staircase shape that climbs toward the crank portion Cd2. As shown in FIG. 16 (B), the crank portion Cd2 is a bent portion that is formed so that steps are successively formed in a direction perpendicular to the extending direction of the conducting wire C and the extending direction of the slot accommodating portion Cc.

  Moreover, about the example of shaping | molding of the radial direction X concerning one conducting wire C, a perspective view is shown to FIG. 16 (A), and a top view is shown to FIG. 16 (B). In FIG. 16B, a region corresponding to one holder member 20 is indicated by a one-dot chain line. As shown in FIGS. 16 (A) and 16 (B), the conducting wire C is formed by bending into a curved shape (that is, a spiral shape) in the radial direction X by a processing device or the like. Molding is performed with a slightly larger curvature so that it becomes a regular dimension after springback.

  An example of combining the conductor assembly CG using the plurality of conductors C described above will be described with reference to FIG. 17 and FIG. When combining a plurality of conducting wires C, they are stacked while being shifted in the extending direction. FIG. 17 shows the stacked state after such a combination. The conductor assembly CG shown in FIG. 17 is a combination of four conductors C for convenience of illustration, but in this embodiment, six conductors C are combined. When the conductor assembly CG shown in FIG. 17 is enlarged around the turn part Cd, the result is as shown in FIG. A conducting wire assembly CG shown in FIG. 15B is an example in which six conducting wires C1 to C6 are combined. The turn portions Cd are stacked such that the stepped portions Cd1 and Cd3 overlap each other in the axial direction Z (vertical direction in the drawing), and the crank portions Cd2 appear sequentially shifted.

(Grouping process)
For the stator winding W (see FIG. 27) manufactured by the winding manufacturing apparatus 10, 48 conductors C are used. On the other hand, the chuck mechanism 22 of the holder member 20 can simultaneously hold six conductors C as shown in FIG. Therefore, in the grouping step, the 48 conductors C are grouped every 6 to obtain 8 groups of conductor assemblies CG.

(Lamination process)
For each conductor assembly CG obtained in the grouping step, the grouped six conductors C are stacked while being shifted in the extending direction. Since each conducting wire C is formed in a regular dimension, in order to avoid interference between the conducting wires C when assembling, the conducting wires C are laminated after being shifted in the extending direction. The stacked state is shown in FIGS. 17 and 15B described above.

(Holding process)
In order to maintain the laminated state obtained in the laminating process, as shown in FIG. 18A, a part of each conductor C of the conductor assembly CG (conductors C1 to C6) is held using the chuck mechanism 22. Specifically, the operating element 22g of the operating shaft 22f is rotated using the operating member, and the piece portion 22T is closed and the conductive wires C are held as shown in FIG. 9B. FIG. 18B shows a state in which the slot accommodating portion Cc located at the end of each conductor C is held. Note that the lead wires C are held by the top portion 22T in a state where the lead wires C are widened as shown in FIG. 11A because the six lead wires C are shifted in the extending direction in the above-described laminating process.

(Interval expansion / contraction process)
Regarding the conductor assembly CG held by each chuck mechanism 22 in the holding step, the interval between the six conductors C shifted in the extending direction is not a regular dimension. Therefore, in the interval expansion / contraction process, all the support shafts 22a and the operation shafts 22f constituting the chuck mechanism 22 are supported by the terminal portion 21 in order to make the interval between the six conductors C regular. Specifically, as shown in FIG. 7B, one end side of each support shaft 22a is put into the through hole 21c, and one end side of each operation shaft 22f is put into the through hole 21e. At this time, the interval between the frame portions 22T is reduced from the expansion / contraction width B1 shown in FIG. 11 (A) to the expansion / contraction width B3 shown in FIG. 11 (C) through the state shown in FIG. 11 (B). Moreover, the connection state of the top part 22T changes from the linear shape shown in FIG. 11A to the fan-like connection state shown in FIG.

  FIG. 19 shows a state in which the distance between the six conductors C applied to one conductor assembly CG is set to a normal dimension using the terminal portion 21. Subsequently, using the gripping mechanism 12 shown in FIG. 2, the chuck mechanism 22 held in the normal dimension by the terminal portion 21 is lowered as indicated by the arrow D4 and attached to the corresponding pedestal portion 23 on the table member 14. Specifically, as shown in FIG. 7B, the other end side of each support shaft 22a is put in the support hole 23d, and the other end side of each operation shaft 22f is put in the support hole 23c. Furthermore, when the terminal portion 21 and the pedestal portion 23 are fixed (fastened) using the fixing member S1, the state shown in FIG. In FIG. 20, only one pedestal portion 23 attached on the table member 14 is shown for easy viewing.

(Deformation holding process)
Each conductor assembly CG obtained by performing the above-described laminating process, holding process, and interval expansion / contraction process has regular dimensions for the shapes and intervals of the six conductors C. Hereinafter, the conductor assembly CG1, the conductor assembly CG2,..., And the conductor assembly CG8 are described in the order of assembly using the holder member 20. As shown in FIG. 20, when the first conductor assembly CG1 is assembled with the holder member 20, the conductors C may interfere when the second and subsequent conductor assemblies CG2 to CG8 are assembled. .

  Therefore, in the deformation holding step, before assembling the second and subsequent conductor aggregates CG2 and the like, the assembled conductor aggregates CG1 and the like are deformed and held to ensure clearance. For example, as shown in FIG. 21, the clearance CL <b> 1 is secured by bending the terminal end Ge of the first conductor assembly CG <b> 1 in the outer diameter direction (arrow D <b> 5 direction) using the deformation holder 16. The termination portion Ge corresponds to the termination portions Ca and Cb on one end side shown in FIG. The clearance CL1 is the distance between the inner-conductor-side conductor assembly CG held by the holder member 20 and the deformation holder 16, and the conductor assembly CG that has not yet been assembled (ie, the second and subsequent conductor-assembly CG2). This is a distance sufficient to avoid interference between the conductors C when assembling. Bending the conductor assembly CG1 in the outer diameter direction means that the conductor assembly CG1 is deformed in a direction against a restoring force to restore the curved shape having a normal dimension indicated by a two-dot chain line. The conductor assembly CG1 having a regular dimension indicated by a two-dot chain line is deformed and held by the deformation holder 16 like the conductor assembly CG1 indicated by a solid line.

(Sequential assembly process)
Since the first holding assembly CG1 is deformed by the deformation holding process and the clearance CL1 can be secured, the second and subsequent conducting assemblies CG2 to CG8 are sequentially assembled through the clearance CL1. First, the assembly of the second conductor assembly CG2 will be described. The conducting wire assembly CG2 first performs the above-described laminating step, holding step, and interval stretching step. The conductor assembly CG2 subjected to these steps is in the same state as the conductor assembly CG shown in the upper part of FIG. 19 and is held by the terminal portion 21 and the chuck mechanism 22. A process of attaching the conductor assembly CG2 to the pedestal 23 is shown in FIG. The pedestal portion 23 to be attached is located on the left side of the holder member 20 that holds the conductor assembly CG1. Then, the state after the assembly of the conductor assembly CG2 is as shown in FIG. 23, and the clearance CL2 is narrower than the clearance CL1 by the amount of the conductor assembly CG2. The conducting wire assemblies CG3 to CG7 are also performed in the same manner as the conducting wire assembly CG2, and the following moving process and assembling process are performed in assembling the conducting wire assembly CG8.

(Transfer process and assembly process)
After the conductor assembly CG that has already been assembled (hereinafter referred to as “attached conductor assembly”), a conductor assembly CG that has not yet been assembled (hereinafter referred to as “scheduled conductor assembly”) will be assembled. In order to suppress damage to the coating, it is necessary to avoid interference between the conductors C. Therefore, the scheduled conductor assembly is moved along a path that avoids interference between the conductors C. For example, FIG. 24 shows an example in which the conductor assembly CG1 to CG7 is applied as the attached conductor assembly and the conductor assembly CG8 as the conductor assembly to be attached is applied. In FIG. 24, illustration of the holder member 20 corresponding to each of the conductive wire assemblies CG2 to CG6 is omitted.

  When the holder member 20 that holds the conductor assembly CG8 is moved along the path (arrow D6) shown in FIG. 24 (A), the conductor assembly CG8 is integrated as shown in the circle in FIG. 24 (B). It interferes with the body CG1 and the conductor assembly CG7. A workaround for avoiding this interference will be described below.

  The first workaround will be described with reference to FIG. First, the holder member 20 that holds the conductor assembly CG1 is moved in the outer diameter direction (arrow D7 direction), and the holder member 20 that holds the conductor assembly CG7 is moved in the inner diameter direction (arrow D8 direction). A clearance is secured between the body CG1 and the conductor assembly CG7. When the holder member 20 that holds the conductor assembly CG8 is moved from above to below the clearance thus secured, the result is as shown in FIG. Finally, the holder member 20 moved in advance is returned to the original position.

  The second workaround will be described with reference to FIG. First, the holder member 20 that holds the conductor assembly CG8 is rotated by the rotation angle θ1 in the rotation direction (arrow D9 direction). The rotation angle θ1 is an angle at which the conductor assembly CG8 does not interfere with the conductor assembly CG1 and the conductor assembly CG7. When the holder member 20 that holds the conductor assembly CG8 is moved from above to below while maintaining the state after rotation, the state is as shown in FIG. Finally, the holder member 20 is returned to the original state by rotating it by the rotation angle θ1 in the direction opposite to the rotation direction.

  The third workaround will be described with reference to FIG. First, the holder member 20 holding the conductor assembly CG8 is inclined by the inclination angle θ2 in the inclination direction (arrow D10 direction). The inclination angle θ2 is an angle at which the conductor assembly CG8 does not interfere with the conductor assembly CG1 and the conductor assembly CG7. While maintaining the state after the inclination, the holder member 20 that holds the conductor assembly CG8 is moved downward from above. Finally, the holder member 20 is returned to the upright state by being inclined by the inclination angle θ2 in the direction opposite to the inclination direction.

  The fourth workaround will be described with reference to FIGS. 25 (B) and 25 (C). The first workaround to the third workaround described above are workarounds when inserting the holder member 20, whereas the fourth workaround is the convex portion of the conductor C (that is, the turn shown in FIG. 17). It is different in that it is a workaround when stacking part Cd). In this 4th avoidance measure, in order to avoid that the turn parts Cd of the conducting wire C included in the conducting wire assembly CG interfere with each other, the moving is performed along the first route R1 and the second route R2. The “movement” is arbitrary including automatic movement by the robot arm and manual movement by the operator. Hereinafter, an example will be described in which the attached conductor assembly is a conductor assembly CG7 and the scheduled conductor assembly is a conductor assembly CG8.

  The first path R1 shown in FIG. 25B moves the conductor assembly CG8 relative to the conductor assembly CG7 along the axial direction Z (downward in the drawing). Depending on the assembly conditions such as the number of conductors C constituting the conductor assembly CG7, the size of the clearance CL1, etc., the first path R5 to be moved larger than the first path R1, or the oblique direction (axial direction Z and radial direction) X may be moved along the first route R3.

  Further, the second route R2 is moved along the radial direction X (the left direction in the drawing). Specifically, the holder member 20 is moved from the first position (see FIGS. 12A and 13A) to the second position (first position (see FIGS. 12B and 13B)). Depending on the above assembling conditions, the second path R4 may be moved smaller than the second path R2, or may be moved in an L shape (non-simultaneous movement between the axial direction Z and the radial direction X). As shown in FIG. 25C, the conductor assembly CG7 and the conductor assembly CG8 may be moved along the first route R1 and the second route R2. The turn part Cd is stacked.

(Deformation release process)
After assembling all the conductor aggregates CG (conductor aggregates CG1 to CG8), a deformation release step is performed. In the deformation release process, the conductor assembly CG1 that is deformed and held by the deformation holding process that is performed before the assembly process is released. That is, the conductor assembly CG1 indicated by a solid line in FIG. 21 is returned to the conductor assembly CG1 indicated by a two-dot chain line, and all the assembled conductor assemblies CG are made to have normal dimensions.

(Release process)
The above-described sequential assembling process (including the moving process and the assembling process) and the deformation releasing process are performed to assemble all the conductor assembly CG (that is, the conductor assemblies CG1 to CG8). When the assembly is finished, the table member 14 fixed to the core member 17 is rotated counterclockwise to rewind the conductor assembly CG, and is wound around the conductor assembly CG. Further, the operating elements 22g applied to all the holder members 20 are rotated, and all the conductor integrated bodies CG1 to CG8 are released from the top portion 22T of the chuck mechanism 22. The state immediately after the release is shown in FIG. In FIG. 26, in order to indicate which holder member 20 holds which conductor assembly CG, reference numerals (CG1 to CG8) corresponding to the parentheses of each holder member 20 are shown. As is apparent from the order indicated by the reference numerals, in this embodiment, the conductor assembly CG is sequentially assembled in the counterclockwise direction.

  When the releasing process is performed, the stator winding W can be taken out from the winding manufacturing apparatus 10, and the taken-out state is shown in FIG. FIG. 27A is a perspective view, and FIG. 27B is a side view. As apparent from these drawings, the stator winding W is an assembly (aggregate) of the conductor assembly CG. Since the terminal portions Ca and Cb of the conductor C constituting each conductor assembly CG are in an upright state, the number of phases (for example, three phases of U phase, V phase, and W phase) of a rotor 51 (see FIG. 31) to be described later ) And bend and bond to match. FIG. 28 is a perspective view showing the stator winding W that can be assembled to a stator core 30 (see FIG. 29) described later.

  A configuration example of the stator core 30 will be described with reference to FIG. FIG. 29A shows a plan view of the stator core 30, and FIG. 29B shows a plan view of the split core 32. A stator core 30 shown in FIG. 29A is formed in an annular shape by connecting a predetermined number of split cores 32 shown in FIG. 29B, and includes a plurality of slots 31 on the inner peripheral side. The split core 32 will be described later. The plurality of slots 31 are groove-shaped portions that are radially formed from the inner peripheral surface toward the outer peripheral side (that is, in the radial direction X). The number of slots 31 is desirably formed corresponding to the number of magnetic poles of a rotor 51 (see FIG. 31) described later, and is 48 in the configuration example of FIG.

  A split core 32 shown in FIG. 29B includes one slot 31 and forms one slot 31 between adjacent split cores 32. Viewed from another viewpoint, it has a pair of teeth portions 33 extending toward the center and a back core portion 34 connected on the outer peripheral side of the teeth portions 33. The split core 32 is formed by laminating a plurality of electromagnetic steel plates. An insulating thin film is disposed between the laminated electrical steel sheets. In addition, you may shape | mold using not only the laminated body of an electromagnetic steel plate but a conventionally well-known metal thin plate and an insulating thin film.

  A stator 40 shown in FIG. 30 includes a stator winding W and a stator core 30. Specifically, the slot accommodating portion Cc (see FIG. 18B) of the conducting wire C constituting the stator winding W is accommodated in the slot 31 of the stator core 30. The conductor C is coated with an insulating film, but an insulating member (such as insulating paper) may be interposed between the stator winding W and the stator core 30. An outer cylinder member 35 that maintains the connected state is fitted to the outer peripheral side of the stator core 30 (specifically, the plurality of connected divided cores 32).

  A configuration example of the rotating electrical machine including the stator 40 having the stator winding W will be described with reference to FIG. The rotating electrical machine MG shown in FIG. 31 corresponds to a generator motor having both a power generation function and an electric function, for example. In addition to the stator 40 described above, the rotating electrical machine MG includes a frame (housing) 50, a rotor 51, a shaft (main shaft or rotating shaft) 53, and the like. That is, in the frame 50, together with the stator 40, a shaft 53 is rotatably provided (for example, rotated in the direction of arrow D11). The shaft 53 is fixed to the frame 50 via a bearing 52, and the rotor 51 is fixed. The stator 40 and the rotor 51 are opposed to each other, and a rotating magnetic field is generated by conduction to the conducting wire C (conductor assembly CG1 to CG8) wound around the stator 40, and the rotor is accompanied by the rotating magnetic field. Rotate 51. Therefore, the rotating electrical machine MG having the features of the stator winding W can be provided.

  According to the embodiment described above, the following effects can be obtained. First, in accordance with claims 1 and 6, a holder member 20 capable of holding a part of the conductor assembly CG (a plurality of conductors C1 to C6), and a table member on which the holder member 20 is movably mounted at a plurality of positions. 14 (see FIGS. 4, 12, and 13). In addition, a configuration is performed in which the lead wire assembly CG is moved along the first route R1 (R3, R5) and moved and assembled along the second route R2 (R4, R6). (See FIG. 25B). According to this configuration, in the moving step, the conductor assembly CG is moved along the first path R1 (R3, R5), and a clearance between the conductor assemblies CG is ensured. In the assembling step, the moved conductor assembly CG is moved along the second path R2 (R4, R6) and assembled. Therefore, it is possible to manufacture the stator winding W while facilitating the assembly while avoiding interference between the conductor assembly CG formed in the normal dimension.

  Corresponding to claim 2, in the moving step, the conductor assembly CG is moved in one or both of the radial direction X and the circumferential direction Y (see FIG. 25B). According to this configuration, by including movement in the radial direction X and the circumferential direction Y, for example, when trying to assemble a new conductor assembly CG that has not yet been assembled, interference with the conductor assembly CG that has already been assembled. To avoid. Therefore, in the process of assembling the plurality of conductor assembly CG, interference between the conductor assemblies CG can be avoided more reliably.

  Corresponding to claim 3, in the assembling step, the conductor assembly CG is moved in the direction opposite to the moving step (see FIG. 24C). According to this configuration, the holder member 20 is moved in the outer diameter direction (the direction of arrow D7 in FIG. 24C) in the moving process, but is moved in the opposite direction in the assembling process. The same applies to the rotation in the direction of arrow D9 shown in FIG. 24D and the inclination in the direction of arrow D10 shown in FIG. Therefore, the normal dimension of the conductor assembly CG can be more reliably maintained in the process of assembling the plurality of conductor assemblies CG.

  Corresponding to claims 4 and 9, the position of the holder member 20 is moved by the action of the moving cam 24, and the conductor assembly CG held by the chuck mechanism 22 of the holder member 20 is moved (see FIG. 7, see FIGS. 12 and 13). According to this configuration, the holder member 20 (and consequently the conductor assembly CG) can be moved simply by rotating the moving cam 24. Therefore, a power source such as a motor is not required, and a simple mechanism can be realized, so that the cost can be kept low.

  Corresponding to claim 5, a grouping step of grouping a plurality of conductors C into a plurality of conductor assemblies CG1 to CG8 is performed (see FIGS. 17 and 15B). A moving process and an assembling process are performed for each conductor assembly CG with respect to the grouped conductor assemblies CG1 to CG8. According to this configuration, the stator winding W can be manufactured with ease of assembly while avoiding interference between the conductor aggregates CG with respect to the plurality of conductor aggregates CG.

  Corresponding to claim 7, the holder member 20 has at least a first position when the conductor assembly CG is moved along the first path R1 (R3, R5) including at least the axial direction Z, and at least the conductor assembly CG. The second position when moving along the second path R2 (R4, R6) including the horizontal direction is configured to be movable (FIGS. 12, 13, 25B, 25). (See (C)). According to this configuration, the conductor assembly CG moves to the first position along the first path R1 (R3, R5) and moves to the second position along the second path R2 (R4, R6). Therefore, it is possible to manufacture the stator winding W that is an assembly by assembling the plurality of conductor assemblies CG while more reliably avoiding interference between the conductor assemblies CG formed into regular dimensions. it can.

  Corresponding to claim 8, the holder member 20 is configured to be movable to a third position that is further displaced in the radial direction X from the second position (FIG. 12C, FIG. 13C, (See FIG. 26). According to this configuration, after releasing the held conductor assembly CG at the second position, the stator winding W as a finished product can be easily taken out simply by moving the holder member 20 to the third position. Can do. Therefore, interference is avoided even when the finished product and the jig are separated.

  Corresponding to claim 10, a part of the conducting wire C held by the holder member 20 is configured to be a slot accommodating portion Cc accommodated in the slot 31 of the stator core 30 (see FIG. 18B). According to this structure, since the slot accommodating part Cc of the conducting wire C is formed in a linear shape, the holder member 20 for holding the slot accommodating part Cc is also configured in a linear shape. Therefore, it can hold | maintain easily and cost can be restrained low compared with the case where the holder member 20 is comprised in complicated shapes, such as a curve shape.

  Corresponding to the eleventh aspect of the present invention, the cylindrical member 13 capable of positioning the plurality of holder members 20 at the second position is provided (see FIGS. 1, 12B, and 13B). According to this configuration, the outer peripheral surface of the cylindrical member 13 becomes the second position, and the plurality of holder members 20 are simply moved to the second position simply by moving them until they contact the outer peripheral surface of the cylindrical member 13. Can do. Therefore, the inner peripheral surface of the stator winding W to be a finished product can be made uniform.

  Corresponding to claim 12, the plurality of conductors C are grouped into a plurality of conductor assemblies CG composed of two or more conductors C, and the holder member 20 (particularly the chuck mechanism 22) is connected to each conductor C1 to C6 of the conductor assembly CG. (Refer to FIGS. 8 to 11). According to this configuration, the holder member 20 can hold the conductor assembly CG (two or more conductors C) as a whole and move it to a plurality of positions. When manufacturing the stator winding W, it is only necessary to assemble as many as the conductor assembly CG, and the possibility of interference between the conductor assemblies CG is greatly reduced. Therefore, it is possible to more reliably avoid interference between the conductive wire assemblies CG formed into regular dimensions.

  Corresponding to claim 13, the rotating electrical machine MG is configured to include the stator winding W manufactured by the winding manufacturing apparatus 10 (see FIG. 31). According to this configuration, since the stator winding W is assembled so as to avoid interference between the conductor aggregates CG, the insulation resistance between the conductor aggregates CG is reliably ensured, and the required electrical machine MG is required. Performance can be demonstrated.

[Other Embodiments]
Although the form for implementing this invention was demonstrated above, this invention is not limited to the said form at all. In other words, various forms can be implemented without departing from the scope of the present invention. For example, the following forms may be realized.

  In the embodiment described above, the conductive wire C has a spiral shape (see FIG. 16B) as a curved shape that is bent and shaped in the radial direction X. Instead of this form, another curved shape such as an arc shape may be applied, or a curved shape including a linear shape in part may be applied. Even when other curved shapes are applied, it is possible to manufacture the stator winding W while facilitating assembly while avoiding interference between the conductors C formed into regular dimensions.

  In the above-described embodiment, the case where the total number of conductors C necessary for manufacturing the stator winding W is 48 is applied, and the conductor assembly CG is configured with six conductors C according to the structure of the chuck mechanism 22. Then, they were grouped into 8 groups of conductor aggregates CG (see particularly FIGS. 8 and 18). Instead of this form, numerical values other than the numerical values shown in the above-described embodiments may be applied to the total number of conductive wires C, the number of conductive wires C constituting the conductive wire assembly CG, and the number of conductive wire assemblies CG. For example, when the total number of conducting wires C is 50, the conducting wire assembly CG may be composed of 5 conducting wires C, and the number of conducting wire assemblies CG may be 10 groups. The numerical value to be applied to each is set in consideration of the conditions such as the type of the stator 40 configured using the stator winding W and the rotating electrical machine MG. Regardless of which numerical value is applied, the stator winding W can be manufactured with ease of assembly while avoiding interference between the conductors C formed into regular dimensions.

  In the above-described embodiment, the number of conductors C necessary for manufacturing the stator winding W is grouped into the conductor assembly CG and assembled for each conductor assembly CG (see FIGS. 17 to 26). It replaces with this form and you may assemble | attach in the state of the conducting wire C shown in FIG. 16, without performing grouping. For example, when the total number of conductors C is 48, assembly may be performed 48 times, and the assembly target is simply changed from the conductor assembly CG to the conductor C. In this case, the holder member 20 may be configured to hold one conductive wire C. Specifically, the chuck mechanism 22 includes a support shaft 22a, a piece portion 22T, a connecting member 22d, an operation shaft 22f, and the like. The number of times of assembling increases as compared with the case of assembling for each conductor assembly CG, but the other points are the same as in the above-described embodiment. Therefore, it is possible to manufacture the stator winding W while facilitating assembly while avoiding interference between the conductive wires C formed into regular dimensions.

  In the above-described embodiment, the chuck mechanism 22 includes six pieces 22T (see FIGS. 8, 11, and 18B). Instead of this form, another number (ie, a number other than 6) of frame portions 22T may be provided. The chuck mechanism 22 is related to the group of conductor assembly CG, and is related to the shape of the turn part Cd to be laminated in the axial direction Z (see FIG. 15). Any number can be set as long as it is set based on these relations. Even when configured with other numbers of top portions 22T, it is possible to manufacture the stator winding W with ease of assembly while avoiding interference between the conductors C.

  In the above-described embodiment, the plurality of top portions 22T are configured to be mounted symmetrically with respect to the center line of the chuck mechanism 22 (see FIG. 11). Instead of this form, one or more piece portions 22T among the plurality of piece portions 22T may be attached with different attachment directions with respect to the other piece portions 22T. In other words, the number of attachment directions to be different is arbitrary as long as the conducting wire C does not interfere with the top portion 22T. For example, the mounting direction is reversed between the two frame portions 22T and the four frame portions 22T. As described above, even when one or more pieces 22T are attached to different pieces 22T, the insulation coating applied to the lead C is damaged when the lead C is held and released. Can be avoided more reliably.

  In the above-described embodiment, the top portion 22T is configured to operate in the normal direction of the surface of the conductor C when the conductor C is held and released (see FIG. 9). Instead of this form, it may be configured to operate in directions other than the normal direction on condition that the conducting wire C does not hit the top portion 22T. Even when the top portion 22T operates in the other direction, since the conducting wire C and the top portion 22T do not interfere with each other, it is possible to more reliably avoid damage to the insulating coating applied to the conducting wire C.

  In the embodiment described above, the movable piece 22b is arranged on the center side of the chuck mechanism 22 (see FIG. 11). Instead of this form, one or more movable pieces 22b are arranged outside the chuck mechanism 22 (on the side away from the center) on the condition that the conducting wire C can be easily held and released and does not interfere with the conducting wire C. It is good also as composition to do. Even when the movable piece 22b is arranged outside the chuck mechanism 22, the conducting wire C and the movable piece 22b do not interfere with each other, so that it is possible to more reliably avoid damage to the insulating coating applied to the conducting wire C.

  In the above-described embodiment, the top portion 22T of the chuck mechanism 22 includes the non-moving top 22c and the movable top 22b (see FIG. 9). Instead of this configuration, the second movable piece 22b may be provided on the condition that the conducting wire C can be easily held and released and does not interfere with the conducting wire C. That is, both pieces move like a laundry basket. Even when the second movable piece 22b is provided, since there is no interference with the conductor C, it is possible to more reliably avoid damage to the insulating coating applied to the conductor C.

  In the above-described embodiment, the chuck mechanism 22 includes the operation element 22g corresponding to each piece 22T (see FIG. 8). In place of this configuration, in the case of a configuration in which the frame unit group (two or more frame units 22T) is operated to open and close in conjunction, a configuration may be provided that includes an operator 22g corresponding to each frame unit group. In order for the top section group to open and close in conjunction, a power transmission mechanism (for example, a gear) that transmits the rotational power of the operating section 22g to each top section 22T between one operating section 22g and a plurality of top sections 22T. Mechanism). In this way, the number of operation elements 22g can be reduced, and the number of rotation operations can be reduced. Therefore, the time required for holding and releasing the conducting wire C can be shortened.

  In the embodiment described above, a part of the conducting wire C held by the chuck mechanism 22 (particularly the top portion 22T) is configured to be the slot accommodating portion Cc accommodated in the slot 31 of the stator core 30 (FIG. 18 ( See B)). Instead of (or in addition to) this configuration, the turn portion Cd of the conductor C may be held. The chuck mechanism 22 holds the conducting wire C by restricting the position and posture of the conducting wire C and ensuring the clearance between the conducting wires C. If this condition is satisfied, a similar effect can be obtained even if the turn part Cd is held.

  In embodiment mentioned above, it applied to the generator motor as the rotary electric machine MG provided with the stator coil | winding W (refer FIG. 31). It may replace with this form and may apply to other rotating electrical machines, such as a generator and an electric motor. In other words, any rotating electrical machine that requires the stator winding W is optional. Even when applied to other rotating electrical machines, the insulation resistance between the conductors C can be reliably ensured, and the required performance of the rotating electrical machines can be exhibited.

10 Winding manufacturing equipment (stator winding manufacturing equipment)
DESCRIPTION OF SYMBOLS 12 Grip mechanism 13 Cylindrical member 14 Table member 15 Slide plate 16 Deformation holder 20 Holder member 21 Terminal part 22 Chuck mechanism 22T Top part 22b Movable top 22c Non-moving top 22d Connection member 22e Holding cam 22g Operating element 23 Base part 24 Moving cam 24a Operating element 24b Cam part 30 Stator core 40 Stator MG Rotating electric machine W Stator winding (workpiece)
C (C1, C2,..., C6) Conductor CG (CG1, CG2,..., CG8) Conductor assembly Cc Slot accommodating portion Cd Turn portion

Claims (13)

In the stator winding manufacturing method of manufacturing a stator winding by stacking and assembling a plurality of conducting wires,
Each of the conductive wires included in the plurality of conductive wires is formed into a curved shape such as an arc shape or a spiral shape in the radial direction, and is formed into a convex shape in the axial direction,
A moving step of relatively moving the conducting wire along a first path including at least an axial direction;
An assembly step of assembling by moving the conductive wire along a second path including at least a horizontal direction;
A method of manufacturing a stator winding, comprising: In the manufacturing method of the stator winding according to claim 1,
In the moving step, the lead wire is moved in one or both of a radial direction and a circumferential direction. The method of manufacturing a stator winding according to claim 2,
In the assembling step, the lead wire is moved in a direction opposite to the moving step, and the stator winding manufacturing method is characterized. In the manufacturing method of the stator winding according to any one of claims 1 to 3,
The method of manufacturing a stator winding, wherein the conducting wire is moved by the action of a moving cam. In the manufacturing method of the stator winding according to any one of claims 1 to 4,
A grouping step of grouping the plurality of conductors into a conductor assembly comprising two or more conductors;
A method of manufacturing a stator winding, wherein the moving step and the assembling step are performed on the conductor assembly grouped by the grouping step. In a stator winding manufacturing apparatus that manufactures a stator winding by stacking and assembling a plurality of conductive wires,
Each of the conductive wires included in the plurality of conductive wires is formed into a curved shape such as an arc shape or a spiral shape in the radial direction, and is formed into a convex shape in the axial direction,
A holder member capable of holding a part of the conducting wire;
A table member on which the holder member is movably mounted at a plurality of positions;
An apparatus for manufacturing a stator winding, comprising: In the stator winding manufacturing apparatus according to claim 6,
The holder member has a first position when moving the conductor along a first path including at least an axial direction, and a second position when moving the conductor along a second path including at least a horizontal direction. And a stator winding manufacturing apparatus that is configured to be movable. In the stator winding manufacturing apparatus according to claim 6 or 7,
The apparatus for manufacturing a stator winding according to claim 1, wherein the holder member is configured to be movable to a third position shifted further in a radial direction or a circumferential direction than the second position. In the stator winding manufacturing apparatus according to any one of claims 6 to 8,
The apparatus for manufacturing a stator winding, wherein the holder member moves to any one of the plurality of positions by the action of a moving cam. In the stator winding manufacturing apparatus according to any one of claims 6 to 9,
A part of the conducting wire held by the holder member is a slot accommodating portion that is accommodated in a slot of the stator core. In the stator winding manufacturing apparatus according to any one of claims 6 to 10,
An apparatus for manufacturing a stator winding, comprising a cylindrical member capable of positioning a plurality of the holder members at the second position. In the manufacturing apparatus of the stator winding | coil as described in any one of Claim 6 to 11,
Grouping the plurality of conductors into a plurality of conductor assemblies comprising two or more conductors;
The said holder member hold | maintains each conducting wire contained in the said conducting wire assembly, The manufacturing apparatus of the stator winding | coil characterized by the above-mentioned.   A rotating electrical machine comprising the stator winding manufactured according to any one of claims 1 to 12.

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